Specialty Equipment

Choosing the Best GSE Batteries: The Key to Efficient and Sustainable Airport Ground Support Equipment Electrification The Significance of Electrification for Airport Ground Support Equipment (GSE) The electrification of airport ground support equipment (GSE) plays a crucial role in advancing sustainability, reducing emissions, and enhancing operational efficiency at airports. One of the most significant benefits of electrication is zero emissions, leading to cleaner air around airports and contributing to global environmental goals. Additionally, electric GSE reduces noise pollution, which is particularly important in densely populated areas near airports. The safety of energy use is also greatly improved, with electric equipment offering enhanced security compared to traditional fuel-based counterparts. In terms of operational efficiency, electrification boosts both energy conversion efficiency and overall airport productivity. By transitioning to electric ground support equipment, airports can achieve not only better performance from individual equipment but also streamline the entire airport operation. The reduced workload for ground crews, coupled with the ease of integrating intelligent systems, accelerates the automotion of airport processes. Overall, electrifying airport ground support equipment ensures environmental benefits, enhances energy security, and improves the overall efficiency of airport operations while pushing forward the integration of smarter, more automated systems. How to Choose the Best GSE Batteries When selecting batteries for electric ground support equipment, it’s essential to understand the specific requirements for these devices. This selection process presents challenges, as airport operations prioritize safety, especially in civil aviation. The safety standards for airport GSE must exceed those required for road vehicles, given the critical nature of airport operations. The reliability of these batteries is also vital – minimizing failure rates is essential to maintaining high fleet availability. Furthermore, airport GSE batteries must be durable, with long lifespans that can withstand the diverse environmental conditions in which these vehicles operate, from extreme temperatures to high humidity levels. The batteries should also be cost-effective, easy to deploy, and capable of fast delivery. For these requirements, safety is paramount. The battery itself must ensure the safety of the equipment and, ultimately, the safety of airport personnel. With this in mnd, we design our battery systems based on four key dimensions of safety: mechanical, electrical, chemical, and functional. This comprehensive approach guarantees that every battery system provides full protection of both the equipment and operators. Our battery factory – production line In terms of improving reliability, we focus on enhancing the lifespan and durability of lithium-ion batteries, using advanced engineering methods to minimize the failure rates throughout the battery’s lifecycle. Innovations in materials, such as optimized cathodes and anodes, as well as the development of advanced manufacturing processes, significantly reduce the risk of mechanical and chemical degradation, thus extending battery life. Additionally, batteries used in airport GSE are designed with features like IP67, IP68, and IP69K ratings, which provide effective moisture and dust protection. High-performance thermal management ensures the battery can operate within a broad temperature range, making it ideal for various environmental conditions found at airports worldwide. Our battery factory – standardized battery modules and packs One major challenge for airport GSE electrification is the relatively small scale of the equipment compared to road vehicles, leading to a greater variety of types and applications. To control costs and reduce development time, we have adopted a standardized solution approach. This includes the use of standardized battery modules and packs to meet the diverse needs of airport ground support equipment. Such a solution ensures that the system is both cost-effective and market-proven,while also offering the flexibility for small-batch, multi-type production. These standardized solutions will significantly support the sustainable development of airport GSE electrification. Choosing the Right Chemical System for Airport GSE Batteries When selecting the chemical system for electric GSE batteries, several factors must be considered. Unlike traditional batteries, lithium-ion batteries for GSE incorporate a complex integration of chemistry, electrical systems, mechanics, and thermal management, creating a highly sophisticated system. To evaluate the performance of these batteries, it’s necessary to assess all these aspects, rather than just focusing on individual material properties. Among the different types of lithium-ion batteries, LiFePo4 (Lithium Iron Phosphate) batteries stand out as the safest and most reliable option for airport GSE. This is primarily due to their stable olivine structure, which ensures that the temperature rise during thermal runaway is slower than that of other battery types. For exmaple, in the event of thermal runaway, LiFePO4 batteries emit smoke but do not catch fire, unlike NCM (Nickel Cobalt Manganese) batteris, which can rapidly accelerate combustion when exposed to heat. Additionally, LiFePO4 batteries offer superior cycle life, with some models reaching up to 4,000 charge cycles. This long lifespan significantly reduces the cost of ownership and increases the reliability of the battery over time. They are also capable of