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Abstract

This article focuses on the rational use of lead-acid batteries in forklifts to enhance the overall efficiency of the equipment. The working principle and characteristics of lead-acid batteries for forklifts are elaborated in detail. The problems existing in the current usage process are analyzed, and reasonable usage strategies are proposed from multiple aspects such as correct charging, daily maintenance, and scientific usage. The aim is to provide references for enterprises and relevant operators, extend the service life of lead-acid batteries, improve the working efficiency of forklifts, and thereby enhance the overall performance of the equipment. Reduce operating costs.

1. Introduction

In modern logistics and warehousing operations, forklifts, as important handling equipment, their efficient operation is crucial to the production and logistics efficiency of enterprises. Lead-acid batteries, as the core power source of electric forklifts, their performance and service life directly affect the working efficiency of forklifts and the operating costs of enterprises. However, in actual use, due to improper use and maintenance of lead-acid batteries, problems such as decreased battery capacity and shortened service life often occur, causing forklifts to frequently stop for maintenance and reducing the overall efficiency of the equipment. Therefore, it is of great practical significance to study how to use forklift lead-acid batteries rationally and improve the overall efficiency of the equipment.

2. Working Principle and Characteristics of Lead-Acid Batteries for Forklifts

(1) Working Principle

Forklift lead-acid batteries are devices that convert chemical energy into electrical energy. They are mainly composed of positive plates, negative plates, separators, electrolyte, etc. During the discharge process, lead dioxide on the positive plate and lead on the negative plate undergo chemical reactions with sulfuric acid in the electrolyte, generating an electric current. When the battery is charged, under the action of an external power source, the chemical reaction proceeds in reverse, restoring the battery to its pre-discharge state and achieving the re-conversion of chemical energy into electrical energy.

(2) Characteristics

1. ** Voltage stability ** : During the discharge process, lead-acid batteries can provide a relatively stable voltage output, ensuring the normal operation of equipment such as forklift motors. Under normal circumstances, the rated voltage of a single lead-acid battery is 2V. By connecting multiple batteries in series, the working voltage required by forklifts can be obtained, such as 24V, 48V, etc.

2. ** Low cost ** : Compared with other types of batteries, lead-acid batteries have mature production technology, abundant raw materials and relatively low prices, which makes them widely used in the forklift field.

3. ** Relatively simple maintenance ** : Although lead-acid batteries require certain maintenance, compared with some new types of batteries, their maintenance operations are relatively easy and do not need special equipment or complex technologies. However, this does not mean that maintenance work can be ignored; otherwise, it will seriously affect battery performance and lifespan.

4. Poor low-temperature performance: The electrolyte of lead-acid batteries is prone to freezing in low-temperature environments, which increases the internal resistance of the battery and reduces its charging and discharging performance. Therefore, when used in a low-temperature environment, corresponding insulation measures need to be taken.

3. Problems Existing in the Current Use of Lead-acid Batteries in Forklifts

(1) Improper charging management

1. ** Over-discharge ** : Some operators do not pay timely attention to the battery power when using forklifts, often causing the battery to over-discharge. When a battery is over-discharged, the active substances on the plates will fall off due to excessive reactions, resulting in a decrease in battery capacity and a shortened battery life. For instance, if a forklift is still in use when the battery voltage drops below 80% of the rated voltage, it is considered an over-discharge situation.

2. ** Untimely charging ** : Some enterprises, in order to improve the efficiency of forklifts, continue to use the forklifts when the batteries are not fully charged, resulting in the batteries being in a long-term state of low power. In this case, irreversible lead sulfate crystals will gradually form on the battery plates, which is known as sulfation, seriously affecting the battery's charging and discharging performance.

3. ** Excessive or insufficient charging time ** : Some operators do not accurately control the charging time. Excessive charging time will cause the battery to heat up and accelerate the aging of the internal components of the battery. If the charging time is too short, the battery cannot be fully charged, which will affect the working time of the forklift.

