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In the daily maintenance and operation preparation work of forklift, the installation of lead-acid battery is a very critical part. Proper installation can ensure the stable operation of the forklift and extend the battery life, on the contrary, once you step into the installation "minefield", it may not only lead to damage to the battery performance, but also bring serious safety risks. The following will give you a detailed analysis of the "minefields" that need to be avoided during the installation of forklift lead-acid batteries.

Minefield 1: Neglect the installation environment choice

Lead-acid batteries have strict requirements for the installation environment, but some operators often ignore this point. If the installation site is not well ventilated, the hydrogen and oxygen generated by the battery during the charge and discharge process cannot be discharged in time, and it is easy to form an flammable and explosive mixed gas environment. According to relevant data, when the volume proportion of hydrogen in the air reaches 4%-75%, an explosion will occur in the event of an open fire or spark. The working environment of forklift trucks is complex, and there are often sparks generated by the operation of various electrical equipment. If the battery installation environment is poorly ventilated, it is tantamount to burying a time bomb.

In addition, the installation location should be away from heat and water sources. Lead-acid batteries in high temperature environment, electrolyte evaporation speed, will lead to battery water loss dry, accelerated plate aging, thereby shortening the battery life. If the battery is near a water source, it may be wet and short-circuited. Once the battery is short-circuited, the large current generated in an instant may cause a fire, which seriously threatens the safety of equipment and personnel. For example, in some warehouses near the boiler room, the installation position of the forklift battery is too close to the boiler, and during the summer high temperature period, the battery frequently appears bulging and leaking, which greatly reduces the efficiency and safety of the forklift truck.

Minefield 2: Battery model does not match the forklift

Choosing a lead-acid battery that does not match the forklift is a common error during installation. Parameters such as the power, working intensity and design voltage of the forklift determine the specifications of the battery required. If the installed battery voltage is lower than the design voltage of the forklift, the forklift is difficult to start, the motor cannot reach the rated speed, the power is obviously insufficient, and the operation efficiency may even be stagnated when carrying heavy objects or climbing hills, seriously affecting the operation efficiency. Conversely, if the battery voltage is too high, it will exceed the voltage tolerance range of the forklift electrical system, damage key components such as the controller and motor, and shorten the service life of the equipment.

Battery capacity cannot be ignored either. The capacity is too small, the mileage of forklift is short, and frequent charging affects the continuity of work; Excessive capacity not only increases the cost, but also causes the overall weight imbalance of the forklift, affects the handling performance, and is prone to collision accidents when turning and driving in a narrow space.

Minefield 3: The battery is not checked before installation

Newly purchased lead-acid batteries must be fully inspected before installation, but many people omit this important step. The appearance inspection is very important, and it is necessary to check whether the battery shell is cracked or damaged, and whether the pole is deformed or corroded. Cracks in the shell may lead to electrolyte leakage, which corrodes the device and contaminates the environment. Human contact may cause burns. Pole deformation and corrosion will affect the stability of the battery connection, increase the contact resistance, heat seriously during charging, and even cause fire.

At the same time, check the electrolyte level and density of the battery. Too low liquid level may be the battery leakage problem, but also lead to the plate can not be fully immersed in the electrolyte, so that the battery capacity is reduced. The abnormal electrolyte density reflects the possible deviation of the chemical reaction inside the battery, which affects the battery performance. For example, a new battery is not checked before installation, and it is found after installation that the liquid level of one of the batteries is too low, although the electrolyte is added, but the battery capacity has been damaged due to the partial drying of the plate in the early stage, and after a period of use, the performance of the entire battery pack is unbalanced and frequent failures.

Minefield four: The installation process is not standardized

1. ** Incorrect cable connection ** : If the positive and negative terminals are reversed when the battery cables are connected, a strong reverse current will be generated immediately after the power is switched on, which will burn the plate and partition inside the battery, causing the battery to be scrapped, and the electrical components of the forklift truck may be damaged, for example, the fuse is blown or the controller is burned. Moreover, the reverse cable may also cause the motor to reverse, if the operator is unaware, it is easy to crash when operating the forklift.

2. ** Loose terminal ** : The terminal is not firmly installed, and the vibration during the operation of the vehicle will gradually loosen the terminal and increase the contact resistance. According to Joule's law, the increase of resistance leads to an increase in heat, which not only reduces the charging and discharging efficiency of the battery, but also may cause a fire. According to statistics, the proportion of forklift electrical failures caused by loose terminals is as high as more than 30%. For example, a forklift truck in a logistics warehouse in operation for a period of time, frequent lack of power, battery overheating phenomenon, after inspection found that the terminal loose, contact resistance is too large caused by.

3. ** Improper installation tools ** : If an inappropriate installation tool is used, for example, the wrench size is too large or too small, the nut may slip or use uneven force when tightening the terminal nut, affecting the connection stability. In addition, if you accidentally touch the positive and negative electrodes of the battery when using metal tools, it will cause short circuit ignition, resulting in safety accidents. For example, during the installation process, the size of the wrench used by the operator is too large, which causes the nut to slip when the nut is forcibly tightened, and the nut has to be replaced again, which not only delays the time, but also may damage the pole due to multiple operations.

Minefield 5: No post-installation debugging and inspection

After the battery installation is completed, everything is not all right, and the debugging and inspection after the installation are equally indispensable. Some people put it into use directly after installation, ignoring the detection of battery voltage and current. If the battery string is improperly connected, the voltage imbalance between the batteries will cause some batteries to be overcharged or undercharged, shortening the service life of the entire battery string. For example, a battery pack composed of 6 batteries is not detected after installation, and after use for a period of time, it is found that two of the batteries appear bulging and the capacity decreases significantly, which is detected because the voltage of these two batteries is lower than that of other batteries and is caused by long-term undercharge.

At the same time, it is necessary to carry out functional testing on the electrical system of the forklift to check whether the motor is running normally and whether the controller is responsive. Improper operation may affect the normal operation of the electrical system during installation. For example, the internal cables are disconnected due to cable extrusion. If the forklift is not tested, dangerous situations may occur, such as sudden stop or loss of control, which poses serious threats to the safety of personnel and cargo.

Every "minefield" in the installation process of forklift lead-acid batteries has huge risks. From the environment selection to the commissioning inspection after installation, any negligence in any link may cause serious consequences. To ensure the safe and efficient installation of lead-acid batteries for forklift trucks, the operators must strictly follow the installation specifications and carefully handle each step to avoid these "minefields".