withstanding high temperatures – up to 65°C – and do not contain heavy metals or harmful pollutants, making them a highly eco-friendly choice for airport GSE. In contrast, NCM batteries are more energy-dense but have lower thermal stability, making them less suitable for use in high-temperature environments, such as those encountered in airport ground operations. Moreover, LiFePO4 batteries are less expensive than NCM batteries and are more widely available, ensuring stable material supply and cost reductions over time. Advantages of Lithium Iron Phosphate (LiFePO4) Batteries for Airport GSE In summary, LiFePO4 batteries offer numerous advantages that make them the ideal choice for airport ground support equipment:  Safety: LiFePO4 batteries are resistant to fire and explosion, providing higher level of safety in demanding environments. Long Cycle Life: With up to 4,000 charge cycles, these batteries have an exceptionally long lifespan, reducing long-term costs. High Capacity: LiFePO4 batteries have a high capacity, which simplifies system configurations and reduces the number of battery packs required. Energy Density: Despite their high safety and durability, LiFePO4 batteries maintain a competitive energy density. Thermal Stability: They can operate efficiently at temperatures up to 65°C, making them suitable for extreme environments. Environmental Friendliness: Free from toxic heavy metals, LiFePO4 batteries are a greener, more sustainable option. Stable Material Supply: Unlike

Electrification Takes Off: The Future of Airport Ground Support Equipment As the push for greener aviation gains momentum, driven by environmental initiatives and eco-friendly airport policies, the electrification of airport ground support equipment (GSE) is rapidly advancing. Airports are uniquely suited for electrification thanks to their controlled environments, predictable routes, low-speed operations, and manageable range requirements. These factors make GSE an ideal sector for electrification, a view shared by industry experts. With ongoing advancements in electrification technology and decreasing battery costs, airports and airlines are expected to adopt electric GSE at scale. The shift is already underway, signaling significant growth for this promising market. Bright Prospects for Electric GSE Airport GSE encompasses a wide variety of vehicles used within airport grounds, including passenger service vehicles, aircraft service equipment, runway maintenance vehicles, and emergency response vehicles – spanning over 20 different types. These vehicles require varying levels of power, typically ranging between 100-300 kWh. For instance, a compact VIP shuttle bus with a seating capacity of around 10 passengers generally needs about 110 kWh, sufficient for a full day of operation. Why LFP Batteries Lead the Way The transition from diesel to electric, and from lead-acid to lithium batteries, has revolutionized aiport GSE. However, one principle remains unchanged: safety is paramount. Lithium Iron Phosphate (LFP) batteries have emerged as the ideal choice for airport electrification due to their high safety profile. LFP batteries offer a proven track record in critical applications, ensuring safe operation, reliable charging, long cycle life, and excellent performance across a wide temperature range. Already, leading airport electric vehicle manufacturers like Yutong and Foton have adopted LFP batteries for their electric GSE, reinforcing their position as the preferred solution for this specialized market. A Promising New Frontier The electrification of airport GSE is poised for rapid expansion as the push for green aviation continues. The market is emerging as a promising new blue ocean, offering significant opportunities for innovation and growth in electrification. At Brogen, we provide customizable electrification solutions for airport GSE, including high-performance lithium batteries, motors, controllers, and integrated electric axles. Our solutions are tailored to meet the unique demands of this sector, delivering safety, reliability, and efficiency to support the transition to cleaner, greener airports. Contact us at contact@brogenevsolution.com Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

The Best Batteries for Airport Ground Support Equipment: Choosing High-Performance GSE Electrification Solutions As airports transition toward sustainability and electrification, choosing the right batteries for ground support equipment (GSE) is crucial. From tow tractors and shuttle buses to baggage conveyors and forklifts, electrification helps reduce carbon emissions, improve energy efficiency, and enhance operational performance.  This guides explores key considerations for selecting airport GSE batteries, comparing battery types, voltage systems, and charging methods to meet the needs of modern airports. Why Lithium Batteries Are the Best Choice for Airport GSE Electrification Lithium-ion vs. Lead Acid Batteries While lead-acid batteries have historically been used in airport vehicles like baggage tractors, the industry has largely shifted to lithium iron phosphate (LFP) batteries due to their superior performance. Here’s a comparison: Feature Lead-Acid Batteries Lithium (LFP) Batteries Energy Density 30-45 Wh/kg 120-160 Wh/kg Charging Time 5-6 hours (0.2C rate) 1-2 hours (0.5-1C rate) Cold Weather Use Poor, with significant loss Good with insulation options Cycle Life 400-1000 cycles 2000-4000 cycles Maintenance High (e.g., water refills) Minimal (virtually maintenance-free) Environmental Impact Lead and acid pollution Green and eco-friendly Battery Management Limited or none Advanced Battery