What Cold Storage Low-Temperature AGV Battery Covers
The core issue is that "lead-acid is useless in cold": at −18 °C capacity drops 40–50%, at −25 °C it drops 60–70%, and at −30 °C it simply does not work. Operators end up equipping each AGV with 2–3 lead-acid sets — one in the cold store, one warming outside. With a PLB cold-storage battery, 1 AGV = 1 battery set: investment halved, efficiency doubled. Discharge down to −20 °C, charge protection below freezing that prevents lithium plating, sealed housings against condensation, and SOC reporting that stays trustworthy in the cold.
Professional Battery Solutions
Battery Swap in Cold Storage — Workers Can't Endure the Cold
Lead-acid dies in 2–3 hours in cold storage, so workers must manually swap heavy batteries (30–60kg each) at −25 °C. Every swap takes 15–20 minutes with frozen fingers and unsafe working conditions. Operators face a dilemma: no swap means the AGV sits idle, swap means workers cannot endure it — and frequent cold-store entry causes temperature swings that affect frozen goods quality.
8+ hours of continuous operation, so workers never enter the cold store to swap. The AGV runs an eight-hour shift and returns for a one-hour charge — zero worker cold exposure, fewer door openings, better temperature stability and preserved frozen-goods quality, with lower occupational health risk.
| Lead-acid | PLB D-series | |
|---|---|---|
| Runtime per charge | 2–3 hours | 8+ hours |
| Swaps per shift | 2-3, by hand at −25 °C | None |
| Worker cold exposure | 15–20 min per swap | Zero |
| Store temperature stability | Disturbed by door openings | Preserved |
-25 °C Cold Storage — Lead-Acid Drops 60%+ Capacity
The pain is specific: -25 °C Cold Storage — Lead-Acid Drops 60%+ Capacity In daily operation, lead-acid or manually managed packs lose capacity between scheduled checks, maintenance teams cannot inspect every unit, and the failure surfaces only when the load is already at risk.
80%+ capacity at -25 °C — 1 set replaces lead-acid's 3 sets. PLB's LiFePO₄ pack and BMS monitor cell voltage, temperature and SOC continuously, alert before a weak cell becomes a failure, and are sized to the application's load profile.
| Conventional / manual | PLB LiFePO₄ | |
|---|---|---|
| Monitoring | Periodic checks | Continuous BMS |
| Fault warning | At failure | Threshold alerts |
| Maintenance | Scheduled visits | Exception-based |
| Service life | 2–3 years | 6,000+ cycles |
Condensation Causes Terminal Corrosion and Short Circuits
Cold storage AGV batteries face a unique challenge — condensation. When AGVs return from -25 °C to a normal-temperature charging area, surfaces and terminals rapidly accumulate condensation. Water enters the terminals and causes corrosion and short circuits. Terminal corrosion rate is 5-10× faster than at normal temperature. Many operators find the batteries aren't worn out — they are "soaked to death" by condensation.
IP67 rating; zero condensation intrusion. Fully sealed IP67 structure — short-term submersible. Gold-plated terminals + sealed silicone dual protection. Tested: 500 cold↔charge temperature cycles, zero terminal corrosion, fully functional.
| Standard pack | PLB freezer pack | |
|---|---|---|
| Sealing | IP54 or none | IP67 with potted terminals |
| Pressure equalisation | Not provided | Membrane vent |
| Insulation risk | Rises with frost cycles | Managed |
Solution Advantages
Low-Temp High-Cap
≥80% at -25 °C
One set replaces three; battery investment is halved.
Low-temp electrolyte + self-heating · 8h+ AGV runtimeNo Swap Needed
One shift, one charge cycle
Zero cold exposure for workers and zero temperature fluctuation in the store.
Fully sealed IP67 · Gold-plated terminals, 10× oxidation resistanceLong Life
2000+ cycles, 5-year warranty
Zero replacements over 5 years; cold-storage battery TCO down 70%.
Saves ¥80,000–120,000/year per 50 AGVsNo Heated Bay
Charge in the cold environment
Saves the energy and floor space a heated charging room would take.
