EnerSysis set to introduce advanced lithium ion technology to its NexSys range of high-performance motive power batteries with the launch of NexSys iON™ battery systems in 2019. The expanded range will encompass superior Thin Plate Pure Lead (TPPL) and lithium ion batteries to offer customers a full spectrum of intelligent and flexible power options for their electric material handling vehicles.

The NexSys iON battery range builds on the reputation of EnerSys for flexibility. Anssi Laitinen, Senior Director of Marketing at EnerSys EMEA comments: “We use a scientific methodology, backed by our vast experience of efficiently matching battery solutions to our customers’ application requirements, irrespective of their fleet size or previous battery technologies. The focus is always on meeting each customer’s TCO and uptime targets, with no restrictions on the technologies used to achieve these. The inbuilt intelligence of our motive power solutions allows users to exceed their targets, with predictable performance from products that require minimal maintenance. What’s more, reliability and availability are built in, every time.”

For added peace of mind, NexSysiON batteries are designed to ISO26262 specifications, which equate to automotive lithium-ion battery safety levels. They employ multiple protective safety layers, an EnerSys- designed algorithm and a specially developed battery management system (BMS) based on ISO26262 ASIL C to achieve these high standards while avoiding adverse thermal events. Additionally, automotive-approved components are used in the construction of the batteries, bringing advanced safety benefits.

Meanwhile, the system design ensures safe, reliable and cost-effective operation for the long term. The batteries cells use NMC (Lithium Nickel Manganese Cobalt Oxide) chemistry, which is one of the most advanced types currently available. It offers high energy density as well as excellent chemical stability. As the product of choice for electric vehicles (EVs), NMC also offers a more solid and reliable supply chain, combined with vast, industry-wide investment into R&D.

Like their TPPL counterparts, NexSysiON batteries are optimised through connection to state of the art remote management tools. For instance, the truck-mounted batteries can communicate wirelessly with the Xinx cloud-based battery operations management system, alerting supervisors to actual or potential battery problems. Xinx enables predictive maintenance to avoid performance downtime issues, which contributes to improved operator behaviour, battery life and productivity. The system also provides data on trucks’ energy use during both operation and charging. It is complemented by the E-Connect mobile phone app, and Truck iQ smart battery dashboard that provides drivers with critical battery status information.

The NexSysiON modular concept enables a system to be sized to fulfil any application requirements. During operation, the modules can be charged with current NexSys+ modular chargers that have been retrofitted with a small upgrade kit. So, existing NexSysTPPL customers can swap to Li-ion when needed, in a safe and easy way.

The EnerSys designed NexSys iON system allows customers to maximise the well-known benefits of lithium ion technology. These include no maintenance requirements, high cycle life and long calendar life (so a truck needs only a single lifetime battery), high energy density, fast recharge times and no gas emissions.

With this combination of unique features and lithium-ion benefits, NexSysiON represents an exciting opportunity. However, EnerSys does not offer it simply as a standalone solution. Instead, NexSysiON shares the NexSys brand as equal partners with the long-established TPPL offering. This is important, because, in many applications, advanced lead chemistry remains very competitive technically, and financially the best solution. Additionally, the chemistry enjoys a long history of productive, reliable performance within the motive power industry.

What’s more, NexSys TPPL offers benefits not available from other lead-acid battery products. Their thin plate, pure lead design imparts very low battery internal impedance, permitting both a very high rate of discharge, and quick, efficient charge acceptance. Therefore, NexSys TPPL products are ideal, for example, in opportunity charging applications where operators can use occasions such as shift changes or lunch breaks to charge at high current for short periods.

Trucks remain in productive operation for a higher proportion of their shift, while the cost and space needed for dedicated charging areas is eliminated. Energy costs also drop, as NexSys TPPL batteries require less overcharging than flooded cells. The batteries provide longer cycle and storage lifetimes than standard AGM and Gel types, together with better energy density. Like earlier VRLA types, they are sealed, with minimal gassing and without need for water top-ups.

We see NexSys as a revolutionary change in the stored energy market” comments Laitinen, “no longer focusing on any specific technology, but offering the most intelligent and flexible power solutions for each of our customers’ specific applications and needs.”

For more information about NexSysiON and NexSys TPPL batteries please visit: http://www.enersys.com/


EnerSys, the global leader in stored energy solutions for industrial applications, manufactures and distributes reserve power and motive power batteries, battery chargers, power equipment, battery accessories and outdoor equipment enclosure solutions to customers worldwide. Motive power batteries and chargers are utilized in electric forklift trucks and other commercial electric powered vehicles. Reserve power batteries are used in the telecommunication and utility industries, uninterruptible power supplies, and numerous applications requiring stored energy solutions including medical, aerospace and defense systems.  With the recent Alpha acquisition, EnerSys provides highly integrated power solutions and services to broadband, telecom, renewable and industrial customers. Outdoor equipment enclosure products are utilized in the telecommunication, cable, utility, transportation industries and by government and defense customers. The company also provides aftermarket and customer support services to its customers in over 100 countries through its sales and manufacturing locations around the world.   

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