Management Systems (BMS) Lithium-ion vs. NCM Batteries: Why Safety Matters Airports require the highest safety standards, making lithium iron phosphate (LFP) batteries are the optimal choice over nickel-cobalt-manganese (NCM) batteries. Why LFP Batteries Are Safer? Thermal Stability: LFP batteries withstand temperatures up to 700-800°C before decomposition, compared to 200°C for NCM batteries, reducing fire risks. Proven Reliability: Widely used in electric buses, LFP batteries account for 98% of China’s electric bus market, demonstrating their safety and performance under demanding conditions. While NCM  batteries are favored for passenger cars due to their compact size and lightweight design, the safety and durability of LFP batteries make them better suited for electric ground support equipment. Key Advantages of Lithium Batteries for Airport GSE High Energy  Density: Delivers more power in a compact and lightweight degisn, optimizing vehicle performance. Longer Lifespan: Reduced replacement frequency translates to lower lifecycle costs. Superior Cold Weather Performance: Ideal for year-round operations, even in outdoor environments. Advanced BMS: Ensures safety, efficiency, and real-time monitoring. High Voltage Systems: Optimizing Efficiency for GSE Batteries When it comes to battery voltage, the choice between low-voltage (80V) and high-voltage (300V-600V) systems is critical. Why High Voltage (300V-600V) is Superior? Higher Efficiency: High-voltage systems minimize energy loss and improve operational efficiency. Enhanced Safety: Lithium batteries, with advanced BMS, support higher voltages safely. Scalability: High-voltage configurations, such as the 576V, meet the power demands of larger GSE. In constrast, lead-acid batteries are limited to 80V systems due to technical constraints, making them less efficient and impractical for modern GSE electrification needs. Charging Solutions for Airport Electric GSE Efficient charging is vital for electrified airport GSE. Here are the best practices for airport battery charging infrastructure: The optimal solution is distributed charging, conveniently located near parking spaces. Use standardized charging equipment (including charging voltage, protocols, and interfaces). Ensures “vehicles are compatible with all stations, and stations are compatible with all vehicles.” Distributed, near-parking charging is the best approach for airport electric ground support equipment due to the diverse range and unique designs of these vehicles. Battery-swapping is challenging and impractical for most airport GSE, making it unsuitable for this approach. Most airport GSE have limited range and are not designed for long-distance charging or swapping, making centralized charging facilities less ideal. Establishing 2-3 battery maintenance stations within the operational zone while receiving periodic battery inspections and maintenance. This is an excellent solution for maintaining battery health in newly constructed airports.  Choosing the Right Motor and Controller for GSE Airport GSE should use permanent magnet brushless motors paired with multi-in-one motor controllers.  Advantages of This Setup: High Motor Efficiency: Permanent magnets enhance efficiency and reliability. Integrated Controllers: Combining multiple controllers (e.g., for drive, hydraulic, and air systems) into a single unit improves compactness, reduces wiring complexity, and enhances reliability. Rugged Design: Water-cooled, IP67-rated controllers withstand harsh operating environments while maintaining electromagnetic compatibility. Conclusion: Powering the Future of Airport Operations Electrifying airport GSE with high-performance electric batteries like LFP systems is essential for achieving sustanability goals. By choosing the right battery type, voltage system, and charging solutions, airports can reduce carbon emissions, lower operating costs, and enhance equipment reliability.  For more insights on the best battery solutions for your airport’s ground support equipment, contact us to explore customized battery systems tailored to your needs. Learn more here: https://brogenevsolution.com/lithium-battery-pack-for-airport-gse/ Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

How to Choose the Right Electric Forklift Battery: The Complete Guide Introduction For businesses that rely on forklifts, the choice of electric forklift battery can significantly impact overall operational efficiency and, in the long run, influence substantial time and financial costs. By selecting the appropriate forklift battery, forklift manufacturers can ensure the safety and performance of their products in a competitive market. This guide will walk you through the various types of electric forklift batteries, their key differences, price ranges, and how these battery options can affect your business’s daily operations. Quick Access Types of Electric Forklift Batteries​ Electric Forklift Battery Lifespan​ Electric Forklift Battery Maintenance​ Requirements for Forklift Battery Charging Stations​ Safety Comparison​ Price​ How to Determine if Lithium-Ion Batteries are Suitable for Your Forklifts​ How to Choose the Right Electric Forklift Battery​ Brogen’s Electric Forklift Battery Solutions​ Contact Us Types of Electric Forklift Batteries There are two primary battery types powering electric forklifts: lead-acid and lithium-ion. Lead-Acid Batteries As the traditional choice for forklift power, lead-acid batteries utilize a chemical reaction between lead plates and sulfuric acid to generate electricity. These batteries are characterized by their bulky size, liquid electrolyte, and requirement