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In modern logistics and industrial production, electric forklift has become an important equipment for cargo handling with its advantages of environmental protection and high efficiency. As the core power source of electric forklift, the performance and life of lead-acid battery directly affect the efficiency and operating cost of forklift. Although users pay attention to the maintenance of the battery, there are still many maintenance blind spots that are easily ignored in daily operation, which are often the key factors leading to the attenuation of the battery life. In-depth analysis of these blind areas is of great significance for prolonging the service life of lead-acid batteries and improving the overall performance of electric forklifts.

1. Maintenance blind area of charging link

(1) Ignoring charging timing and frequency

Many operators are used to charging the forklift after it runs out of power, thinking that this can make full use of the battery capacity. However, excessive discharge of the lead-acid battery will aggravate the vulcanization of the plate

. When the battery depth exceeds 80%, a large number of coarse and difficult to reduce lead sulfate crystals will be generated on the negative plate, which will not only block the plate micropores, hinder the contact between the electrolyte and the active substance, but also increase the internal resistance of the battery, resulting in a decrease in battery capacity. Long-term excessive discharge will seriously shorten the battery life.

At the same time, frequent charging is not beneficial. Some operators charge as long as the forklift is slightly idle, which will make the battery in a shallow charging and shallow discharge state, and also easily cause plate vulcanization problems. In addition, each time the battery is charged, the electrolytic water reaction will occur inside the battery, and frequent charging will accelerate water consumption, resulting in higher electrolyte concentration and further corrosion of the plate.

(2) Charging equipment mismatch and improper parameter setting

There are many electric forklift brands on the market, and the supporting charging equipment is also different. Some users do not fully consider the match between the device and the battery when replacing the charging device. Using a mismatched charger may cause problems such as too high or too low charging voltage and too large charging current.

When the charging voltage is too high, excessive gas evolution reaction will occur inside the battery, resulting in active substances falling off and plate corrosion worsening. The charging voltage is too low, it can not make the battery fully charged, long-term undercharge state, will also cause plate vulcanization. Charging current is too large, the battery will produce a lot of heat in a short time, if the heat dissipation is not timely, the battery temperature rises rapidly, not only will accelerate the evaporation of electrolyte water, but also may damage the internal structure of the battery. In addition, the parameter setting of some chargers is more complex, and some operators fail to set reasonably according to the actual situation of the battery due to unfamiliar operation, which will also have a negative impact on battery life.

(3) Poor management of charging ambient temperature

Lead-acid batteries are extremely sensitive to the temperature of the charging environment. Charging in a high temperature environment, the internal chemical reaction speed of the battery is accelerated, the gas reaction is intensified, and the water evaporation is rapid. When the ambient temperature exceeds 40 ° C, the water loss rate of the battery will increase significantly, the electrolyte will dry up, the plate will be exposed to the air, and oxidation and vulcanization will easily occur, seriously affecting the battery life.

At low temperature, the viscosity of the electrolyte increases, the ionic diffusion rate slows down, the internal resistance of the battery increases, and the charging acceptance decreases. If you charge the battery according to the charging parameters at room temperature, the battery may not be fully charged and will remain undercharged for a long time. At the same time, low temperature will also reduce the utilization of active substances in the battery, resulting in a decrease in battery capacity. For example, in an environment of -10 ° C, the battery capacity may drop to 60% to 70% of the normal temperature.

2.The blind area of electrolyte maintenance

(1) Electrolyte level monitoring is not timely

During the use of electric forklift trucks, the battery will decrease the electrolyte level due to the gas reaction during charging and daily vibration. However, some operators failed to check the electrolyte level regularly. When the liquid level is too low, the upper part of the plate will be exposed to the air, an oxidation reaction will occur, and the resulting lead oxide will reduce the activity of the plate. At the same time, in the subsequent charging process, the exposed plate will be aggravated by excessive local current density, resulting in thinning of the plate and the loss of active substances, which seriously affects the battery capacity and life.

In addition, some operators add blindly when supplementing the electrolyte. The battery liquid level is not added based on the actual battery liquid level requirements. If the liquid level is too high, the electrolyte overflows during the charging process, which not only wastes the electrolyte, but also corrodes the battery shell and peripheral devices, and may even cause safety problems such as short circuit.

(2) The control of electrolyte purity and density is not accurate

The purity and density of the electrolyte have an important effect on the performance of the battery. In order to reduce the cost, some users used distilled water that did not meet the standard or electrolyte containing impurities when replenishing the electrolyte. These impurities may cause chemical reactions inside the battery to generate additional resistance, consume battery energy, and reduce the efficiency of battery charging and discharging. At the same time, impurities may also react with the plate, accelerating plate corrosion and shortening battery life.

