NEWS
24
2026
-
07
Smart Lithium-Ion Retrofit of an AGV Fleet at an E-Commerce Warehouse
Jiaxing, Zhejiang - a large e-commerce fulfilment centre, 4:00 a.m. Inside the tens-of-thousands-square-metre sorting hall, thirty automated guided vehicles (AGVs) are rapidly moving racks, transporting ordered goods from storage to the packing area.
Jiaxing, Zhejiang - a large e-commerce fulfilment centre, 4:00 a.m. Inside the tens-of-thousands-square-metre sorting hall, thirty automated guided vehicles (AGVs) are rapidly moving racks, transporting ordered goods from storage to the packing area. On the dispatch centre's big screen, the battery level, task status, and travel path of each AGV are clearly displayed at a glance.
This Jiaxing e-commerce centre is a key order fulfilment hub for the region, processing over 50,000 orders per day on average. Ahead of Singles' Day 2022, to cope with the surge in order volume, the warehouse introduced thirty AGVs for goods-to-person smart picking operations.
During major sales events, the AGVs run almost 24/7. Each AGV required two to three battery changes per day - that's sixty to seventy swap operations across the fleet. With each lead-acid battery weighing 35-40 kg, workers had to move over two tonnes of batteries daily.
"Back then, several workers complained about back pain," recalls Lao Chen with a wry smile. "Swapping batteries to the point of lumbar strain is no joke."
Even more frustrating was the charging speed. A full charge for a lead-acid battery took 8 to 10 hours - meaning the warehouse had to keep at least three to four sets of spare batteries on hand just to maintain AGV rotation. The spare batteries not only consumed valuable storage space, but lead-acid batteries also degraded quickly under frequent deep cycling - typically needing complete replacement after just over a year.
"One Singles' Day, order volume spiked and the AGVs ran for over 30 hours straight," Lao Chen recalls. "We ran out of spare batteries, and the newly swapped ones hadn't finished charging. That night, eight AGVs went down simultaneously, and the entire picking line was halted for over an hour."
By the end of 2024, Lao Chen and his team evaluated multiple battery suppliers and system integrators, finally settling on a combined Wysher + Victron Energy solution.
"Wysher supplied their 48V AGV-specific LiFePO₄ batteries," says Lao Chen. "LiFePO₄ has five to six times the cycle life of lead-acid, supports fast charging, and requires virtually no maintenance. Most importantly - Wysher's batteries have a built-in smart BMS that communicates in real time with Victron's system controller via CAN-bus."
Victron Energy's solution addressed the charging management side. Victron's MultiPlus inverter/chargers support adaptive charging technology, automatically adjusting the charging curve based on battery status; the Cerbo GX system controller acts as the "brain" of the entire charging station, managing the charging process of multiple AGVs simultaneously via CAN-bus.
"Victron's Smart IP43 charger series includes a 48V model specifically for electric forklifts and warehouse vehicles," says Lao Chen. "We paired one charger with every two AGVs - when an AGV runs low, it automatically returns to the charging zone, plugs in, and fast-charges. The key is that Cerbo GX allows remote monitoring of every battery's status, so we can see all the data on our big screen."
The Final System Configuration
After detailed on-site surveys and system design, the system integrator, in partnership with Wysher, developed a complete lithium-ion plus smart-charging solution for this e-commerce centre's AGV fleet:
Component | Model | Qty |
AGV traction batteries | Wysher 48V AGV-specific LiFePO₄ | 30 units |
Smart chargers | Victron Smart IP43 48V/13A | 15 units |
System controller | Victron Cerbo GX | 1 |
Monitoring display | GX Touch 70 | 1 |
Shunt | Victron SmartShunt 500A | 1 set |
(Note: The above reflects the actual setup at the Jiaxing e-commerce distribution centre. Wysher's 48V AGV-specific batteries feature a modular design and are compatible with multiple AGV models. Victron's Smart IP43 charger supports a dedicated lithium-ion charging profile, ensuring optimal charging. Cerbo GX enables remote monitoring via the VRM portal.)
During the retrofit, the original lead-acid battery compartments were emptied, and the Wysher LiFePO₄ battery packs were precisely installed in the AGV chassis - dimensions matched perfectly for a seamless fit.
During the first Singles' Day after the battery swap, Lao Chen truly felt the difference.
First, runtime. The old lead-acid batteries ran out in four to five hours. After switching to LiFePO₄, runtime increased to nearly ten hours - more than doubled.
"Before, each AGV needed at least two battery changes a day. Now, once a day is enough," says Lao Chen. "And LiFePO₄ supports fast charging - when an AGV runs low, it automatically returns to the charging zone, and Victron's Smart IP43 charger brings it back to over 80% in just over an hour. After a one-hour 'rest' in the charging zone, it can run for several more hours."
Even more significant was the optimisation of charging strategy. Previously, lead-acid batteries had to be charged to 100% before use - otherwise unstable voltage would affect AGV operation. Now, with LiFePO₄ and Victron's adaptive charging technology, there's no need to charge to full every time - charging to 80% is enough to resume work, with the remaining 20% topped up gradually during the next operational gap.
"This effectively means the AGVs can 'charge while working,'" says Lao Chen. "Whenever a vehicle's battery gets low, it automatically returns to the charging zone for a quick top-up, then goes back to work. AGV utilisation has increased from under 70% to over 90%."
What pleased Lao Chen most was the remote monitoring capability of Cerbo GX. Previously, workers had to guess whether batteries had enough charge and how much runtime was left. Now, on the dispatch centre's big screen, every AGV's battery level, state of health, and cycle count are clearly displayed.
In May 2026, Victron Energy has just launched the 48V model of the Smart IP43 charger, specifically targeting the electric forklift and warehouse vehicle market. Meanwhile, Wysher's AGV-specific LiFePO₄ batteries offer a mature, reliable, and field-proven energy storage choice for this fast-growing industry.
According to industry statistics, China's smart warehousing market has surpassed RMB 100 billion, with annual growth rates above 20%. As e-commerce, express delivery, and manufacturing continue to expand, the installed base of AGVs will grow rapidly - and a reliable, long-life, remotely monitorable smart battery system is fast becoming a standard requirement for intelligent warehousing.
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