Commercial intelligent warehousing AGVs (Automated Guided Vehicles) serve as core logistics equipment in automated stereoscopic warehouses, smart factories and e‑commerce logistics centers, undertaking automatic handling, storage and sorting of goods. The static‑elimination high‑voltage power supply is a critical supporting component for AGVs, delivering stable high‑voltage output to ion air bars, static eliminators and electrostatic detection sensors. It ionizes air to generate positive and negative ions, neutralizing static electricity accumulated on vehicle bodies, cargo, racks and conveyor surfaces. This eliminates risks such as particle adhesion, dust buildup, electronic breakdown, scanning failure and flammable hazards, ensuring continuous safe operation and sorting efficiency. Its long‑term reliability, maintenance‑free lifespan, vehicle‑mount adaptability, low power consumption and safety protection directly determine AGV uptime, warehouse stability and overall logistics operational costs. AGV static‑elimination applications impose eight distinctive technical challenges compared with conventional industrial static power supplies. First, extreme long life and maintenance‑free operation for unattended scenarios. AGVs run continuously 7×24 with annual operating hours exceeding 8,000. Large fleets spread across warehouses create extremely high maintenance costs. Power failures cause halts, line congestion and workflow interruptions. Requirements include MTBF ≥ 1×10⁵ hours, design life ≥ 10 years and full lifecycle maintenance‑free performance without regular cleaning or component replacement. Traditional static power supplies cannot meet such demands. Second, rigorous vehicle‑mount operating condition adaptability. AGVs experience continuous vibration, shock and tilt during movement, elevator access and ramp travel. Environments range −10 ℃ to +55 ℃ with humidity above 90 % RH, heavy dust, condensation in cold storage and corrosive gases in chemical warehouses. Powered by fluctuating 24 V / 48 V lithium batteries, the power supply must feature outstanding vibration resistance, wide temperature tolerance and full protection while supporting broad input voltage variation. Third, ultra‑miniature size and lightweight design. Installation space on AGVs is extremely limited beside forks, scanning modules and chassis surfaces. Every additional 100 g reduces payload capacity. Required specifications: volume ≤ 10 cm³, weight ≤ 50 g and power density ≥ 200 W/in³ for seamless integration inside ion bars and narrow chassis gaps. Fourth, low power consumption and high energy efficiency. AGVs rely entirely on onboard lithium batteries; static power consumption directly reduces operational duration. Peak efficiency ≥ 90 %, static power ≤ 5 mW and standby power ≤ 1 mW are mandatory to preserve battery life. Fifth, highly stable output and consistent static elimination performance. Cargo types include cartons, plastic trays, electronics, chemicals and cold‑chain goods with vastly different surface resistance and static accumulation. Temperature and humidity variations affect ionization efficiency. Output must be continuously adjustable from 4 kV to 12 kV with stability better than ±1 % and constant current characteristics to maintain balanced ion production regardless of environmental or load changes. Sixth, comprehensive safety protection and electrical isolation. AGVs operate near personnel, metal structures and flammable chemical vapors. Full non‑bypass protection against short circuit, overcurrent, overvoltage, overtemperature and arcing is required. Short‑circuit output current ≤ 100 μA, double insulation with ≥ 3,000 VAC isolation and flame‑retardant explosion‑proof construction prevent electric shock and fire risks. Seventh, ultra‑low electromagnetic interference and full EMC compliance. AGVs integrate laser navigation, vision scanning, wireless communication and servo drives, all highly sensitive to EMI. Switch noise and radiation may cause positioning drift, scanning failure, communication dropout and servo instability. Conducted and radiated emissions must comply with GB/T 17626 and GB/T 9254 while maintaining strong immunity to onboard electromagnetic noise. Eighth, intelligent control and deep AGV system integration. Connected to WMS and WCS warehouse management platforms, high‑voltage power supplies must support remote parameter adjustment, real‑time status monitoring, fault alarming and closed‑loop static control. Automatic mode adaptation based on travel speed, cargo type and environmental data enables fully automated intelligent warehousing workflows. Addressing these requirements, the methodology establishes a complete technical framework covering long‑lifetime topology design, full‑cycle reliability optimization, vehicle‑mount environmental adaptation, maintenance‑free protection and AGV system integration. It supports AGVs, sorting robots and AMRs, providing standardized guidelines for domestic core component upgrading. The universal design adopts **high‑frequency self‑excited push‑pull topology + full‑hardware closed‑loop control + integrated potting protection**. This eliminates traditional limitations such as short service life, regular maintenance and poor vehicle adaptability. The push‑pull structure minimizes component count, size and cost while delivering inherent short‑circuit current limiting with nanosecond fault response. Fully sealed epoxy potting ensures lifelong maintenance‑free performance, while extreme component derating achieves ≥ 10‑year lifespan and MTBF ≥ 1×10⁵ hours. The design follows eight core principles: 1. Long‑lifetime high‑reliability topology Optimized self‑excited push‑pull inversion with voltage multipliers limits components ≤ 20 to reduce failure points. Symmetrical transformer design delivers high efficiency ≥ 90 %. Wide input support covers 18–60 V for 24 V / 48 V battery fluctuation. Natural current limiting restricts short‑circuit current ≤ 100 μA. Soft switching lowers stress and aging. Symmetrical voltage multipliers apply heavy derating ≤ 50 % voltage stress using long‑life ceramic and fast‑recovery diodes without electrolytic capacitors. 2. Full lifecycle maintenance‑free protection Integrated vacuum epoxy potting fully seals PCBs, transformers and terminals against dust, moisture and corrosive gas, achieving lifelong no‑clean operation. Potting enhances vibration stability. Full IP68 environmental protection includes conformal coating and gold plating. Fully solid‑state construction eliminates fans, relays and wearable parts. AC bipolar ion output reduces dust adhesion on electrodes and maintains stable ionization even with minor contamination. 3. Vehicle‑mount anti‑vibration reinforcement Monolithic rigid potted structure eliminates loose components, resisting up to 50 g shock and 10 g random vibration. High‑Tg thick FR‑4 PCBs, fully SMD assembly and reinforced solder joints prevent fracture. Heavy components are fully embedded in potting. Silicone damping mounting isolates chassis vibration. All designs pass GB/T 2423 vibration and shock qualification. 4. Wide environmental adaptability Industrial extended‑temperature components (−40 ℃ to +85 ℃) ensure stable operation −10 ℃ to +55 ℃ with output drift ≤ ±1 %. Adaptive temperature compensation corrects parameter drift in cold and hot warehouses. Overtemperature derating and shutdown protect against overheating. Input range 18–60 V fully covers battery discharge with reverse and overvoltage protection. IP68 sealing prevents condensation failures in cold storage. Metal shielding ≥ 40 dB and multi‑stage EMI filtering guarantee EMC compliance without interfering with navigation or communication. 5. Ultra‑compact lightweight low‑power optimization Switching frequency raised to 100–200 kHz drastically reduces magnetic component size. Multi‑layer PCBs and double‑sided mounting achieve volume ≤ 10 cm³, weight ≤ 50 g and power density ≥ 200 W/in³. Full‑load efficiency ≥ 90 %, light‑load ≥ 80 %. Three power modes (full / standby / sleep) reduce static power ≤ 5 mW and deep sleep ≤ 1 mW to extend battery runtime. Low‑density materials minimize weight impact on payload. 6. High‑stable adaptive static elimination Full‑hardware closed regulation ensures stability ≤ ±1 % with adjustable output 4–12 kV. Constant current maintains consistent ion density despite humidity, dust or load variation. Balanced positive/negative ion control limits residual voltage ≤ ±50 V. Three intelligent modes (continuous / intermittent / sensor adaptive) optimize energy consumption according to real‑time static levels. 7. Comprehensive safety protection Nanosecond hardware short‑circuit limiting caps current ≤ 100 μA for personnel safety. Double insulation ≥ 3,000 VAC with triple‑insulated transformers isolates high voltage from vehicle systems. V‑0 flame‑retardant materials support chemical warehouse applications. Hardware interlocks link with AGV emergency stop and collision systems to cut high voltage instantly during faults. 8. Intelligent AGV integration UART, I²C and CAN interfaces support Modbus for remote tuning, diagnostics and runtime logging. Closed‑loop collaboration with static, temperature and humidity sensors optimizes ion balance and elimination effect. Built‑in health monitoring predicts aging and potential faults for predictive maintenance, supports remote firmware upgrades and full data traceability. In summary, this framework resolves traditional static power limitations in lifespan, maintenance, vibration tolerance and EMI interference. All‑solid‑state derated design achieves 1×10⁵‑hour reliability and 10‑year service life. Sealed potting enables maintenance‑free operation. High‑frequency miniaturization realizes ultra‑small lightweight integration. Strict current limiting ensures human‑machine safety, while full EMC optimization protects navigation and communication. The solution widely supports AGVs, AMRs, sorting robots and port handling equipment, delivering core domestic technological advancement for intelligent logistics.