(2) Insufficient daily maintenance

1. Untimely inspection of the electrolyte: During the use of lead-acid batteries, the electrolyte will gradually decrease due to evaporation and chemical reactions. If the electrolyte is not replenished in time, it will cause the plates to be exposed to the air, accelerating the sulfation and corrosion of the plates and reducing the battery performance. However, many operators in enterprises often neglect the inspection and replenishment of the electrolyte.

2. ** Inadequate battery cleaning ** : During the operation of the forklift, the battery surface is prone to accumulate dust, oil stains and other impurities. These impurities can cause leakage on the battery surface, increase the self-discharge rate of the battery, and may also corrode the battery casing and terminals, affecting the normal use of the battery.

3. ** Lack of regular inspection ** : Some enterprises have not established a complete battery inspection system and are unable to detect potential problems with batteries in a timely manner. For instance, the failure to detect key indicators such as the internal resistance changes of the battery and the content of active substances on the plates in a timely manner leads to the accumulation of problems and ultimately affects the service life of the battery.

(3) The usage environment is unreasonable

1. ** High-temperature environment ** : In a high-temperature environment, the chemical reaction rate inside the battery increases, the evaporation of the electrolyte intensifies, and the aging speed of the battery will also significantly accelerate. For instance, when the ambient temperature exceeds 40℃, the battery's service life may be shortened by 30% to 50%.

2. ** Humid environment ** : A humid environment can easily cause the battery casing and terminals to rust and corrode, reducing the battery's insulation performance, increasing the risk of leakage, and also affecting the normal charging and discharging of the battery.

(4) Insufficient training for operators

Many forklift operators have limited knowledge of the use and maintenance of lead-acid batteries and lack correct operation norms and maintenance awareness. This leads to the inability to use and maintain the battery in the correct way in actual work, thereby affecting the performance and lifespan of the battery.

4. Strategies for the Rational Use of Lead-Acid Batteries in Forklifts

(1) Scientific charging management

1. Avoid excessive discharge: Install a battery power display device on the forklift to monitor the battery power in real time. When the battery level drops to 20% to 30% of the rated capacity, promptly return the forklift to the charging area for charging to prevent excessive discharge. At the same time, a strict charging management system should be formulated, requiring operators to abide by the electricity usage standards.

2. ** Timely charging ** : After each use of the forklift, the battery should be charged as soon as possible to avoid it remaining in a state of low power for a long time. If the forklift is not used for a short period of time, the battery should also be recharged at regular intervals to prevent self-discharge of the battery and resulting in low power.

3. ** Control charging time ** : Calculate the charging time reasonably based on the battery capacity and charging current. Generally speaking, the charging time of a common lead-acid battery is 8 to 10 hours. During the charging process, a segmented charging method can be adopted. First, perform rapid charging with a relatively large current. When the battery's charge reaches around 80%, then proceed with trickle charging with a relatively small current to ensure the battery is fully charged without overcharging.

(2) Strengthen daily maintenance

1. ** Regularly check the electrolyte ** : Check the electrolyte level at least once a week, and the level should be maintained 10-15mm above the plates. If the liquid level is too low, distilled water or special lead-acid battery replenishment fluid should be added. Do not add tap water as it contains impurities that can affect battery performance. When adding electrolyte, be careful to prevent it from splashing out. If it accidentally splashes out, rinse it with clean water immediately and neutralize it.

2. ** Keep the battery clean ** : After using the forklift every day, wipe the battery surface with a clean damp cloth to remove dust, oil stains and other impurities. Regularly inspect the battery terminals and connecting wires to ensure a firm connection without any loosening or corrosion. If the terminal post is corroded, it can be sanded clean with sandpaper and an appropriate amount of special battery anti-rust agent can be applied to prevent further corrosion.

