AGV/AMR Battery Cycle Life Estimator
Cycle-life and state-of-health auditor for AGV/AMR LFP packs — expected cycles at your depth of discharge and time left at your duty.
Chemistry: LiFePO₄ (LFP) (rated at 80% DoD)
Cycle life scales with depth of discharge: N(DoD) = N_rated × (80%/DoD)^1. With your numbers: 3,000 × (80/60)^1 = 4,000 cycles. SoH assumes linear fade from 100% to 80% over the cycle life — verify against a measured capacity test.
Field notes from maintenance practice
AGVs cycle shallow and often — opportunity charging at every drop-off means dozens of micro-cycles a day, which is precisely where LFP shines (this estimator's equivalent-full-cycle input matters more than 'charge events'). The fleet-level insight: charging scheduling is battery management. Spreading charge events across vehicles, and capping routine charge at 90% SoC, adds years across a fleet.
Heat is LFP's main enemy in AGV duty: fast charging in a warm charging bay ages packs faster than the cycles themselves — keep charge rooms ventilated and charge rates within spec. Treat the state-of-health figure as a planning estimate: a measured capacity test (full charge, metered discharge) is the ground truth, and the tool's linear-fade assumption should be re-anchored to it once a year.
Sources & references
- IEEE 1188 / IEEE 450 — recommended practice for maintenance, testing and replacement of stationary batteries
- Battery University BU-501a — depth of discharge vs cycle life
- LFP cell datasheets (CATL/EVE) — cycle life vs DoD and temperature
Planning estimate only — verify pack health with a measured capacity test before relying on it for critical duty.
AGV/AMR Battery Cycle Life Estimator for maintenance and reliability teams: Cycle-life and state-of-health auditor for AGV/AMR LFP packs — expected cycles at your depth of discharge and time left at your duty. Free, private (everything runs in your browser) and ready for daily plant use.
About AGV/AMR Battery Cycle Life Estimator
This auditor estimates how many charge/discharge cycles your AGV/AMR LFP packs (LiFePO₄) will deliver at the depth of discharge you actually use, how much of that life is consumed, and roughly when replacement lands at your current duty. It uses the manufacturer-style power law N(DoD) = N_rated × (DoD_rated/DoD)^k — shallower cycling means disproportionately more cycles.
How to use AGV/AMR Battery Cycle Life Estimator
- 1Set the rated cycle life from the cell/pack datasheet and your real average depth of discharge.
- 2Enter cycles completed so far (use energy throughput ÷ capacity for partial cycling) and your cycles per week.
- 3Read expected life at your DoD, estimated state of health and the time remaining at your duty.
Why use AGV/AMR Battery Cycle Life Estimator?
- ✓Cycle-life and state-of-health auditor for AGV/AMR LFP packs — expected cycles at your depth of discharge and time left at your duty — computed instantly with the standard formula
- ✓100% free and unlimited, with no sign-up, login or paywall
- ✓Runs entirely in your browser — readings and asset data never leave your device
- ✓Niche-specific defaults and thresholds for AGV/AMR LFP packs, traceable to the cited standards
Frequently asked questions
How many cycles should AGV/AMR LFP packs last?+
At the datasheet rating point, LiFePO₄ cells of this class are typically rated around the default shown (to 80% remaining capacity). Cycle at a shallower depth of discharge and the count rises steeply — that is the (DoD_rated/DoD)^k term. Heat, fast charging and storage at full charge all shorten it.
Our AGVs charge 30 times a day — how do I even count cycles?+
Count energy, not plugs: pull total kWh (or Ah) throughput per vehicle from the charger or BMS logs, divide by pack capacity, and that's equivalent full cycles — the number this estimator wants. Thirty 3%-top-ups are ~1 EFC. LFP barely cares about cycle shallowness, so EFC throughput plus calendar time and average temperature predict AGV pack life well.
What counts as one cycle if I only partially discharge?+
Count equivalent full cycles: two 50% discharges ≈ one full cycle of energy throughput. If your charger or BMS reports total Ah or kWh throughput, divide by the pack's rated capacity to get equivalent full cycles — that is the number to enter as cycles completed.
When is the battery actually 'done'?+
Industry convention is 80% of original capacity — beyond that, fade accelerates and runtime becomes unpredictable. Fleets usually retire packs at 80% for the duty they were bought for, then cascade them to lighter duty rather than scrapping immediately.
Does depth of discharge really matter that much?+
Yes — it is the single biggest lever you control. Lead-acid cycled to 50% instead of 80% roughly doubles cycle count; lithium chemistries gain similarly with the exponent k shown in the formula. Sizing a pack so daily use is a shallower fraction of capacity is usually cheaper than replacing packs early.
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