How to extend the service life of lead-acid batteries in forklifts

Time：2025-04-26 10:11:45

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The following will explore in detail the methods to extend the service life of lead-acid batteries in forklifts from multiple aspects.

In the industrial field, forklifts, as important handling equipment, the performance and service life of their power source - lead-acid batteries - are of vital importance. Extending the service life of lead-acid batteries in forklifts can not only reduce the operating costs of enterprises, but also improve work efficiency and reduce equipment downtime caused by battery failures. The following will explore in detail the methods to extend the service life of lead-acid batteries in forklifts from multiple aspects.

1. Correct Charging Management

(1) Master the right charging time

Avoiding excessive discharge is the key. When the battery power of a forklift remains at around 20% to 30%, it should be charged. Excessive discharge can cause sulfation of the plates, resulting in a decrease in battery capacity. The battery level can be monitored in real time through the battery level display device on the forklift dashboard. If there is no accurate battery level display, the charging time can also be roughly estimated based on the working hours and intensity of the forklift.

(2) Choose an appropriate charging method

1. **Constant current charging**: At the initial stage of charging, using a larger constant current can accelerate the charging speed. However, as the battery voltage increases, the current needs to gradually decrease to avoid overcharging. This charging method is suitable for use when the battery power is low.

2. ** Constant Voltage charging ** : In the later stage of charging, keep the charging voltage constant, and the current will gradually decrease as the battery power increases. When the current decreases to a certain extent, it indicates that the battery is nearly fully charged. Constant voltage charging can ensure the saturation of battery charging, but using it alone may lead to insufficient charging.

3. ** Smart Charging ** : Modern smart chargers can automatically adjust the charging current and voltage based on the battery's status, achieving a charging process of constant current first and then constant voltage, and also avoiding overcharging and undercharging situations. It is recommended to use an intelligent charger to charge the lead-acid batteries of forklifts to improve charging efficiency and battery life.

(3) Control the charging time

Each charging time should not be too long, generally around 8 to 10 hours. If the charging time is too long, it will cause the battery to heat up and accelerate the aging of the internal plates and electrolyte of the battery. However, the charging time should not be too short either; otherwise, the battery cannot be fully charged, which will affect the working time of the forklift. At the same time, avoid frequent short-time charging, as this will cause the battery's memory effect and reduce its capacity.

2. Reasonable Usage norms

(1) Avoid high current discharge

When a forklift starts, accelerates and climbs a slope, the current will increase instantaneously. Sudden acceleration and braking should be avoided as much as possible. The forklift should be operated smoothly to reduce the situation of large current discharge. You can plan the driving route in advance to avoid frequent starts and stops as well as climbing slopes. This can not only reduce the burden on the battery but also improve work efficiency.

(2) Control the working temperature

The optimal operating temperature for lead-acid batteries is around 25℃. When the ambient temperature is too high, the chemical reaction rate inside the battery accelerates, and the evaporation of the electrolyte intensifies, which can lead to the aging of the battery plates and the shedding of active substances. When working in a high-temperature environment, appropriate cooling measures can be taken, such as installing air conditioners or fans in the charging area to lower the battery's temperature. When the ambient temperature is too low, the chemical reaction rate of the battery slows down, its capacity decreases, and its charging acceptance ability also deteriorates. At this point, the battery can be wrapped with an insulating cover, or the forklift and battery can be placed in a warm indoor environment to ensure the normal working performance of the battery.

(3) Regular deep discharge

It is recommended to perform a deep discharge every 2 to 3 months, that is, to reduce the battery power to a lower level, and then fully charge it. This can activate the active substances on the battery plates, prevent sulfation of the plates, and increase the battery's capacity and service life. However, it should be noted that the frequency of deep discharge should not be too high; otherwise, it will also cause damage to the battery.

3. Daily Maintenance and Care

(1) Check the electrolyte level

Regularly check the electrolyte level inside the battery. The level should be maintained 10 to 15 millimeters above the plates. If the liquid level is too low, it will cause the plates to be exposed to the air, resulting in oxidation and sulfidation of the plates. When the electrolyte level is found to be insufficient, distilled water or special lead-acid battery replenishment fluid should be added. Tap water should be avoided as it contains various impurities that can affect the battery's performance.

(2) Clean the surface of the battery

Keep the battery surface clean and dry to prevent dust, moisture and corrosive substances from adhering to the battery. Dirt on the battery surface may cause the battery to self-discharge, reducing its service life. The battery surface can be wiped regularly with a clean damp cloth to remove dirt and dust. At the same time, check if there is any corrosion on the battery terminals. If so, you can gently sand them with sandpaper and then apply a layer of Vaseline to prevent further corrosion of the terminals.

(3) Check the battery connection

Regularly check whether all connection parts of the battery are firm and whether there is any loosening, oxidation or other conditions. Loose connection will lead to an increase in contact resistance, generating heat during charging and discharging, which can damage the battery and connection components. If loose connection parts are found, they should be tightened in time. If there is oxidation, it should be cleaned and treated to ensure a good connection.

4. Storage Management

(1) Short-term storage

If the lead-acid battery of the forklift needs to be stored for a short period of time, it should be fully charged first, and then a supplementary charge should be carried out every two weeks to prevent self-discharge of the battery from causing the power to be too low. The storage environment should be kept dry and well-ventilated, avoiding direct sunlight and dampness.

(2) Long-term storage

For batteries that have been stored for a long time (more than 3 months), they should also be fully charged first, then the electrolyte should be drained, the interior of the battery should be rinsed with distilled water, and then an electrolyte with a density of 1.28g/cm³ should be added. Charge the battery once every month. After charging, wipe the battery surface clean and then store it. Before reusing the battery, a complete charge and discharge cycle should be carried out first to activate the battery's performance.

5. Personnel Training and Management

Enterprises should enhance the training of forklift operators and maintenance personnel, enabling them to understand the working principle, performance characteristics and correct usage and maintenance methods of lead-acid batteries. Operators must strictly follow the operating procedures when using forklifts to avoid damaging the battery due to improper operation. Maintenance personnel should regularly inspect and maintain the batteries to promptly identify and address any issues existing with them. At the same time, a complete battery usage and maintenance record system should be established to document information such as the number of battery charges, usage duration, and maintenance conditions, so as to track and analyze the performance and lifespan of the batteries and adjust maintenance strategies in a timely manner.

To extend the service life of lead-acid batteries in forklifts, it is necessary to take comprehensive measures from multiple aspects such as charging management, usage norms, daily maintenance and care, storage management, and personnel training. Only in this way can the performance of lead-acid batteries be fully exerted, their service life be prolonged, the operating costs of enterprises be reduced, production efficiency be improved, and greater economic benefits be created.

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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