What Makes a Reliable AGV Lithium Battery Manufacturer?
When you search for an AGV battery manufacturer or AGV lithium battery manufacturer, you usually see a long list of companies claiming “long life”, “fast charging” and “high safety”. But behind those slogans, what actually separates a true industrial-grade manufacturer from a simple battery assembler?
A real AGV lithium battery manufacturer:
- Chooses LiFePO4 cells that are proven in industrial duty – not just any cheap cell from the spot market.
- Designs packs and modules around your voltage, runtime and charging strategy, not the other way around.
- Integrates a BMS with CAN / RS485 that talks reliably to your AGV controller and fleet management system.
- Runs testing and validation that simulate years of warehouse shocks, temperature swings and continuous operation.
- Provides clear traceability and documentation, so your own system certification is easier.
In this article, we’ll walk through how SAFTEC approaches AGV lithium battery manufacturing – from cell selection to BMS integration – and what you should look for when evaluating any AGV battery manufacturer. Throughout the article, we’ll also point you back to our standard 24V / 48V AGV LiFePO4 packs, so you can see how these principles show up in real products.
What Does an AGV Lithium Battery Manufacturer Actually Do?
Large cell brands (for example global LiFePO4 cell companies) produce cylindrical or prismatic cells in the millions. These cells are the “raw material”. An AGV lithium battery manufacturer turns those cells into a complete power system that can safely run inside your vehicles for many years.
That system includes:
- Cell modules and pack assembly
- Busbars, fuses, contactors and wiring harnesses
- BMS hardware and firmware
- Mechanical enclosure, seals and mounting interfaces
- Connectors, communication ports and labels
For AGV OEMs and system integrators, this pack manufacturer is your everyday partner. You don’t negotiate directly with the cell factories about tolerances, BMS algorithms or IP ratings. You work with the pack manufacturer to define voltage, capacity, charge rate, lifetime, communication, mechanical interface and documentation.
So when you pick an AGV battery supplier, you are really picking:
A technical partner who designs and builds the pack, not just a reseller who buys and resells batteries.
Step 1 – LiFePO4 Cell Selection for AGV Duty
Why LiFePO4 is the default chemistry for AGVs
Most modern AGV and AMR platforms are moving towards LiFePO4 (LFP) cells because they offer a useful combination of:
- Long cycle life (often several thousand cycles at moderate depth of discharge)
- Excellent thermal stability and a wide safe operating window
- Relatively flat voltage curve, which helps with SOC estimation
- Good tolerance of opportunity charging during short pauses
- Lower maintenance than flooded lead-acid systems
Other chemistries still exist in the field – flooded lead-acid, AGM, sometimes NMC – but for 24/7 intralogistics LiFePO4 has become the sensible baseline. A serious AGV lithium battery manufacturer therefore starts from LFP cell platforms unless there is a very specific reason not to.
Key parameters when selecting LiFePO4 cells
Inside the factory, cell selection is not just about nominal capacity. SAFTEC – and any responsible manufacturer – will look at parameters such as:
- Capacity & nominal voltage – 3.2 V LFP cells with various Ah ratings form the building blocks of 24 V and 48 V packs.
- Continuous and peak current (C-rate) – How much current the cell can deliver continuously and for short bursts, without overheating or losing life quickly.
- Internal resistance & consistency – Cells in the same string should have tight resistance and capacity tolerances to keep balancing currents low and avoid early ageing.
- Cycle life vs depth of discharge & temperature – Lab data across different DoD levels and temperatures tells us how the cell will behave under opportunity charging or deep cycling.
- Safety & compliance – Shock, vibration and abuse test data, plus UN38.3 and other cell-level certifications.
- Supply stability – Long-term availability, not just one good price for a single container.
How SAFTEC qualifies and matches cells
At SAFTEC, cell selection for AGV projects follows a structured flow:
- Define the duty cycle – Typical daily energy throughput, peak currents, ambient temperature range, charging strategy (shift-end, fast charge, opportunity charging).
- Screen suitable LFP cell families – From qualified mainstream brands with known cycle performance and safety test reports.
- Run incoming inspection – Capacity and internal resistance testing, visual inspection, batch traceability and documentation check.
- Match cells to project goals –
- Longest life and minimal downtime → prioritize higher-endurance LFP cells.
- High power for towing or ramps → prioritize higher C-rate capability.
- Cost-sensitive retrofits → trade a little cycle life for better $/kWh.
