End of Life (EOL) Analysis of Batteries in Floor Scrubber Equipment

End of Life (EOL) Analysis of Batteries in Floor Scrubber Equipment

In floor scrubber equipment, End of Life (EOL) refers to the stage when the battery can no longer provide sufficient energy to maintain standard operation. When the battery's capacity drops to below 70%-80% of its original capacity, it is generally considered to have reached the EOL stage. Although the battery may still function, the operating time of the equipment is significantly reduced, making it unable to meet daily cleaning requirements, and the frequency of charging increases, which impacts operational efficiency.

Key Indicators of EOL Status

1. Significant Reduction in Run-Time Performance
   As the battery capacity depletes, the floor scrubber’s ability to sustain its operation decreases, making it difficult to complete a full cleaning cycle.

2. Increased Charging Frequency
   Aging batteries require more frequent charging, leading to higher maintenance costs and decreased operational efficiency.

3. Extended Charging Time (ECT)
   With the increase in the battery's Internal Resistance (IR), charging efficiency decreases, resulting in noticeably longer charging times.

4. Frequent Alarms from the Battery Management System (BMS)
   As the battery deteriorates, the Battery Management System (BMS) may issue frequent warnings indicating the worsening health of the battery.

5. Increased Thermal Management Issues
   As the battery ages, reduced electrochemical efficiency leads to more heat generation, potentially causing thermal management and safety concerns.

Factors Affecting Battery Life

1. Charging and Discharging Habits

   • Overcharging and Deep Discharging: Frequently charging the battery to full or discharging it completely accelerates its degradation. Deep discharges are particularly detrimental to battery life. Maintaining a State of Charge (SoC) between 20%-80% is the optimal strategy for prolonging battery life.
   • High-Frequency Fast Charging (HFFC): Frequent use of fast charging increases battery temperature, accelerating electrolyte decomposition and shortening battery lifespan. It is recommended to prioritize slow charging during regular use.

2. Operational and Environmental Conditions

   • Thermal Effects: Batteries are highly sensitive to temperature. High temperatures increase chemical activity inside the battery, accelerating capacity degradation, while low temperatures increase internal resistance, reducing performance. Prolonged operation under extreme temperatures can significantly shorten the battery’s Lifecycle.
   • Humidity and Mechanical Vibration: Excessive humidity or frequent vibration can damage the physical structure of the battery, accelerating aging and increasing safety risks.

3. Battery Chemistry and Quality

   • Chemical Composition Variability: Common battery types in floor scrubbers include Lead-Acid Batteries (LABs) and Lithium-Ion Batteries (LIBs). Lithium-ion batteries have higher energy density and longer cycle life, while lead-acid batteries, though cheaper, have a shorter lifespan.
   • Manufacturing Quality: High-quality battery cells and superior manufacturing processes can significantly extend battery life and improve the safety and reliability of the equipment.

4. Operational Behavior

   • Frequent Start-Stop Operations: Repeated starting and stopping of the equipment imposes a heavy load on the battery, leading to increased temperature and accelerated performance degradation.
   • Prolonged Low SoC Operation: Operating the battery for extended periods at low charge levels increases current load, speeding up the aging process.

Disposal Options for EOL Batteries

1. Second-Life Applications
   Batteries that reach EOL typically retain 70%-80% of their original capacity. While no longer suitable for floor scrubbers, they can still be used in energy storage systems or low-power devices, maximizing their remaining value.

2. Resource Recovery and Recycling
   Through specialized recycling processes, valuable metals such as lead, nickel, and lithium can be extracted from spent batteries. These materials can then be reprocessed and used to manufacture new batteries, reducing resource waste and environmental pollution.

3. Environmental Disposal
   Batteries that cannot be reused or recycled must be disposed of through strict environmental procedures to prevent heavy metal leakage and other environmental hazards. Ensuring that the disposal is handled by certified recycling companies is essential for environmental compliance.

Best Practices for Extending Battery Life in Floor Scrubbers

1. Optimized Charging Practices: Avoid overcharging and deep discharging, keep the SoC between 20%-80%, and reduce the frequency of fast charging to slow down battery degradation.

2. Controlled Operational Environment: Avoid using floor scrubbers in extreme temperatures, especially during prolonged operations in hot or freezing environments.

3. Rationalized Operational Practices: Avoid frequent starting and stopping, and strive to maintain continuous operation to alleviate battery load stress.

4. Routine Maintenance and Monitoring: Regularly check the battery’s health status, ensure the BMS is functioning properly, and identify potential issues early for timely resolution.

Common Misconceptions and Methods for Identifying EOL Batteries

1. Misconception: EOL Batteries Are Completely Useless
   In fact, EOL batteries can still be used in low-power applications such as backup power supplies or energy storage devices. While they may no longer support the long-term operation of a floor scrubber, they still have residual value.

2. Misconception: Replacing with New Batteries Will Always Provide Longer Runtime
   Although new batteries restore a device's run-time capabilities, poor charging and usage habits can still limit the lifespan of the new battery.

3. Misconception: Fast Charging Is Harmless to Batteries
   Although fast charging technology has advanced, frequent use of fast charging can still negatively impact battery lifespan. When possible, it is recommended to use slow charging.

EOL Identification Methods

By using key data provided by the BMS, such as Capacity, Internal Resistance (IR), and Cycle Count, the health status of a battery can be accurately assessed. Combined with the actual performance of the device, such as noticeable reductions in run-time and increased charging frequency, one can effectively determine whether the battery is nearing its EOL phase.

Conclusion

Extending the life of batteries in floor scrubbers requires a combination of optimized operational behaviors and sound maintenance management strategies. Understanding the symptoms and factors influencing battery EOL can help better manage and utilize floor scrubber equipment. Additionally, proper disposal of EOL batteries not only protects the environment but also maximizes the remaining value of these batteries.