Heli forklift lead-acid battery maintenance and repair is a key part of battery performance maintenance

Heli forklift lead-acid battery maintenance and repair key steps

Time：2025-04-03 12:01:46

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In the field of logistics handling, Heli forklift has become the right-hand man for material transportation of many enterprises with its excellent performance and reliability.

In the field of logistics handling, Heli forklift has become the right-hand man for material transportation of many enterprises with its excellent performance and reliability. As the core power source of forklift, the performance of lead-acid battery directly determines the working efficiency and operating cost of forklift. With the increase of the use time, the battery inevitably appears various problems, at this time maintenance and repair has become the key link to maintain the battery performance and extend the service life, from the traditional means to a new height of technological innovation, is escorting the continuous and efficient operation of the forklift lead-acid battery.

Frequent traditional failures highlight the urgency of maintenance and repair

●Common fault sorting

The problem of plate vulcanization of lead acid battery in heli forklift truck is common under long-term high strength operation. When the forklift is used in a bad environment, the charging is not timely and non-standard, and the battery is in a state of loss of power for a long time, the surface of the plate will gradually generate a layer of white and hard lead sulfate crystal, that is, the vulcanization phenomenon. This not only increases the internal resistance of the battery, hinders the electrochemical reaction, but also causes the battery capacity to decrease significantly, and the mileage of the forklift is significantly shortened.

Battery leakage is also a major problem. Battery housing due to collision, aging cracks, pole sealant failure, or safety valve failure, can lead to electrolyte leakage. The electrolyte is highly corrosive. Once leaked, it will not only corrode the battery compartment and surrounding components of the forklift truck, but also pollute the working environment and endanger the health of the operator. At the same time, the leakage leads to the reduction of the amount of electrolyte, the imbalance of the electrochemical reaction inside the battery, and further accelerates the deterioration of the battery performance.

Self-discharge anomalies also plague forklift users. The presence of impurities in the battery, short circuit between the plates, or uneven electrolyte density will cause the self-discharge speed to accelerate. Even if the forklift is idle, the power will be rapidly lost, resulting in failure to start normally when used again, delaying the work progress. In some open work sites, due to the large dust in the environment, impurities are easy to enter the battery, which aggravates the phenomenon of self-discharge, and brings a lot of inconvenience to the operation of forklifts.

●Traditional maintenance dilemma

Traditional maintenance of forklift lead-acid batteries, for plate vulcanization, the use of long-term small current charging method to try to dissolve lead sulfate crystals, but for the severely vulcanized plate, the effect is often poor, and the time is very long, seriously affecting the normal use of forklift trucks. In the repair of the battery leakage problem, if the shell crack is small, the maintenance personnel will use ordinary glue for simple sealing, but this method has poor durability and is easy to leak again; For the pole seal problem, the traditional operation of replacing the sealing rubber ring has high technical requirements for maintenance personnel, and it is difficult to ensure the sealing effect. In the face of self-discharge faults, traditional detection means are limited, and maintenance personnel often need to rely on experience to investigate one by one, which is inefficient and difficult to accurately locate the root cause of the fault, resulting in a long maintenance cycle and high cost.

Breakthrough in technological innovation, opening up a new path for maintenance and repair

●Advanced detection technology, accurate fault location

Nowadays, intelligent testing equipment is widely used in heli forklift lead-acid battery maintenance. The high-precision battery internal resistance tester can quickly and accurately measure the internal resistance of each cell of the battery. By comparing the standard internal resistance data, it can quickly determine whether the plate has vulcanization, short circuit and other problems. In addition, the multifunctional battery analyzer can simultaneously monitor battery voltage, current, temperature, SOC (state of charge) and other parameters, and draw battery performance curves through data analysis software to visually present the health status of the battery, providing a scientific basis for the development of subsequent maintenance plans.

●Innovative repair process to improve maintenance effectiveness

For plate vulcanization, the pulse repair technology has achieved remarkable results. The technology uses high frequency pulse current to shock the plate, break the lead sulfate crystal, make it dissolve back into the electrolyte, and restore the activity of the plate. The experimental data show that the capacity of the battery after pulse repair can be restored to 80%-90% of the initial capacity. In an e-commerce logistics center, 50 groups of vulcanized batteries were repaired with pulse repair equipment, and the average mileage of forklift trucks after repair increased by 30%, effectively reducing the frequency of battery replacement and reducing operating costs.

For the repair of battery leakage, new polymer sealing materials and professional repair technology came into being. When the battery shell cracks, the maintenance personnel first use special tools to clean the cracks, grinding, and then apply with high strength, acid and alkali resistant polymer sealant, after curing treatment, the sealing effect is excellent, can withstand the shock and impact of forklift trucks in complex conditions. To solve the problem of pole seal, the heat shrink sealing technology is used to heat and shrink the special heat shrink sealing sleeve on the pole to form a tight and durable sealing layer and effectively eliminate the risk of electrolyte leakage.

In order to solve the problem of self-discharge, ion exchange resin purification electrolyte technology is used. The electrolyte containing impurities is passed through the device filled with ion exchange resin, and the active groups in the resin exchange with the impurity ions in the electrolyte to remove harmful impurities such as copper and iron, reduce the conductivity of the electrolyte, and thus inhibit self-discharge. After treatment with this technology, the self-discharge rate of the battery can be reduced to 1/3-1/2 of the normal level, which greatly extends the battery power retention time when the forklift is idle.

●Maintenance and upgrade after repair to ensure the long-term operation of the battery

After repair, maintenance is also critical. The intelligent battery management system (BMS) is introduced to monitor the charging and discharging process of the battery in real time, automatically adjust the charging voltage and current, avoid overcharging and overdischarging, and extend the cycle life of the battery. At the same time, deep activation treatment is carried out regularly on the repaired battery, and the active substance of the battery plate is stimulated by specific charging and discharging procedures to maintain the stable performance of the battery. In daily maintenance, use special battery cleaning liquid and tools to regularly clean the battery surface to prevent dust, electrolyte residue accumulation caused by short circuit and other problems to ensure that the battery is always in good working condition.

The maintenance and repair of lead-acid batteries of Heli forklift trucks has gradually moved from traditional empirical and inefficient operations to a new stage relying on advanced technology, precision and efficiency. The advanced detection technology accurately locate the fault, the innovative repair process effectively solves various problems, and the upgraded maintenance measures ensure the long-term operation of the battery, which improves the battery performance maintenance level in an all-round way. This not only saves a lot of costs for the users of the joint forklift truck, ensures the efficient and stable operation of the forklift truck, but also injects new vitality into the sustainable development of the entire forklift power system, and promotes the logistics handling industry to move towards a more efficient, more economical and more environmentally friendly direction.

Statement: The articles on this site are written by the GSGT team or reprinted from other media or compiled by AI.No reproduction without permission.For copyright or other issues, please contact:gsgtpower@163.com.

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