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In the field of modern logistics and warehousing, forklift is a key material handling equipment, and the optimization of its operation mode plays a decisive role in improving the overall operation efficiency and reducing costs. As the traditional power source of forklift trucks, traction lead-acid batteries are quietly reshaping the operation mode of forklifts through a series of technical innovations and application expansion, injecting new vitality into the development of the industry.

1. Pain point analysis of traditional forklift operation mode

Traditional forklifts rely on internal combustion engines or early powertrains. Taking internal combustion forklift as an example, although the power is strong, but the exhaust emissions are serious, in the indoor storage environment, not only pollute the air, endanger the health of the operator, but also need to be equipped with complex ventilation equipment, increase operating costs. At the same time, the operation of the internal combustion forklift truck is noisy, which interferes with the working environment and limits its use in noise-sensitive areas.

Early electric forklifts solved exhaust gas and noise problems, but they were limited by battery technology. Such as nickel-cadmium battery, low energy density, short battery life, forklift frequent charging, greatly affecting the continuity of operation. In addition, nickel-cadmium batteries have memory effects, requiring strict charge and discharge management, otherwise it will quickly reduce battery life, increase the cost of use and maintenance difficulty.

2. Technical upgrade of lead-acid batteries

(1) Innovation of high energy density materials

Modern traction lead-acid batteries have made major breakthroughs in materials. The use of new lead alloy grid, such as multi-component lead calcium alloy, compared with traditional lead antimony alloy, its corrosion resistance is greatly improved, reduce grid corrosion caused by battery failure, extend battery life. At the same time, the active substance is optimized, and the specific surface area of the active substance is increased by improving the formulation and manufacturing process, and the efficiency of its participation in the electrochemical reaction is improved, so as to increase the energy density of the battery. This allows the forklift to store more power when equipped with the same volume and weight battery, the driving range is significantly increased, and a single charge can meet the needs of a longer time and a wider range of operations.

(2) Intelligent charge management system enabling

The advanced intelligent charge management system has become the key technical support for the traction of lead-acid batteries. The system can monitor the charging state of the battery in real time, including voltage, current, temperature and other parameters. Through accurate algorithm, the charging current and voltage are automatically adjusted to realize multi-stage intelligent charging such as constant current, constant voltage and trickle. When the battery is nearly full, it automatically switches to trickle charging to avoid damage to the battery caused by overcharge and effectively extend the battery cycle life. At the same time, it has the charging fault diagnosis function, once the abnormal is detected, the charging will be stopped immediately and the alarm will be issued, prompting the maintenance personnel to troubleshoot the problem, ensuring the charging process is safe and reliable, reducing the faults and accidents caused by improper charging, and ensuring the continuity of the forklift operation.

3. The specific performance of hauling lead-acid batteries to reshape the operation mode of forklifts

(1) Forklift operation efficiency has been greatly improved

With higher energy density and intelligent charge management, the operating efficiency of forklifts powered by lead-acid batteries is significantly improved. Long endurance reduces the frequency of forklift operation interruption due to charging. In large logistics centers and storage areas, forklifts can continuously shuttle between shelves to carry goods without frequent return to the charging area to wait for charging. For example, in a large e-commerce warehousing center covering tens of thousands of square meters, the use of new forklifts pulling lead-acid batteries can extend the daily operation time from the original 6-8 hours to 10-12 hours, and the corresponding increase in cargo handling volume by 30%-50%. Intelligent charge management shortens the single charge time. The charging process, which used to take several hours in the past, can now complete most of the power in a short time by optimizing the charging curve, further improving the efficiency of the forklift truck.

(2) The adaptability of the working environment is enhanced

In cold storage and other low temperature environment, the performance of traditional power forklift is greatly reduced, the fuel combustion of internal combustion forklift is insufficient, and the power is weakened. Some batteries have serious capacity attenuation at low temperatures. The traction lead-acid battery can maintain good performance in low temperature environment by improving the electrolyte formula and insulation design. The freezing point of the electrolyte is reduced, the battery can be charged and discharged normally in the cold storage of more than ten degrees Celsius below zero, and the forklift truck can operate stably, meeting the needs of the cold chain logistics warehousing for the high-intensity operation of forklifts in the low-temperature environment. In high temperature environment, the heat dissipation system and high temperature resistant materials of the battery ensure that it will not affect the performance and life due to overheating, and ensure the normal operation of the forklift in outdoor or high temperature workshops in different climatic conditions.

(3) Maintenance costs are reduced and operational sustainability is improved

The long life characteristics of the new traction lead-acid battery reduce the maintenance cost of forklifts. Due to the extended battery replacement cycle, enterprises do not need to frequently purchase new batteries and reduce capital investment. At the same time, the intelligent charge management and fault diagnosis system reduces the battery failure rate, reducing the number of maintenance and maintenance costs. In addition, lead-acid battery materials are highly recyclable, waste battery recycling system is mature, after the end of its service life, most of the materials can be re-refined and reused, reduce environmental pollution, in line with the modern logistics industry green sustainable development concept. The forklift is powered by clean electric energy and has no exhaust emissions, which further promotes the transformation of warehousing logistics operations to the direction of green environmental protection, which is in line with the current society's pursuit of sustainable development and establishes a good environmental image for enterprises.

4. Industry application case analysis

The parts storage workshop of a large automobile manufacturing enterprise used to use internal combustion forklift truck for material handling. The exhaust gas in the workshop is diffuse, the ventilation equipment runs 24 hours, the cost is high, and the noise affects the communication and working status of the workers. After the replacement of the electric forklift equipped with a new type of lead acid battery, the air quality of the workshop is significantly improved, and the noise is greatly reduced. The life of the forklift meets the operation needs of most of the day, and the intelligent charging takes advantage of the low electricity price period at night to reduce the cost of electricity. In one year, ventilation equipment operating costs were reduced by 60%, battery replacement and maintenance costs were reduced by 40%, and overall operating costs were significantly reduced, while improving worker satisfaction and productivity.

In a very large logistics hub serving e-commerce enterprises, forklift operation intensity is extremely high. After the introduction of a fleet of forklift trucks equipped with advanced lead-acid batteries, the efficiency of forklift trucks was increased by 45% through optimized charging management and job scheduling, and the daily cargo throughput was increased from 50,000 to 72,000. Moreover, the long life and recyclable characteristics of the battery make the logistics hub perform well in environmental compliance, obtain environmental protection awards and policy support from the local government, and enhance the comprehensive competitiveness of the enterprise.

5. Future Outlook

With the continuous progress of science and technology, traction lead-acid battery technology will continue to upgrade. On the one hand, in the material development, it is expected to further improve the energy density, reduce the battery volume and weight, and achieve longer endurance and stronger power without affecting the design and operational flexibility of the forklift. On the other hand, intelligent interconnection technology will be deeply integrated into the battery management system, and the forklift battery will achieve real-time data interaction with the forklift management platform and the logistics center control system. Through big data analysis, we can accurately grasp the use of forklift batteries, predict faults in advance, optimize charging plans and forklift operation routes, further improve the intelligent and efficient level of forklift operation mode, and continue to promote the logistics and warehousing industry to flourish in the direction of green, intelligent and efficient.