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Operator Aboard Battery Extractors

Industrial IoT Integration on Forklift Battery ExtractorsBHS offers a variety of distinct Operator Aboard Battery Extractors (BE) for operations of all sizes. These industrial battery pullers are the first of their kind to offer cloud-based digital integrations, giving users access to the Industrial Internet of Things (IIoT).

While each forklift battery changer is designed and built for a specific application, all units have features that make them the most versatile, reliable, and cost-effective options for Industry 4.0 applications. BHS battery changers reduce change-out times substantially, ensuring a more productive facility, and fully hydraulic operation allows for easier maintenance and longer operating lifespans.

These units provide full usage reporting through the BHS IIoT Portal, accessible with secured login from virtually any computer or mobile device. The Portal gives adminstrative users access to detailed session logs, system-health data, user authorization controls, and more. The Operator Aboard Battery Extractor’s heavy duty steel construction and durable powder-coat finish resist damage, while internal sensors send alerts for condition-based or predictive maintenance plans.

Digital and Mechanical Safety Features Eliminate Hazards

Safety features vary by model and include velocity fuse protection, which prevents vertical drops due to hydraulic hose damage. A three-point safety switch system requires proper gate closure, key, and foot switch activation for operation, and a floor-drive cutout system prevents the vehicle from moving when the extractor arm is outside the carriage.

Meanwhile, IIoT systems provide further safeguards. Operators must log in to the equipment’s operating system to power units on, preventing unauthorized access. Every 24-hours the completion of the digital Operator Daily Checklist is required; this protects both operators and the equipment by ensuring all systems are in optimal condition before use.

BHS forklift battery changers are essential equipment for any facility that requires frequent change-outs, and we combine ergonomic design with data collection and analytics to provide our clients with a fast return on investment.

Click on any of the products below for more information. To speak with our sales department, call 1.800.BHS.9500.

Single Side Battery Extractor (BE-SS)

Dependable side-extraction for smaller forklift fleets.

Single Level Battery Extractors (BE-SL)

Quick, safe battery changes along a single-level row of stands.

Double Stack Battery Extractors (BE-DS)

Pairs with Double Stack System Stands for efficient change-out.

Triple Stack Battery Extractors (BE-TS)

Utilizes vertical space to limit battery room footprint.

Quad Stack Battery Extractors (BE-QS)

High-speed battery changes for large forklift fleets.

Competitor Replacement Battery Extractors

Battery handling equipment that adapts to non-BHS systems.

Choosing a Forklift Battery Changer for Your IIoT-Ready Facility

Forklift battery changers that collect and transmit data maximize the value of the entire fleet, and Operator Aboard Battery Extractor Systems provide fast and safe battery handling for every shift.

forklift battery changing system

Consider the following features when choosing a forklift battery changer for side-extraction fleets:

  • Extractor Arm Design

    Extractor arms provide the horizontal force required to push and pull large forklift batteries. Every model of BHS Battery Extractor (BHS BE) provides arm travel along two chrome-hardened shafts. Movement is powered by a chain driven screw or “worm gear.” This dual-shaft design allows BHS Battery Extractors to complete battery change-outs with extraordinary efficiency — often within 2-3 minutes per changeout. Combined with metal shielding that protects components from debris, these heavy duty travel shafts offer a lifetime of dependable performance.

  • Lift Capabilities

    Four hydraulic lift cylinders provide safe, smooth vertical travel for Single Level, Double, Triple, and Quad Stack Battery Extractors. As the weight of forklift batteries shifts during the change-out process, the BHS Non-Inner-Flow Manifold carefully controls hydraulic power, limiting stress on mechanical components while ensuring steady positioning for the operator. Inner frames maintain their level at any height thanks to a fully synchronized eight-point equalization system. An accelerometer detects dropped batteries and other unsafe use, generating push notifications for managers via the IIoT system.

  • Roller Bed Configuration

    Dual roller beds increase change-out efficiency. Five powered rollers in each compartment provide smooth battery transfer as well as acting as a brake for safe machine travel while loaded. Tilt sensors mounted to the frame detect out of level operation which could lead to component and frame damage.

  • Floor Travel Systems

    Single-actuated floor travel is the industry standard for forklift battery changers, but BHS Battery Extractors double the power with two independent drive wheels, providing positive traction on wet or dry surfaces.

  • Safety Features

    BHS Operator Aboard Battery Extractors are designed with numerous safety features that provide multiple levels of dependable redundancy. Lift systems provide a high level of safety with eight point equalization and a velocity fuse, which freezes the lift cylinders if a hydraulic hose is damaged.

    Password-protected operator login ensures that only trained and authorized users have access to the equipment. Condition-based and predictive maintenance keeps all systems in optimal condition for safer operation, while also reducing downtime considerably. Managers can limit user PIN code access for operators remotely through the mobile portal, allowing them to prevent unsafe use on reciept of email notifications for out-of-spec systems.

    The substantial list of safety options includes an Overhead Guard and an Operator Shield for maximum operator protection. Other options include BE path blue lights, strobe lights, horns, and alarms to warn pedestrians of the BE’s movements. A Safety Scanner can automatically stop the BE’s movements when it senses someone in the travel path.

BHS Battery Extractors are built for reliable, long-lasting service, with the low maintenance requirements provided by system condition monitoring. Heavy duty steel construction with an acid- and scratch-resistant powder coating makes these powerful battery handling devices suitable for the toughest of environments, and only seven zerk fittings provide access for stress-free lubrication.

With the right forklift battery changer, your operation can see improved efficiency, dependable safety and better productivity overall. BHS Operator Aboard Battery Extractors and their IIoT software systems can be customized for virtually any type of facility, and our sales team is ready to help you choose appropriate options. Call us today at 1.800.BHS.9500 for more information or to find a dealer near you.