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1. Introduction

In the field of modern logistics and industrial production, forklift as a key material handling equipment, its efficient and stable operation is very important. The power core of forklift truck, traction lead-acid battery, has a decisive impact on the performance, operating cost and service life of forklift truck. Due to the different needs of forklift trucks in different industries and different operation scenarios, accurate and suitable customized solutions for forklift traction lead acid batteries have become the key to improve the operation efficiency of forklifts. This article will explore how to develop customized solutions, from battery selection, design optimization to maintenance management, to meet the diverse application needs of forklifts.

2.Forklift operation scene analysis

(1) Indoor warehouse operations

The indoor warehouse space is limited, and forklifts frequently start, stop, and turn, which requires high instantaneous large current discharge capacity of the battery to ensure that the forklift can quickly respond to operation commands and improve cargo handling efficiency. At the same time, the indoor environment has certain requirements for the safety and environmental protection of the battery, and it is necessary to ensure that there is no harmful gas leakage during the operation of the battery, so as to avoid affecting the health of the staff in the warehouse and the storage of goods.

(2) Outdoor goods yard operations

The operating environment of the outdoor freight yard is complex and the temperature changes greatly, so the forklift may face the working conditions of high temperature exposure or low temperature cold. High temperature will accelerate the battery water loss and plate aging, low temperature will reduce the battery capacity, affecting the power output of the forklift. In addition, outdoor operations often require forklifts to have a long driving range to reduce charging frequency and improve operational efficiency, which puts higher requirements on the energy density and capacity of the battery.

(3) Cold storage environmental operations

The temperature in the cold storage is very low, and the ordinary lead-acid battery increases the viscosity of the electrolyte at low temperature, slows down the ion conduction speed, increases the internal resistance of the battery, and the capacity decreases significantly. Therefore, the forklift in the cold storage environment needs the battery to have good low temperature performance, and can stably output enough electric energy in the low temperature environment to ensure the normal operation of the forklift.

3.Lead-acid battery characteristics and selection points

(1) Working principle and structure of lead-acid batteries

Lead-acid batteries are mainly composed of positive and negative plates, electrolytes (sulfuric acid solution), partitions, and battery slots. Its working principle is based on the electrochemical reaction between the active substance on the positive and negative plates and the electrolyte. In the discharge process, the positive lead dioxide and the negative lead react with sulfuric acid to form lead sulfate and water, converting chemical energy into electrical energy; When charging, the reaction is reversed by an external power supply to restore the battery's power reserve.

(2) The advantages of lead-acid batteries

1. ** Cost advantage ** : Compared with other types of batteries, the raw material cost of lead-acid batteries is low, the production process is mature, and the overall price is relatively close to the people, which is more attractive for enterprises with limited budgets.

2. ** High rate discharge performance ** : It can provide large current in a short time to meet the instantaneous high power needs of forklift trucks such as frequent start and acceleration, and ensure the sensitivity and efficiency of forklift operation.

3. ** High safety** : After long-term development, lead-acid battery technology is mature, the structure is relatively simple, under normal use and maintenance conditions, the probability of serious safety accidents is low.

(3) Selection points

1. ** Capacity matching ** : According to the operation intensity and running time of the forklift, the required battery capacity is accurately calculated. Generally, the battery capacity can be determined by measuring the average current and operating time of the forklift in a complete operating cycle, combined with the depth of discharge (DOD) of the battery.

2. ** Voltage adaptation ** : The electric system such as the motor and controller of the forklift truck has specific requirements for voltage, and the nominal voltage of the selected battery must be matched with the electrical system of the forklift truck to ensure the normal operation of the equipment and avoid equipment damage or performance degradation due to voltage mismatch.

3. ** Low temperature performance considerations ** : For cold storage and other low temperature operating environments, lead-acid batteries with good low temperature performance should be selected, such as using special formula electrolyte, optimizing plate structure, etc., to improve the capacity retention rate and discharge performance of the battery at low temperatures.

4. Customized design scheme

(1) Battery structure optimization

1. ** Plate design ** : For forklift trucks with high load operation, the thickened plate design can be used to increase the active substance content and improve the capacity and service life of the battery. At the same time, the grid structure of the plate is optimized to reduce the resistance and improve the performance of high current discharge. For example, the use of a new mesh grid structure, compared with the traditional grid, can make the current distribution more uniform, reduce local overheating phenomenon.

2. ** Separator selection ** : Select high-performance partitions, such as those with high porosity, low resistance, good chemical stability and puncture resistance. High quality separator can effectively prevent short circuit of positive and negative plates, extend battery cycle life and improve battery performance. In some places with high safety requirements, flame retardant partitions can be used.

3. ** Battery groove Improvement ** : According to the installation space and use environment of the forklift, customize the special shape and material of the battery groove. In the operating environment with high vibration, the use of high-strength, impact-resistant battery tank materials, and increase the shock absorption design, reduce the vibration damage of the battery during transportation and operation. For outdoor forklift trucks, the battery slot can be designed to have the functions of sun protection, water resistance and dust resistance to protect the internal structure of the battery from the external environment.

