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In the field of modern logistics warehousing and industrial production, forklift is the core equipment of material handling, and its dynamic performance is directly related to operation efficiency and operating costs. With the increasing demand for efficient, durable and stable operation of forklift trucks, the upgrade of power system has become a key link in the technological innovation of forklift trucks. Among the many power source options, the traction lead-acid battery, with its unique advantages, plays an irreplaceable key role in the power upgrade process of forklift trucks.

Forklift power status and challenges

Traditional forklift power mainly has two kinds of internal combustion and electric. Using diesel, gasoline or liquefied petroleum gas as fuel, the internal combustion forklift has strong power and is suitable for heavy load, long distance handling and outdoor complex conditions. However, its emissions are not friendly to the environment, its use is limited in indoor closed or workplaces with high air quality requirements, and engine maintenance is complicated, and fuel costs fluctuate greatly with oil prices.

In recent years, electric forklifts have emerged due to their environmental advantages and gradually become the main force of indoor warehousing and logistics. However, early electric forklifts used relatively basic power configurations, especially in the battery, facing many bottlenecks. Ordinary lead-acid battery capacity is limited, the mileage is difficult to meet the needs of high-intensity continuous operation, frequent charging not only interrupts the work process, but also affects the overall production rhythm. The number of charge and discharge cycles is limited, and the life is short, which increases the long-term use cost. In the low temperature environment, the battery performance deteriorates greatly, and in the low temperature scenes such as the northern winter or cold storage, the operation efficiency of the forklift is greatly reduced, which seriously restricts the further expansion of the application scope of the electric forklift and the improvement of the operation efficiency.

Unique advantages of traction lead-acid batteries

High capacity and long endurance

Traction lead-acid batteries are designed for high-load, continuously operating equipment such as forklifts with greater capacity. By optimizing plate material, structure, and electrolyte formulation, more electrical energy can be stored to provide lasting and stable power output for forklifts. Taking the common 2-ton electric forklift as an example, after the replacement of high-performance traction lead-acid batteries, the mileage can be increased by 30%-50% compared with ordinary batteries, and a single charge can meet the operational needs of conventional intensity for a whole day, greatly reducing the charging frequency, improving the proportion of actual working time of the forklift, and significantly improving the logistics turnover efficiency.

Excellent charge and discharge performance

The battery performs well during charging and discharging. The charging ability is strong, and the fast charging technology can be used to replenish a large amount of electricity in a short time. Some advanced traction lead-acid batteries support fast charge mode, which can be charged to about 80% within 30 minutes, and can quickly replenish energy to resume operation even if the working gap is short. When discharging, it can output with stable voltage to ensure that the motor always obtains sufficient power under different working conditions such as full load starting, climbing, accelerating, etc., to maintain stable running speed and strong torque, avoid power shortage or equipment failure caused by voltage fluctuations, and ensure the fluency and reliability of forklift operation.

Long life and economy

Compared with ordinary lead-acid batteries, the design and manufacturing process of traction lead-acid batteries fully consider the characteristics of frequent charge and discharge of forklift trucks. By enhancing the corrosion resistance of the plate and optimizing the electrolyte circulation system, the charge and discharge cycle life of the battery is greatly improved. Under normal circumstances, its cycle life can reach 1500 times, long life means lower replacement frequency, reducing battery procurement costs and downtime losses in the replacement process, from the whole life cycle point of view, greatly reduce the operating costs of forklifts, improve economic benefits.

Good environmental adaptability

In low temperature environment, traction lead-acid battery through special electrolyte additives and insulation structure design, can effectively improve the low temperature performance. Even in the cold storage environment of -20 ° C, it can still maintain 70%-80% of the normal temperature capacity, ensuring the normal operation of forklifts, and expanding the application of electric forklifts in the field of low temperature. In a high temperature environment, its heat dissipation structure and heat stabilization material can ensure that the internal temperature of the battery is in a reasonable range, prevent capacity attenuation and shortened life caused by overheating, adapt to various complex climates and working environments, and ensure the stability of the power output of the forklift.

Technological innovation drives performance improvement

In recent years, technological innovations in the field of traction lead-acid batteries have emerged in an endless stream. In terms of material research and development, new lead alloy plate materials continue to emerge, such as the use of lead calcium tin aluminum alloy, effectively reduce the gas extraction rate of the plate, improve the battery charging acceptance capacity and cycle life. At the same time, the application of high-performance partition materials enhances the ion conductivity inside the battery, reduces the self-discharge phenomenon, and further improves the overall performance of the battery.

In the manufacturing process, the internalization process is used to complete the formation process of the plate in the battery, avoid the damage of the traditional externalization process to the plate, improve the utilization rate of the active substance of the plate, and thus improve the consistency of the battery capacity and performance. The introduction of automated production equipment has achieved high-precision and standardized production, ensuring that each battery can meet strict quality standards and reducing product performance fluctuations caused by differences in production processes.

In addition, intelligent management system has become an important development direction of lead-acid batteries. The built-in sensor monitors the battery's voltage, current, temperature, remaining power and other parameters in real time, and the intelligent management system can accurately evaluate and regulate the battery status. When the battery is overcharged, overdischarged, overheated and other abnormal conditions, the system can timely alarm and take protective measures to extend the battery life, and provide accurate battery information for the forklift operator, so as to facilitate reasonable scheduling of operations and charging plans, and improve the overall operation efficiency.

Industry development trend and outlook

With the increasingly stringent global environmental regulations and the in-depth promotion of Industry 4.0 and intelligent logistics, the demand for forklift power upgrades will continue to grow. As a mature and innovative power solution, traction lead-acid batteries will occupy an important position in the future forklift market. On the one hand, technological innovation will continue to deepen towards higher energy density, longer life, faster charging speeds and smarter management, further narrowing the performance gap with emerging battery technologies such as lithium batteries, while maintaining cost advantages. On the other hand, with the diversification of market demand, traction lead-acid batteries will develop a more targeted product series for different application scenarios and forklift truck types, such as high-capacity, high-power batteries for heavy-duty forklifts, and lightweight and compact batteries to meet the flexible operation needs of micro-forklifts.

In addition, battery rental, recycling and other supporting service models will gradually improve. Through battery leasing, enterprises can reduce the cost of early equipment investment and improve the efficiency of capital use; The standardized recycling system helps to reduce environmental pollution, realize the recycling of resources, and promote the sustainable development of the forklift power industry.

In the journey of forklift power upgrade, traction lead-acid battery with its own advantages and innovative technology, has become a key force to promote the efficient, green and intelligent development of the forklift industry, inject strong impetus into modern logistics and industrial production, in the future market competition and technological change, will continue to write a brilliant chapter, help the industry to a new height of development.