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Battery product manual Analysis of lead-acid battery strategies for frequent start and stop of forklift trucks

Analysis of lead-acid battery strategies for frequent start and stop of forklift trucks

Time:2025-03-29 14:32:58

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For the lead-acid battery as the power source of forklift trucks, this condition brings great challenges, but through a series of targeted design and optimization, lead-acid batteries can effectively cope.

In logistics warehousing, factory workshops and other scenarios, frequent start and stop operation of forklifts is the norm. For the lead-acid battery as the power source of forklift trucks, this condition brings great challenges, but through a series of targeted design and optimization, lead-acid batteries can effectively cope.

One, plate structure strengthening design

During frequent start and stop, the lead-acid battery needs to quickly output large current for the forklift to start in a short period of time, and then quickly switch to the charging receiving state, which has a huge impact on the plate. In order to enhance the stability of the plate under this condition, the thickened plate design is adopted. Thicker plates have more active substances, which can provide sufficient reaction sites during high current discharge, reducing the loss caused by excessive discharge of the plate. At the same time, the grid structure of the plate is improved, and alloy materials with high strength and good electrical conductivity are selected, such as lead-calcium alloy. This alloy grid frame can not only withstand frequent large current shocks, ensure smooth current transmission, but also reduce its own resistance, reduce the loss of electric energy in the transmission process, and improve the overall performance of the battery.

Two, electrolyte optimization formula

Electrolyte plays a key role in ion conduction during charging and discharging of lead-acid batteries. In the face of frequent start and stop of forklift trucks, the electrolyte needs to have rapid response ability. The electrolyte formulation was optimized by adjusting the concentration of sulfuric acid. Appropriately increasing the concentration of sulfuric acid can enhance the ionic conductivity of the electrolyte, so that the battery can quickly release a lot of electric energy at the start of the moment. At the same time, special additives, such as stannous sulfate, are added to the electrolyte. These additives can inhibit the vulcanization of the plate, prevent the formation of lead sulfate crystals on the surface of the plate that are difficult to participate in the reaction due to frequent charging and discharging, maintain the normal reaction of the active substance of the plate, maintain the stable charging and discharging performance of the battery, and extend the service life of the battery.

Three, heat dissipation system upgrade

The frequent start and stop of the forklift truck causes frequent charging and discharging of the lead-acid battery, intensifies the chemical reaction inside the battery, and generates a lot of heat. If the heat is not distributed in time, it will accelerate the aging of the battery and even cause safety risks. Therefore, it is crucial to upgrade the cooling system. In the design of the battery shell, the heat dissipation fins are added to increase the heat dissipation area and accelerate the heat dissipation to the surrounding environment. Some advanced batteries are also equipped with forced air cooling or liquid cooling systems. The forced air cooling system introduces the outside cold air into the battery through the fan, taking away the heat; The liquid cooling system uses the coolant to circulate inside the battery, absorb and take away heat, ensure that the battery works within the appropriate temperature range, stabilize the battery performance, and improve the reliability of the battery in response to frequent start-stop conditions.

Four, charge and discharge management system intelligent

Intelligent charge and discharge management system is one of the core technologies for lead-acid batteries to adapt to the frequent start and stop of forklift trucks. The system monitors the battery voltage, current, temperature and other parameters in real time. At the moment when the forklift starts, the system accurately controls the battery to output the best large current to meet the starting power demand of the forklift, while avoiding the battery damage caused by excessive current. When the forklift stops running and enters the charging stage, the system adopts intelligent charging algorithm according to the current state of the battery, such as pulse charging and segmentation constant current charging. These algorithms can dynamically adjust the charging current and voltage according to the remaining battery power, temperature and other factors, improve the charging efficiency, reduce the charging time, avoid overcharge and undercharge, extend the battery cycle life, and ensure the stable operation of the lead-acid battery in the frequent start and stop operation of the forklift truck.

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