For some OEMs, we supply complete packs with cells from our qualified list. For others, we build cell-ready packs:
- The customer chooses the cell brand and manages the cell purchase;
- SAFTEC designs and manufactures the pack structure, BMS, wiring and enclosure;
- Cells are assembled under an agreed process so that final responsibility and traceability remain clear.
This “cell-ready” option is very attractive for AGV manufacturers who already have global contracts with specific cell brands but still need a specialist to handle pack and BMS engineering.
Step 2 – Designing the AGV Battery Pack & Modules
Voltage platforms and capacity planning
Most AGV systems use a small range of DC bus voltages. Common platforms include:
- 24 V nominal – Typically 8s LFP configurations; used in smaller AGVs, tuggers and custom carts.
- 48 V or 51.2 V nominal – 16s LFP platforms; common for medium to large AGVs and AMRs with higher power demands.
As an AGV battery manufacturer, we start from the vehicle constraints:
- Motor & inverter voltage requirements
- DC bus range of the controller
- Current draw during acceleration, gradients and braking
- Target runtime between charges
From there, we decide on:
- The series count (S) to match the voltage platform;
- The parallel count (P) needed to reach the required Ah and peak current margin;
- The usable capacity (kWh) at a reasonable depth of discharge, not 0–100%.
For example, a mid-size warehouse AGV might end up with a 51.2 V 120 Ah pack, while a smaller unit could use a 24 V 60 Ah pack. The exact numbers vary, but the method is always “start from power and energy demand, then choose pack topology”, not the reverse.
Mechanical & thermal design
Once the electrical topology is defined, the mechanical design turns that into a rugged pack:
- Modular architecture – Using repeatable modules (e.g. 24 V blocks) that can be combined to serve different AGV models, simplifying service and inventory.
- Enclosure design –
- Tray-type packs that slide into a battery compartment,
- Drawer-style packs for quick maintenance,
- Top-mounted packs for small AMRs.
- Ingress protection – Gaskets, cable glands and seals sized to meet IP54, IP65 or other project-specific targets.
- Thermal considerations –
- Cell spacing and airflow for natural convection,
- Heat paths from the hottest cells to the enclosure,
- Optional fans or ducting on very high-power designs.
All of this must fit inside the AGV’s envelope while leaving space for harness routing, service access and safe clearances to other components.
Safety & protection hardware
Beyond the BMS logic, hardware protection is crucial:
- Properly rated fuses and contactors for both charge and discharge paths
- Pre-charge circuits to avoid inrush currents into the DC bus capacitors
- Adequate creepage and clearance distances in busbar and PCB layouts
- Mechanical protection to shield cells from shock and impact
A trustworthy AGV battery manufacturer designs these not as after-thought add-ons, but as core parts of the system architecture.
Step 3 – BMS Design & CAN/RS485 Integration
What the BMS really does in an AGV pack
In industrial packs, the BMS is much more than a simple protection board. It is effectively the battery controller:
- Monitors cell voltages, pack current and multiple temperature points
- Balances cells during charge to keep them within tight limits
- Calculates state of charge (SOC) and state of health (SOH)
- Controls pre-charge and main contactors for safe connect/disconnect
- Records fault events and operating statistics for diagnostics
If you’re evaluating an AGV lithium battery manufacturer, always ask:
How does your BMS estimate SOC and SOH? What data can I access over communication?
Vague answers here are a red flag.
Communication with AGV controllers (CAN / RS485)
Most AGV platforms today expect the battery to talk to the vehicle and sometimes to a fleet system. Common industrial interfaces include:
- CAN bus – Often with OEM-specific message maps or standards similar to J1939/CANopen.
- RS485 – For simpler systems or where legacy hardware is already installed.
An integrated AGV BMS will typically communicate:
- SOC and estimated remaining runtime
- SOH or “usable capacity vs design capacity”
- Charge and discharge current limits
- Alarms (over-temperature, over-current, cell imbalance, low SOC, etc.)
- Pack identification and cycle count
SAFTEC’s packs are designed so the BMS can be mapped to the AGV controller’s expectations. For OEM projects, we work with your engineering team to:
- Share documented CAN/RS485 message sets,
- Provide sample DBC or register maps,
- Support parameter adjustments during field validation.
Why good integration matters for uptime
When the AGV’s controller trusts the battery data, you can:
- Trigger controlled slow-down or return-to-charge actions before voltage sags cause trips.