for regular maintenance. Key components include cells, bars, plates of lead dioxide, cables, and electrolytes. The electrochemical reaction between the lead plates and the electrolyte solution allows for the flow of ions, producing an electric current. Lithium-Ion Batteries (Primarily Lithium Iron Phosphate) Introduced in the early 1990s, lithium-ion batteries, particularly Lithium Iron Phosphate (LFP), have gained significant popularity in the material handling industry. These batteries offer higher energy density and a more compact design compared to lead-acid batteries. They are sealed and require minimal maintenance. Lithium-ion batteries operate on the principle of lithium-ion movement between the anode and cathode through an electrolyte. During discharge, lithium ions move from the anode to the cathode, generating electricity. Electric Forklift Battery Lifespan Like any business expense, electric forklift batteries are a cost that needs to be managed over time. The type of battery a forklift uses determines how often the battery needs to be manually replaced. Lead-acid and lithium-ion batteries have different lifespans: Lead-Acid Batteries: 1000 – 1500 cycles Lead-acid batteries have a longer charging time compared to lithium-ion batteries. They are primarily charged using traditional charging methods, typically overnight after a shift, using a low current charge for approximately 8 to 10 hours until fully charged. After a long charging period, the batteries need to cool for 6 to 8 hours before they can be used again.  Traditional charging is mostly done overnight, making it suitable for single-shift operations. This also means that lead-acid batteries typically do not undergo opportunity charging. Doing so can quickly damage the battery, wear it out faster, and reduce the number of cycles. Overall, lead-acid forklift batteries can last 3 to 5 years (or 1000 to 1500 charge cycles) with a normal weekly operation of 40 hours. Lithium-Ion Batteries: 3500 cycles Lithium-ion batteries can be easily charged using opportunity charging because they can be fast-charged. This type of charging involves using a specialized high-current charger to quickly recharge the battery. Opportunity charging can be done as needed or at convenient times, making lithium-ion batteries more efficient. If properly maintained, lithium-ion forklift batteries can last 2000 to 3000 cycles, or approximately 7 to 10 years (assuming 300 working days per year). Electric Forklift Battery Maintenance To ensure that lithium-ion and lead-acid batteries perform at their best, proper maintenance is essential. Without appropriate forklift battery maintenance, their lifespan can be significantly reduced. To maximize lifespan and overall battery capacity, users of both types of batteries should follow certain practices. However, lead-acid batteries require more care and attention compared to lithium-ion batteries. Lead-Acid Forklift Battery Maintenance Requirements Equalization (Battery Balancing): In traditional lead-acid batteries, internal acid, and water can often stratify (separate horizontally, with more concentrated acid near the bottom). This can lead to the formation of sulfate crystals at the bottom of the battery, reducing its ability to hold a charge. Equalization helps break down these crystals, but if the battery is left too long, the crystals may not break. Temperature Control: Lead-acid batteries must be kept within a certain temperature range to avoid shortening their lifespan. They can become very hot during charging, requiring a temperature-controlled space for charging and storage. Typically, using lead-acid batteries requires a significant fixed space to store the batteries. Water Level Management: These batteries need to be checked approximately every 10 charge cycles to ensure they have enough water. “Watering” the battery can be a tedious and time-consuming task for individual batteries. Lithium-ion Batteries Maintenance In comparison, lithium-ion batteries require much less maintenance. They come equipped with a Battery Management System (BMS) that automatically balances the cells, operate well at higher temperatures (making temperature control less of an issue), and do not require any water level management. Requirements for Forklift Battery Charging Stations Lead-Acid Forklift Battery Lead-acid forklift batteries must be completely removed from the forklift and placed onto a separate forklift battery charger. Many of these chargers can perform equalization. If there are many forklifts in operation, multiple chargers are needed, and sufficient space is required for cooling several units after charging.  This process involves employees using specialized lifting equipment to swap out discharged batteries for charged ones regularly. While not physically demanding, this task can be time-consuming and may impact operational efficiency for those looking to optimize productivity.  Additionally, lead-acid batteries require dedicated charging areas with proper ventilation and temperature control. This is because they can become very hot and release harmful fumes during charging. Lithium-ion Battery In contrast, lithium-ion forklift batteries do not require separate charging spaces, cooling, or a fully charged backup battery when another is fully discharged—they can be plugged directly into the charger without needing to be removed from the forklift, making the charging process straightforward with no further actions required. Safety Comparison Safety Risks of Lead-Acid Forklift Batteries Spillage: Lead-acid batteries contain highly toxic sulfuric acid, which can spill, especially since these