3. ** Regular battery performance inspection ** : Conduct a comprehensive inspection of the battery once a month, including measuring battery voltage, internal resistance, electrolyte density and other indicators. By detecting the data, the performance status of the battery can be understood in a timely manner, and any problems found can be dealt with promptly. For instance, when the internal resistance of a battery increases significantly, it may indicate that the plates are aging or the active material has fallen off, and corresponding repair measures should be taken or the battery should be considered for replacement.

(3) Optimize the usage environment

1. ** Temperature Control ** : Provide dedicated charging and storage areas for forklift batteries, install air conditioners or ventilation equipment, and keep the ambient temperature between 20℃ and 30℃. In the hot summer, measures such as shading and heat dissipation can be taken. In winter when the temperature is low, keep the battery warm, such as by using thermal insulation covers or heating devices, to improve the battery's working performance.

2. ** Keep dry ** : Ensure that the storage and usage environment of the battery is dry and avoid dampness. Desiccants can be placed in the storage area, and the environmental humidity should be checked regularly. When the humidity exceeds 60%, dehumidification measures should be taken. At the same time, prevent the battery from coming into contact with water and avoid using the forklift in rainy days or on damp ground.

(4) Strengthen the training of operators

1. Conduct professional training: Regularly organize forklift operators to participate in professional training courses on the use and maintenance of lead-acid batteries, and invite professional technicians to give lectures. The training content includes the working principle of batteries, correct charging methods, key points of daily maintenance, and handling of common faults, etc.

2. ** Assessment and Supervision ** : After the training is completed, the operators will be evaluated to ensure that they master the relevant knowledge and skills. Meanwhile, a supervision mechanism should be established to regularly inspect the operation norms and maintenance work implementation of the operators, and promptly correct and punish any violations of regulations.

5. The Significance of Rational Use of Lead-Acid Batteries in Forklifts for Enhancing the Overall Efficiency of the Equipment

(1) Extend the battery life

Through reasonable charging management, daily maintenance and optimization of the usage environment, problems such as sulfation and corrosion of battery plates can be effectively reduced, and the service life of lead-acid batteries can be prolonged. Under normal circumstances, the service life of properly used lead-acid batteries can reach 3 to 5 years. Compared with batteries used unreasonably, their service life is extended by 1 to 2 years, thereby reducing the cost of battery replacement.

(2) Enhance the working efficiency of forklifts

The rational use of lead-acid batteries can ensure that the batteries are always in good performance condition, providing stable power output for forklifts and reducing the time forklifts need to be shut down for maintenance due to battery problems. In this way, forklifts can complete handling tasks more efficiently, improve the efficiency of logistics and warehousing operations, and thereby enhance the production efficiency of enterprises.

(3) Reduce operating costs

Extending the battery life and reducing the downtime for forklift maintenance directly lower the costs for enterprises in battery replacement and equipment maintenance. At the same time, the rational use of batteries can also reduce energy consumption, improve energy utilization efficiency, and further lower the operating costs of enterprises.

6. Conclusion

The rational use of lead-acid batteries in forklifts is a key link to enhance the overall efficiency of the equipment. By understanding the working principle and characteristics of lead-acid batteries, and in response to the problems existing in current use, adopting scientific charging management, strengthening daily maintenance, optimizing the usage environment and intensifying the training of operators and other strategies, the service life of batteries can be effectively prolonged, the working efficiency of forklifts can be improved, and the operating costs of enterprises can be reduced. Enterprises should attach great importance to the rational use of lead-acid batteries in forklifts, incorporate them into the important content of equipment management, continuously improve the overall efficiency of the equipment, enhance the competitiveness of the enterprise, and adapt to the rapid development needs of the modern logistics and warehousing industry. In the future, with the continuous advancement of technology, attention should also be paid to the application of new battery technologies in the forklift field. At the same time, the usage and management methods of lead-acid batteries should be continuously optimized to create greater value for enterprises.