Customer Challenge
Commercial trucking fleets depend on liftgates for heavy pallet deliveries. These systems place significant strain on batteries, especially during frequent stops and freezing weather. Downtime from weak batteries leads to costly jump-starts, delayed deliveries, frustrated drivers, and premature electrical component failures.
Our customer asked: Can solar panels keep liftgate batteries powered for a full day of heavy use, even on cloudy days?
PowerFilm’s Solution
-
Four 110W panels (total output: 440W). This solution uses two panels in parallel and two in series, optimizing solar output by reducing resistive losses while keeping the cable gauge manageable for installation. Finally, it keeps the system voltage below 50V, which is within a human-safe threshold.
-
Maximum Power Point Tracking (MPPT) IP67-rated charge controller.
-
Connected to the liftgate battery system.
Test Methodology
-
Cycles Completed: 29 full lift cycles (up and down).
-
Timing: Cycle the lift up and wait one minute, then cycle the lift down and wait three minutes.
-
Load: 2,000 lb per pallet.
-
Weather: Approximately half of the test was performed in partly cloudy to shaded conditions, with the remainder in partial sun.
This approach was designed to simulate fleet operations over a whole day.
Key Benefits for Fleets
-
Reliability: Maintains liftgate readiness even during heavy-duty operation.
-
Battery Life Extension: Reduced strain means fewer replacements and lower maintenance costs.
-
Downtime Prevention: Avoids costly roadside jump-starts and delays.
-
All-Weather Confidence: Demonstrated stability in cloudy and shaded conditions.
Liftgate Lifetime Extension: Average battery voltage during lift operation remains higher, reducing current to the motor and extending liftgate and battery lifespan.
Test Results
The system powered a full trailer of 2,000 lb pallets with only a minimal reduction in battery charge, even under cloudy conditions.
-
Starting Voltage Under Load: ~12.24V
-
Ending Voltage Under Load: ~12.15V
-
Net Drop: ~0.09V
The solar panels effectively offset the battery draw from repeated liftgate use, enabling sustained operations for a full day of deliveries.
The consistently high voltages also reduce current through the liftgate's electromechanical components. Keeping the current through these components as low as possible is important because, as the current increases, so does the heat generated in the system, which accelerates wear and tear.
When high battery voltage is maintained, three major benefits are realized: more liftgate cycles per day, a longer interval between battery replacements, and an increased lifetime of electromechanical components.
Conclusion
PowerFilm’s 440W solar liftgate solution provides fleets with dependable power for demanding delivery operations. By integrating solar into their equipment, fleets can expect higher uptime, fewer battery failures, and long-term cost savings.