Electrolyte density is also a key parameter. If the density is too high, it will increase the internal resistance of the battery and accelerate plate corrosion. If the density is too low, the discharge capacity of the battery will be reduced. The electrolyte density required for batteries varies with different seasons and use environments. For example, in winter, in order to improve the low-temperature performance of the battery, it is necessary to appropriately increase the electrolyte density; In the summer, in order to prevent the battery from overheating, the electrolyte density should be appropriately reduced. However, many operators do not adjust the electrolyte density according to the actual situation, resulting in reduced battery performance.

3. The maintenance blind area in daily use

(1) Poor forklift operation habits

During the use of electric forklifts, the bad operation habits of some operators will have a negative impact on battery life. Frequent rapid acceleration and sudden braking will make the battery output large current instantaneously. The high current discharge will cause the rapid consumption of active substances on the battery plate and accelerate the aging of the plate. For example, in the rapid acceleration, the battery output current may reach several times of the normal working current, this impact of large current discharge, will aggravate the active substances on the surface of the plate, reducing the battery capacity.

In addition, the long time operation of the forklift in a full load or overload state will also increase the battery burden. The battery needs to continuously output a large current to drive the forklift, which will not only increase the temperature of the battery, but also accelerate the chemical reaction inside the battery, causing the battery to decay prematurely. Moreover, during the operation of the forklift, if it is often on the bumpy road, the battery will be subjected to greater vibration. Frequent vibration may loosen the connecting parts inside the battery, damage the plate, and affect the performance and life of the battery.

(2) The battery has been shelved for a long time and has not been properly handled

In the off-season of enterprise production or during forklift maintenance, some electric forklifts are put on hold for a long time. However, many users do not take proper maintenance measures when the battery is shelved for a long time. Lead-acid batteries will self-discharge even when not in use. If it is shelved for a long time and no charging maintenance is carried out, the battery power will gradually run out, resulting in plate vulcanization. When the battery power is less than 50%, the self-discharge speed will be accelerated, and the risk of plate vulcanization will be significantly increased.

In addition, if the battery is placed in a high temperature, humidity or corrosive gas environment for a long time, the battery shell and plate will be corroded, further damaging the battery. For example, in a humid environment, the battery shell is easy to rust, and the internal plate will also oxidize due to moisture, reducing the battery performance.

4. Neglect regular inspection and maintenance

(1) Lack of inspection of the battery appearance and connecting parts

In daily maintenance, operators often only pay attention to the battery power and the operating status of the forklift, while ignoring the inspection of the battery appearance and connecting parts. If the battery cover is damaged or deformed, the electrolyte may leak, corrode peripheral devices, and damage the internal structure of the battery, affecting the battery performance. If the connecting parts such as poles and cables are loosened or oxidized, the contact resistance will be increased, resulting in serious heating during the battery charging and discharging process, reducing the charging and discharging efficiency, and even leading to open circuit failures.

For example, the oxide on the pole can hinder current conduction, so that the battery cannot fully accept electrical energy when charging, and the output power is reduced when discharging. Loose connected parts that have not been treated for a long time may also be completely disconnected due to vibration during the operation of the forklift, causing the forklift to suddenly stop working and affecting the production schedule.

(2) Periodic battery performance testing is not carried out

After a period of use, the performance of lead-acid batteries will gradually decline. However, many users do not perform regular battery performance tests. Through professional testing equipment, you can measure the battery capacity, internal resistance, voltage and other parameters, and timely understand the health of the battery. For example, measure the internal resistance of the battery regularly. If the internal resistance increases significantly, it indicates that there may be problems such as plate vulcanization and active substance shedding inside the battery, and repair measures need to be taken in time.

Without regular performance testing, potential problems with the battery cannot be found in advance, and when the battery fails seriously, it often has a greater impact on production, and also increases the cost of replacing the battery. Moreover, due to the inability to accurately grasp the remaining life of the battery, it may lead to the sudden failure of the battery during the peak season of production, affecting the normal operation of the enterprise.

The daily maintenance blind area of the life decay of lead-acid batteries for electric forklifts involves many aspects such as charging, electrolyte maintenance, daily use and regular inspection. Only by comprehensively understanding and paying attention to these blind areas and taking scientific and reasonable maintenance measures can we effectively extend the service life of lead-acid batteries, reduce operating costs, improve the use efficiency and reliability of electric forklifts, and provide a strong guarantee for the production and operation of enterprises.