Opportunity charging supportedFrom Selection to After-Sales — PLB Stays With You
Four commitments that apply to every page in this category, from the first technical question to long-term support.
Technical Selection Support
Engineer recommends within 24 hours
Tell us the robot duty cycle, charge window and bay dimensions — our engineers size the pack and recommend the model within 24 hours.
Dedicated technical team · 24-hour response
OEM / ODM Customization
From cell to pack, fully customizable
From cells, BMS, housing and terminals to the nameplate, everything can be customized.
4–8 week customization · Tooling development supported
Global Shipping
Export to 100+ countries
Export-compliant packaging with UN 38.3 air transport certification and worldwide delivery.
UN 38.3 certified · MSDS available · Export compliant
Warranty & Support
Standard warranty, lifetime support
Standard products carry a full warranty, backed by lifetime technical support.
Warranty terms on request · Lifetime technical supportWhy Choose PLB?
Years of Manufacturing
Founded in Dongguan, China in 2014
Countries Served
Export-compliant packaging and worldwide delivery
Voltage Platforms
From 25.6V to 512V, built on the same cell platform
After-Sales Rate
Monitored by the internal quality traceability system
Full Range & Model Selection
Complete product range and model selection — lightweight packs for goods-to-person robots, high-current packs for forklift AGVs and low-temperature versions for freezers.
| Model | Voltage | Capacity | Continuous current | Typical robot | Applications |
|---|---|---|---|---|---|
| 25.6V 40Ah | 25.6V | 40Ah | 60A | Goods-to-person AGV | E-commerce picking · sorting |
| 25.6V 60Ah | 25.6V | 60Ah | 80A | AMR with manipulator | Assembly feeding · hospital logistics |
| 51.2V 100Ah | 51.2V | 100Ah | 150A | Forklift AGV | Pallet handling · 1–1.5t lift |
| 80V 200Ah | 80V | 200Ah | 250A | Heavy forklift AGV | Port · steel coil · 2t+ lift |
| D-25.6V 40Ah | 25.6V | 40Ah | 60A | Freezer AGV | Cold chain · −20 °C operation |
By robot type: Goods-to-person AGV → 25.6V 40Ah.
By environment: Ambient warehouse → standard series.
Not sure? Send us the duty cycle and charge window — our engineers will size the pack directly.
Frequently Asked Questions
The questions AGV and AMR integrators ask most about LiFePO₄ robot packs in the Cold Storage scenario — 25.6V (system voltage) and −20 °C (discharge operation), and what it takes to qualify.
Will a PLB pack replace the lead-acid unit in the Cold Storage scenario without rework?
Packs are built to the robot bay envelope, system voltage and connector, with CAN bus and RS485 as standard and an outline matched to common robot bays. For Cold Storage builds the range starts at D-25.6V 40Ah and D-25.6V 60Ah, specified at 25.6V (system voltage).
What runtime and output can we expect over a shift in the Cold Storage scenario?
LiFePO₄ accepts partial charging without a memory effect, so the robot tops up at every idle window instead of waiting for a full overnight cycle.
What temperature and ingress rating is specified for the Cold Storage scenario?
Specification: −20 °C (discharge operation). Charging is blocked below freezing to prevent lithium plating, and sealed housings keep dust and washdown water out of the pack. Endurance: 2,000+ (deep cycles).
Can the pack report SOC and alarms to monitoring already used in the Cold Storage scenario?
CAN bus and RS485 report SOC, voltage, current and temperature to the fleet manager, with SOC accuracy high enough for charge scheduling.
Which models cover the Cold Storage scenario, and how is delivery handled?
Typical models are D-25.6V 40Ah and D-25.6V 60Ah. Custom packs take 4–8 weeks including tooling, and lead time for standard models is confirmed on the quotation. Tell us the robot duty cycle, charge window and bay dimensions — our engineers size the pack and recommend the model within 24 hours.
Need a Selection Recommendation?
Tell us the duty cycle, charge window and bay size — our engineers will recommend the matching battery within 24 hours.
NDA available upon request · Typical response within 12 hours