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Custom Battery Chargers for Industrial Applications

In many industrial applications, standard charging systems simply aren’t enough.
Electric industrial vehicles, robotic platforms, construction machinery, and automated logistics systems often require a custom battery charger designed according to specific electrical and operational requirements.

GEBAT develops customized charging systems for industrial electric vehicles and machines, adapting power architecture, charging algorithms, and communication interfaces to the unique needs of each application.

With over 50 years of experience in industrial battery charging, the company designs reliable and efficient solutions, specifically engineered to perform in complex industrial environments where high-performance chargers are essential.

Custom Battery Charger Design

Every project begins with a deep analysis of the application’s technical specifications.

GEBAT engineers collaborate with:

  • Electric industrial vehicle manufacturers.
  • Machine and equipment OEMs.
  • Battery manufacturers.
  • System integrators.

Our goal is to develop customized charging solutions and integrated systems designed around the specific electrical architecture of the machine or fleet.

The primary parameters we can customize include:

  • Output voltage and current.
  • Charger power rating.
  • Compatibility with different battery chemistries.
  • Charging algorithms and profiles.
  • BMS communication and CANBUS protocols.
  • Mechanical configuration and cabinet design.
  • Monitoring and communication systems.

This approach allows us to create integrated battery chargers tailored for specific industrial applications and demanding operating conditions.

Modular Charging Systems and Fast Chargers

Many GEBAT solutions are based on modular architectures, allowing for flexible power configuration based on application needs.

A modular forklift battery charger offers several key advantages in industrial settings:

  • Scalable power architecture.
  • Service continuity in case of a module failure.
  • Simplified maintenance.
  • Future power expansion capabilities.

These platforms are particularly suited for industrial vehicle fleets, automated logistics systems, and intensive work cycles where fast chargers are required to minimize downtime and evolve with growing energy demands.

Integrated Charging Systems

In many projects, the battery charger must operate as an integral part of the machine’s electrical system or the energy infrastructure.

GEBAT develops integrated charging systems and battery chargers designed to work in perfect coordination with:

  • Battery Management Systems (BMS).
  • Vehicle control systems.
  • Industrial energy management systems.

Integration optimizes charging cycles, improves energy efficiency, and ensures reliable operation in the most demanding industrial applications.

Custom chargers for Lithium and Solid-state batteries

The growing adoption of lithium batteries in industrial machinery requires chargers designed for specific battery technologies and communication protocols.

GEBAT charging systems support various storage technologies, including:

  • Lithium-ion batteries.
  • Hybrid storage systems.
  • Supercapacitors.

The flexibility of our charging platform allows us to develop fast chargers optimized for the specific battery pack and the machine’s operational cycle.

Typical System Specifications

Depending on the application, GEBAT custom systems can support a wide range of operating conditions, including:

  • Battery voltages from 12 V up to several hundred volts.
  • Charging power from a few dozen Watts to systems exceeding hundreds of kW.
  • Full compatibility with both lithium and lead-acid forklift battery chargers.
  • BMS communication via CANBUS or dedicated protocols.

Charging systems can be configured as off-board charging stations or as on-board systems integrated into the machine or energy infrastructure.

Development Process for Charging Systems

Our custom charging systems are developed through a structured engineering process.
A typical project includes:

L

Application Analysis

Evaluating battery specs, machine architecture, and duty cycles.
3

Electrical System Design

Defining charger topology, power range, and communication interfaces.
3

Prototype Development

Creating custom configurations and initial validation tests.
3

Testing and Optimization

Verifying performance, reliability, and system integration
L

Production and Implementation

Manufacturing and supplying the final charging system.
This process ensures that every design is optimized for its application and built for long-term industrial performance.

OEM Partnerships

GEBAT partners with OEMs and system integrators focused on developing industrial electric vehicles and machinery.

Our technical team supports clients throughout the entire product development cycle, from initial system design to charger integration, validation, and long-term operational support.

This collaborative approach results in charging solutions designed specifically for the electrical architecture and operational needs of the machine.

Industries and Applications

GEBAT’s custom battery chargers and fast chargers are utilized across numerous industrial sectors.

Forklifts

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AGV, AMR, Robotics & Supercapacitors

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Light Material Handling & Intralogistics

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Airport GSE Charging

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Earthmoving & Construction Equipment

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Agricultural Vehicles

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Electric Buses & Trucks

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Mining Equipment

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Battery Testing, Cycling & Rejuvenation

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