(2) Electrical performance customization

1. ** Charging characteristics optimization ** : In order to meet the charging needs of forklifts in different operating scenarios, the charging characteristics of the battery can be customized. For example, for forklifts with short working gaps and limited charging time, the fast charging function is designed to shorten the charging time without affecting the battery life by optimizing the internal structure of the battery and adopting a special charging algorithm. At the same time, it is equipped with an intelligent charge management system to monitor the charging status of the battery in real time, prevent overcharge and undercharge, and extend the service life of the battery.

2. ** Discharge characteristics adjustment ** : According to the actual working conditions of the forklift, adjust the discharge characteristics of the battery. For forklift trucks that need to start, stop and climb frequently, the instantaneous large current discharge capacity of the battery is enhanced; For forklifts that run smoothly for a long time, the continuous discharge performance of the battery is optimized to improve energy utilization efficiency. The discharge characteristics can be accurately customized by adjusting the electrolyte formula and the active material composition of the plate.

(3) Intelligent management system integration

1. ** Battery condition monitoring ** : Sensors are integrated inside the battery to monitor the battery's voltage, current, temperature, remaining charge (SOC) and other parameters in real time. The data is transmitted to the forklift management system or remote monitoring platform through the wireless communication module, so that operators and maintenance personnel can know the working status of the battery at any time, find potential problems in time, and perform maintenance in advance.

2. ** Fault warning and diagnosis ** : Use intelligent algorithms to analyze the monitoring data and establish a battery fault model. When the battery is abnormal, the system can send early warning information in time, and provide fault diagnosis report to help maintenance personnel quickly locate the fault cause, take appropriate maintenance measures, reduce downtime, and improve the availability of forklift trucks.

5. Maintenance management plan

(1) Routine maintenance points

1. ** Electrolyte check and supplement ** : Check the electrolyte level regularly to ensure that the liquid level is within the normal range. If the liquid level is too low, distilled water or special electrolyte should be added in time. At the same time, the electrolyte density is regularly detected, and the charging and discharging state and health status of the battery are judged according to the density change, and the adjustment is made if necessary.

2. ** Battery appearance Check ** : Check whether the battery shell is damaged, deformed, leakage, etc., if there is a problem, replace the battery in time. Clean the battery surface to prevent short circuit or corrosion caused by accumulation of dust and electrolyte. Check whether the battery pole is firmly connected. If loose, tighten it in time to avoid excessive contact resistance affecting battery performance.

3. ** Charge management ** : Operate in strict accordance with the charging requirements of the battery to avoid overcharge and undercharge. Use the appropriate charger, according to the battery capacity and charging state to choose the correct charging mode and parameters. During the charging process, pay attention to the temperature and charging current of the battery. If there is any abnormality, stop charging immediately and check.

(2) Regular maintenance items

1. ** Capacity test ** : Periodically conduct capacity tests on the battery to evaluate the difference between the actual capacity and the nominal capacity of the battery. Through the capacity test, you can find the deterioration of the battery performance in time, and provide a basis for battery replacement or maintenance. It is generally recommended to perform capacity testing every 3-6 months.

2. ** Balanced charging ** : During the use of the lead-acid battery, due to the differences in the characteristics of each single battery, some batteries may be overcharged or undercharged. Regular balanced charging can make the voltage and capacity of each battery be consistent, and extend the overall service life of the battery pack. The frequency of balanced charging is generally once every 1-2 months.

3. ** Deep discharge and activation treatment ** : For the battery that is in the shallow charge and shallow discharge state for a long time, periodically carry out a deep discharge (the discharge depth reaches about 80%), and then carry out activation charging, which helps to restore part of the capacity of the battery and improve battery performance. However, the deep discharge should not be too frequent to avoid irreversible damage to the battery.

(3) Personnel training and management

1. ** Operator training ** : Train forklift operators on battery use and maintenance, so that they can understand the basic working principle, performance characteristics, correct operation methods and precautions of the battery. The training content includes how to correctly start and stop the forklift, avoid excessive discharge, reasonably arrange the charging time, etc., improve the operator's awareness of battery protection, and reduce the battery damage caused by improper operation.

2. ** Maintenance personnel training ** : Professional skills training for battery maintenance personnel, so that they can master battery maintenance methods, fault diagnosis and repair technology. The training covers the preparation and replacement of the electrolyte, the inspection and repair of the plate, the commissioning and maintenance of the charging equipment, etc., to ensure that the maintenance personnel can timely and accurately deal with various problems of the battery and ensure the normal operation of the battery.

3. ** Establish maintenance files ** : Establish detailed maintenance files for each group of batteries, recording the use of batteries, maintenance items, maintenance time, maintenance personnel and other information. Through the analysis of maintenance files, the fault law of the battery can be summarized, the maintenance plan and scheme can be optimized, and the maintenance management level of the battery can be improved.

6. Conclusion

Accurate and suitable customized solutions for forklift traction lead-acid batteries are the key to improve forklift operation efficiency and reduce operating costs. Through in-depth analysis of the operation scenario of forklift trucks, scientific selection and customized design combined with the characteristics of lead-acid batteries, and complete maintenance and management schemes, it can meet the diverse needs of forklift trucks for batteries in different industries and different working conditions. In the future, with the continuous progress of technology and the continuous change of application demand, the customized solution of forklift traction lead-acid battery will be continuously optimized and improved, providing more powerful support for the development of logistics and industrial production.