- Implement smart opportunity charging based on SOC and queue position.
- Log and analyze energy use by route, mission type or shift.
Poor integration leads to “jumping SOC”, nuisance alarms and unplanned stops – not a chemistry problem, but a communication and BMS design problem. That’s why working with an experienced AGV lithium battery manufacturer is so important.
Step 4 – Testing, Validation & Certification
Electrical & functional testing
Before any AGV battery pack leaves the factory, it should have gone through more than a single quick discharge test. At SAFTEC, a typical procedure includes:
- 100% functional testing – Verifying contactor operation, protection thresholds and communication on every pack.
- Capacity & internal resistance testing – Confirming the pack meets its rated Ah and that IR is within design bands.
- Charge/discharge cycling – At least short validation cycles on production units, and extended life tests on representative samples.
For new designs or highly customized packs, we also run controlled cycle tests under different DoD and temperature conditions to verify lifetime assumptions.
Mechanical & environmental validation
AGV batteries seldom live in calm environments. They experience:
- Repeated bumps over thresholds and floor joints
- Constant vibrations from drive units
- Temperature swings between cool storage and warmer electronics bays
Validation therefore includes:
- Vibration and shock testing – Following relevant industrial profiles to check mounting points, welds and wiring.
- Ingress protection checks – Ensuring the pack meets the agreed IP rating in real mounting orientations.
- Thermal behavior – Monitoring cell temperatures under long discharge and charge cycles.
Certifications for industrial AGV lithium batteries
Industrial AGV projects often need proof that the battery system is designed to recognized standards. Depending on your region and application, manufacturers typically work towards:
- UN38.3 – Mandatory for transport of lithium batteries by air and sea.
- IEC 62619 / IEC 62620 or similar – For industrial rechargeable lithium batteries.
- IEC 60529 – Defining IP ratings for dust and water ingress.
- Regional safety marks – Such as CE in Europe or others as required.
A serious AGV lithium battery manufacturer will design and test packs with these standards in mind and provide documentation to support your system certification, even when the customer is the one applying for final machine approval.
Step 5 – Reliability, Traceability & OEM / ODM Collaboration
Data & traceability
For fleets of AGVs, tracking performance over years matters as much as hitting the initial spec. That’s why pack and BMS traceability are built into SAFTEC’s process:
- Every pack receives a unique serial number linked to cell batch, assembly line, test reports and firmware version.
- End-of-line test data – capacity, IR, insulation resistance, communication checks – are stored for future reference.
- BMS logs capture fault events, max/min temperatures, over-current incidents and deep-discharge occurrences, helping diagnose issues in the field.
When you are comparing AGV battery manufacturers, ask how they handle traceability. A “we don’t really store that” answer can become a costly problem later.
Typical OEM / ODM project flow
For AGV OEMs and integrators, working with SAFTEC as an AGV lithium battery manufacturer usually follows a clear, engineering-driven flow:
- Requirements & application study
- Voltage platform, power profile, daily energy usage, charging strategy
- Mechanical envelope, mounting style, IP rating
- Target lifetime (years and cycles), certification and documentation needs
- Cell & pack topology proposal
- Proposed LFP cell families and series/parallel configuration
- Expected usable kWh, C-rates and cycle life at your DoD
- Mechanical & BMS design review
- 3D pack models, mounting and connector positions
- BMS schematic, safety concept and draft CAN/RS485 map
- Prototype packs & lab testing
- Build small prototypes for bench testing and initial integration
- Adjust mechanical details and parameters based on early results
- Pilot run on vehicles
- Install packs into several AGVs for real-world validation
- Collect BMS logs and operator feedback; fine-tune limits and messages
- Mass production & quality control
- Stabilize the design, set up production jigs and test routines
- Maintain batch records and periodic audit tests
- After-sales support & continuous improvement
- Assistance with diagnostics, replacements and upgrades
- Options for capacity or feature updates on new batches
When “cell-ready packs” make sense
In addition to complete packs, SAFTEC can design cell-ready AGV battery packs – fully engineered PACK + BMS + enclosure, shipped without cells. This structure is ideal when:
- You already have a global supply agreement with a specific LFP cell brand;
- Local regulations or logistics make it easier to buy cells domestically;
- You want all your equipment (AGVs, forklifts, storage systems) to share the same cell family, but prefer a specialist to handle pack and BMS integration.
