Knowledge

In the wake of smart manufacturing, medical logistics, and warehouse automation,
HAION Caster PAS (Power Assist System) motorized system
has become standard equipment for enterprises to reduce labor burdens
and improve handling efficiency. However, when planning purchases,
apart from payload capacity and thrust,
the most common questions enterprises ask are:
"How do we calculate the battery life? How long can it run on a single charge?"
"Will an increased payload affect the battery life?"
"If there are ramps in the factory, will it drain the battery quickly?"
In fact, the battery life performance of a motorized system
cannot be evaluated solely by the battery size.
This article will fully break down the key factors affecting the battery life
and power consumption of a motorized system.
What is Battery Life?
Simply put, battery life is
"how long the system can continuously operate after the battery is fully charged."
How is the Battery Life of a Motorized System Calculated?
The battery life of the HAION Caster PAS motorized system is primarily determined by
battery capacity and the average power consumption of the motor.
In actual operating environments, power consumption changes dynamically with
road conditions and payloads;
therefore, the actual battery life usually differs from the theoretical value.
Below, we break down the 5 key factors that affect power consumption.
5 Key Factors Affecting the Battery Life of HAION Caster Motorized Systems
  1. Payload Size
      The higher the payload, the greater the torque and instantaneous
      starting current required by the motor, which significantly increases power consumption.
  2. Ground Material
      Outdoor surfaces, carpets, and rough concrete present greater resistance
      and result in higher power consumption.
      Conversely, flat epoxy or tiled floors are more energy-efficient.
  3. Ramp Environments
      When going uphill, the motor must overcome additional gravitational force.
      The greater the force required and the longer the travel distance,
      the faster the power consumption will multiply.
  4. Start-Stop Frequency
      Frequently starting and turning in narrow aisles or hospital wards forces the system
      to repeatedly overcome static friction and payload inertia.
      This consumes far more power than continuous, long-distance walking.
  5. Operating Speed
      Operating the motorized system in "high-speed mode"
      for extended periods significantly increases the motor's power consumption,
      thereby drastically shortening the battery life.
Frequently Asked Questions (FAQ)
  Q1: Is the battery life of the HAION Caster motorized system typically measured in
  "travel distance (km)" or "operating time (hours)"?
    A: In industrial and warehousing application environments,
    "operating time (hours)" is primarily used as the evaluation standard.
    This is because factory handling involves a large amount of spot turning,
    waiting for materials, and starting from a standstill.
    Planning by operating hours allows enterprises to align equipment usage more precisely
    with shift schedules and charging timelines.
  Q2: Why does the battery life of a motorized system decrease in
  cold or low-temperature environments?
     A: Battery chemical activity is affected by temperature.
     In low-temperature environments, the internal resistance of the battery increases,
     leading to a drop in energy release efficiency. Simultaneously,
     low temperatures can cause a slight increase
     in the rolling resistance of the lubricants and the tires on the ground.
  Q3: If the speed is set to the slowest setting (low-speed mode),
  will the battery life definitely be the longest?
    A: Not necessarily. Although the motor's power consumption is lower at low speeds,
    moving too slowly extends the "total time" required to complete the same handling distance.
    Sometimes, driving at a moderate speed allows the cart to reach its destination faster,
    shortening the motor's operating time and achieving better overall energy efficiency.
  Q4: How can we tell if the battery life of our current motorized system
  has begun to degrade?
     A: Under the condition that the payload, road conditions,
     and operating habits remain unchanged, if you notice that the
     "operating time after a full charge is significantly shortened"
     (for example, it used to last half a day, but now runs out in 2–3 hours),
     or if the battery indicator drops drastically just as the cart starts moving,
     it indicates that the internal resistance of the battery is too high,
     and it should be replaced as soon as possible.