What Are the Core Power Requirements for Modern Robotic Systems?

You are designing an advanced robotic system, but choosing the right power architecture is a critical challenge. A mismatch in the power supply can cripple a robot’s performance and autonomy, leading to project failure.

Modern robots run on DC power, which is supplied either by a battery pack for mobile robots or an AC-to-DC converter for stationary ones. The battery choice, typically Lithium-ion for AI robots, is critical for determining the robot’s operational lifespan and capabilities.

I once consulted with a team building a sophisticated AI inspection robot. They were focused on the software but had overlooked the power demands. Their first battery choice gave them only 30 minutes of runtime. We had to re-engineer the entire power system to meet their 8-hour operational goal.

How long do robot batteries last?

This question has two very different answers. The first is about runtime on a single charge. The second is about the total operational life of the battery pack itself.

A robot’s runtime can be anywhere from 30 minutes to over 24 hours on a single charge. The battery pack’s total lifespan is typically 5 to 10 years, which comes from the 2,000 to 5,000 charge cycles you get from a high-quality LiFePO4 pack.

Factors Influencing Runtime (Per Charge)

The runtime is the most visible performance metric. It’s determined by how big the "fuel tank" is and how fast the robot consumes that fuel. Key factors include:

• Battery Capacity (Ah)¹: A higher Amp-hour (Ah) rating means more energy is stored, leading to a longer runtime.
• Payload²: A robot carrying a heavy load must draw more current to its motors, draining the battery faster.
• Terrain³: Moving up an incline or across a high-friction surface like a thick carpet requires significantly more energy than rolling on smooth concrete.
• Task and Components: A robot using power-hungry sensors like LiDAR and running intense computations will have a shorter runtime than a simple robot just driving back and forth.

Factors Influencing Total Lifespan (In Years)

The lifespan is about long-term value and reliability. As engineers, we design systems to maximize it.

• Battery Chemistry⁴: Lithium Iron Phosphate (LiFePO₄) offers the longest cycle life (3,000-5,000 cycles), making it the best choice for industrial robots that operate daily.
• Charging Habits⁵: Using the "80/20 Rule" (keeping the battery between 20% and 80% charge) can triple the number of cycles.
• Operating Temperature⁶: Extreme heat is the enemy of battery life. A good pack design includes thermal management to keep the cells in their optimal temperature range.

What batteries do AI robots use?

AI-powered robots, like autonomous mobile robots (AMRs) in warehouses, have enormous power needs. They are running complex software on powerful processors while also powering sensors and motors.

AI robots almost exclusively use high-energy-density lithium-ion (Li-ion) or lithium-polymer (LiPo) battery packs. These are the only mature technologies that can power the robot’s brain, sensors, and motors in a reasonably small and light package.

Why Lithium is Essential for AI

Running an AI model, processing data from a 3D LiDAR unit, and powering high-torque motors all at once creates a massive power demand. A traditional lead-acid battery with the same energy would be far too big and heavy for a mobile robot. Lithium’s high energy density is the key enabling technology.

Custom Pack Design⁷ for AI Systems

Off-the-shelf hobby batteries are not suitable for commercial AI robots. These advanced systems require custom-engineered battery packs from specialists like us. We work directly with robotics companies to design packs that feature:

• A Custom Form Factor: The battery is shaped to fit perfectly within the robot’s unique chassis, maximizing capacity in a limited space.
• Multiple Voltage Outputs: The pack might provide 48V for the drive motors, 12V for the main computer, and 5V for specific sensors, all from a single source.
• A "Smart" BMS: The Battery Management System communicates directly with the robot’s main computer over a CAN bus or SMBus. This allows the AI to monitor the battery’s health, temperature, and precise state-of-charge, enabling it to make smart decisions like returning to its charger autonomously.

What are the two main types of power supplies for robots?

When you look at the entire field of robotics, the power supplies can be sorted into two very clear categories. The choice depends on one question: does the robot need to move?

The two main types of power supplies are onboard battery packs for mobile robots and external, wired power converters for stationary robots. One provides freedom of movement, the other provides unlimited runtime.

A Comparison of Power Architectures

Do robots use AC or DC?

This is a fundamental question in electrical engineering for robotics. The answer determines how the entire power system is structured.

Robots use DC (Direct Current) power for all of their internal components. A stationary robot may plug into an AC wall outlet, but that power is immediately converted to the DC voltages needed to run the system.

Why DC is the Universal Standard in Robotics

Everything inside a robot runs on DC power.

• Motors: The brushless DC motors that drive the wheels and joints are optimized for DC.
• Computers: The main processor, microcontrollers, and memory all require stable, low-voltage DC power.
• Sensors: Cameras, LiDAR, and proximity sensors are all DC-powered electronic devices.

Batteries naturally provide DC power, which makes them a perfect fit for mobile robots. For stationary robots, the first component in their power system is always an AC-to-DC converter.

Do all robots need a power supply?

This may sound like a simple question, but it gets to the very definition of what a robot is.

Yes, absolutely all robots need a power supply. A robot is a machine designed to perform physical work, and according to the laws of physics, performing work requires a constant input of energy. Without a power supply, a robot is just a lifeless sculpture.

Energy is a Prerequisite for Work

The first law of thermodynamics tells us that energy cannot be created or destroyed. This means that for a robot to move its arm, spin a wheel, or even process data, it must draw that energy from a source. Every single action consumes watts of power that must be provided by its power supply⁸.

Some robots might use non-electrical systems, like hydraulic or pneumatic actuators. However, those systems still require an external power source. The hydraulic fluid needs a pump, and the pneumatic system needs an air compressor. In nearly every case, those pumps and compressors are run by a powerful electric motor, which gets its energy from… a power supply.

Conclusion

Every robot needs a reliable DC power supply to function. For the modern generation of mobile and AI-driven robots, a custom-designed lithium-ion battery pack is the critical foundation that enables their autonomy, performance, and long-term value.