Free tool · Industrial

AGV, AMR & Industrial Wireless Charging Calculator

Estimate full-charge time or size an opportunity-charging system from route energy, available stops, battery current limits and efficiency.

Calculation type

Estimate the time to replace a selected depth of discharge, or size power for a target time.

Battery and system limits

Use measured DC-to-DC efficiency when available.

Battery parameters

Estimate full-charge time or size an opportunity-charging system from route energy, available stops, battery current limits and efficiency.

Calculation methodology

How to calculate AGV charging time and charger power

Start with the battery-side energy that must be restored, then divide it by the time actually available for charging. The calculator converts that requirement to nominal charger power using the entered system efficiency and checks the result against the battery’s permitted charging current.

Formulas used by the calculator

Full or recovery charging

Energy to restore (Wh) = voltage (V) × capacity (Ah) × depth of discharge

Required nominal charger power (W) = energy to restore ÷ target hours ÷ efficiency.

Opportunity charging

Total charging time (h) = minutes per stop × number of stops ÷ 60

Required nominal charger power (W) = energy used per period (Wh) ÷ total charging time ÷ efficiency.

Worked AGV charging examples

These examples use planning assumptions, not guaranteed vehicle performance. Replace them with measured route energy and the battery manufacturer’s limits.

01

48V battery recovery

48V, 100Ah, 80% depth of discharge, 1.5kW charger and 85% efficiency.

3.84kWh must be restored. Estimated time is about 3 hours 1 minute, at approximately 26.6A battery-side current.

02

Regular opportunity stops

0.50kWh used per period, eight 5-minute stops, 48V battery, 30A limit and 85% efficiency.

Minimum nominal power is about 882W. A 1.5kW system supplies about 0.85kWh across the stops, leaving a 0.35kWh planning margin.

03

Current-limited battery

The same opportunity schedule, but the battery permits only 10A at 48V.

Battery-side power is capped near 480W. The stops return about 0.32kWh, creating a 0.18kWh shortfall that requires more time, more stops or an approved higher current.

What each calculator input means

Battery voltage

Use the operating or charging voltage relevant to the calculation, then verify the charger supports the battery’s complete charging-voltage range.

Battery capacity

Enter the rated ampere-hour capacity from the current battery datasheet.

Depth of discharge

Enter the percentage of rated capacity that must be restored, not the final state-of-charge target.

Maximum permitted current

Use the lowest applicable limit from the battery, BMS, connector and vehicle wiring.

System efficiency

Use measured DC-to-DC performance at the intended air gap and alignment. Use a conservative value during early planning.

Route energy and stops

Measure energy use and count charging windows over the same route, cycle or shift period.

Planning limits and final validation

  • The result is an engineering estimate, not a guaranteed charging time or compatibility approval.
  • Battery voltage changes during charging; CC/CV taper, temperature and state of charge affect average power.
  • Wireless efficiency varies with coil gap, lateral offset, mounting materials and thermal conditions.
  • The battery and BMS must approve the charging voltage, current, profile, communication and interlocks.
  • Validate the selected system on the real vehicle using measured consumption and missed-stop scenarios before fleet rollout.

Continue your AGV charging research

AGV wireless charging systems →Opportunity charging guide →AGV battery charging guide →Industrial wireless charging products →

Need a different spec?

Output voltage and current can be configured within range to match your battery. Hardware changes are possible as a development project — talk to us first.

Technical Consultation

FAQ

How do I calculate the wireless charging power my AGV or AMR needs?

Multiply your battery voltage by the charging current the battery management system (BMS) allows, then check that the energy consumed per work cycle can be returned within the available charging time. Always add 10–15% margin for efficiency losses and alignment variation. This calculator does the estimate for you and maps the result to a standard ONEPOINTECH wireless charging module or system.

What efficiency should I assume for industrial wireless charging?

Modern inductive wireless charging systems reach 85–92% DC-to-DC efficiency at their rated air gap (typically 10–50mm depending on the module). Efficiency drops when the gap increases or the coils are misaligned, so design your dock around the rated gap and alignment tolerance of the specific module.

Can opportunity charging replace a large overnight charger?

Yes — for fleets with regular short stops (loading points, waiting zones, parking areas), opportunity charging lets you use a smaller charger that runs more often instead of one large charger that runs overnight. Sum the energy recovered during each stop; if it covers the energy used per cycle, the vehicle can run 24/7 without deep discharges.

What if my battery is not 24V or 48V?

Standard modules cover common AGV, AMR and LEV voltages, and the output is configured to your battery specification within the supported range (roughly 12–60V depending on the model). For unusual voltages, higher currents, or larger air gaps, ONEPOINTECH builds custom wireless charging systems — send your battery spec through the contact form.