In these projects, responsibilities and interfaces are clearly defined so that safety and performance are maintained even though cell purchasing is separated from pack manufacturing.
When Should You Work Directly with an AGV Battery Manufacturer?
You don’t always need a full custom design. Standard 24 V / 48 V packs might already cover many needs. But there are certain triggers where working directly with an AGV lithium battery manufacturer like SAFTEC is the right move:
- You are developing a new AGV/AMR platform and need a long-term, platform-level battery solution.
- You are planning a fleet conversion from lead-acid/AGM to LiFePO4, with different capacities and charge strategies by vehicle type.
- Your application requires opportunity charging, fast charging or inductive charging, and you need the battery, charger and control strategy aligned.
- Your end customer or safety assessor has strict documentation and standards requirements, and you need a manufacturer who understands industrial certifications.
- You want the option to use your preferred cell brand, but would like an external partner to handle pack design, BMS and validation.
If you recognize your situation in the list above, it’s time to treat the battery not as a commodity, but as a critical subsystem designed together with a dedicated manufacturer.
Partner with SAFTEC as Your AGV Lithium Battery Manufacturer
SAFTEC focuses on LiFePO4 AGV lithium battery packs for warehouses, factories and logistics centers. As an AGV battery manufacturer, we combine:
- Experience with mainstream LiFePO4 cell platforms used in industrial equipment
- Pack topologies optimized for 24 V and 48 V AGV DC buses
- BMS design and CAN/RS485 integration tailored to your controller and fleet software
- Factory testing, documentation and traceability for global OEM and retrofit projects
- Flexible models: complete packs with cells, or cell-ready packs designed around your preferred cells
If you are evaluating AGV battery manufacturers, a practical first step is to review our standard AGV LiFePO4 packs and see how their voltage, capacity and features match your platform. From there, our engineering team can extend or customize the design to match your exact requirements.
AGV Battery Manufacturer FAQs
How do I choose a reliable AGV lithium battery manufacturer?
Look for a company that can explain its process from cell selection to pack design and BMS integration in concrete terms, not just marketing phrases. They should be able to describe which LFP cells they qualify and why, how they design for your voltage and current needs, how their BMS communicates over CAN/RS485 and which tests and standards they design to. Ask for example test reports and sample CAN documentation – genuine manufacturers have them ready.
Can an AGV battery manufacturer work with my preferred cell brand?
Yes, many OEM projects start exactly this way. A capable AGV lithium battery manufacturer can design pack topology, BMS and mechanical structure around a specific LFP cell family, provided the cell meets safety and performance requirements. In some cases, you purchase the cells under your own contract while the manufacturer handles pack engineering and assembly as a cell-ready pack solution.
What information should I prepare before asking for a custom AGV battery pack quote?
To get a meaningful proposal, you should prepare at least:
- Required voltage platform and typical current draw (continuous and peak)
- Target runtime between charges and planned charging strategy (shift-end, opportunity, fast charge)
- Mechanical envelope, mounting interface and target IP rating
- Desired lifetime in years and approximate cycles, plus ambient temperature range
- Any specific certifications or test standards you must meet
The more clearly you describe your AGV duty cycle, the better the manufacturer can match cell choice and pack design.
Can you customize the BMS CAN/RS485 protocol for my AGV controller?
A specialized AGV battery manufacturer should be prepared to adapt their BMS communication to your controller. In practice, this means mapping SOC, SOH, current limits and alarms into your CAN or RS485 message format, and sometimes adding application-specific messages. At SAFTEC, this is part of the OEM/ODM project flow: we provide message documentation, review your controller requirements and adjust parameters during field testing.
What certifications should an AGV lithium battery manufacturer support?
At minimum, the manufacturer should understand and work with standards such as UN38.3 for transport, industrial lithium battery standards (e.g. IEC 62619/62620) and relevant IP protection standards. Depending on your market, you may also need CE or other regional marks. While the overall machine or AGV certification remains your responsibility as the OEM, a good manufacturer will design packs in line with these standards and provide supporting test data.
Do manufacturers offer AGV battery packs without cells if I want to supply my own cells?
Some do, but not all. If you already have strong cell sourcing agreements, ask explicitly about packs without cells or cell-ready packs. In this model, the manufacturer designs and builds the mechanical structure, BMS, wiring and connectors, while you purchase and sometimes even install the cells under an agreed process. SAFTEC offers this option for OEM projects where separating cell procurement and pack design makes commercial or logistical sense.
