News

In the modern logistics and warehousing industry, forklifts, as important handling equipment, the performance and capacity of their power source - lead-acid batteries - have a crucial impact on the working efficiency, operating costs and safety of forklifts. Different operation scenarios have varying requirements for the working intensity, continuous working time and operating conditions of forklifts. Therefore, reasonably matching the capacity of lead-acid batteries for forklifts to meet the needs of various operation scenarios has become a key link in improving the utilization efficiency and economic benefits of forklifts.

1. Basic Concepts and Influencing Factors of Lead-Acid Battery Capacity in ForkLifts

The capacity of lead-acid batteries is usually expressed in ampere-hours (Ah), which represents the amount of charge that the battery can release under certain discharge conditions.

Temperature is one of the important factors affecting the capacity of lead-acid batteries. In a low-temperature environment, the chemical reaction rate inside the battery slows down, and the fluidity of the electrolyte deteriorates, resulting in a decrease in the battery's capacity. Generally speaking, for every 1℃ drop in temperature, the capacity of lead-acid batteries decreases by approximately 0.8% to 1%. Conversely, in high-temperature environments, although the initial capacity of the battery may increase, excessively high temperatures will accelerate the aging of the battery and the corrosion of the plates, thereby shortening the battery's service life.

The discharge rate also has a significant impact on battery capacity. Discharge rate refers to the ratio of the current magnitude during battery discharge to the rated capacity of the battery. When discharging at a higher discharge rate, the polarization phenomenon inside the battery intensifies, the voltage drop rate accelerates, and the actual capacity that can be released is lower than the rated capacity.

In addition, the number of charge and discharge cycles, charging methods, and maintenance conditions of the battery will also affect its capacity and performance. Frequent deep discharges and improper charging methods will accelerate the aging of the battery and reduce its capacity. Regular maintenance and care, such as checking the electrolyte level and specific gravity, and cleaning the battery surface, can effectively extend the battery life and maintain the stability of battery capacity.

2. Analysis of Common Work Scenarios

(1) Indoor storage operations

Indoor warehousing operations usually have the characteristics of relatively enclosed space, relatively fixed operation routes, and short handling distances. In this scenario, forklifts mainly undertake the tasks of stacking, picking and short-distance transportation of goods. The intensity of work is generally stable and there will be no continuous high-intensity work for a long time. For instance, in large e-commerce warehouses, forklifts need to frequently move goods from the storage area to the picking area. The distance of each move may range from tens of meters to hundreds of meters, and the weight of the goods being moved is relatively moderate, generally around 1 to 3 tons.

(2) Port and Wharf Operations

Ports and docks are important hubs for the loading, unloading and transfer of goods, where forklifts undertake heavy tasks of goods handling and stacking. In this scenario, the working environment is complex, with harsh conditions such as high temperature, high humidity and salt spray. Forklifts need to work continuously for long periods of time, with high work intensity. The weight of the goods they handle is usually quite heavy, reaching 3 to 10 tons or even more. Moreover, the operation time is not fixed and they may need to run non-stop for 24 hours. For instance, at container terminals, forklifts need to unload containers from cargo ships and transport them to designated storage yards for stacking, or move containers from storage yards to transport vehicles. The entire process requires the continuous and efficient operation of forklifts.

(3) Factory production workshop operations

The operation scenarios in factory production workshops vary depending on the type of production. For some light industrial production workshops, such as those in the electronics and food industries, forklifts are mainly used for the handling of raw materials and the transportation of finished products. The weight of the goods is relatively light, generally around 1 to 2 tons, and the working environment is relatively good. However, high flexibility and precision are required for forklifts. In heavy industrial production workshops, such as those in the steel and mechanical manufacturing industries, forklifts need to handle large raw materials and finished products. The weight of the goods can reach 5 to 10 tons or even heavier. The working environment is rather harsh, with issues like high temperatures and dust. Forklifts must have strong power and stability, and may need to work continuously for long periods of time.

3. Matching Methods for Lead-Acid Battery Capacity of Forklifts in Different Working Scenarios

(1) Capacity matching for indoor warehousing operations

Due to the relatively low intensity of indoor warehousing operations and the regular working hours, the battery capacity can generally be selected based on the average working time and average load current of the forklift. Considering a certain margin and the attenuation of battery capacity, a battery capacity slightly larger than the calculated value is usually chosen. This way, it can not only meet the daily operation requirements, but also ensure that the battery can still meet the work requirements after being used for a period of time, while avoiding cost waste caused by excessive battery capacity.

(2) Capacity matching for port and terminal operations

The operation intensity at ports and docks is high and they need to run continuously for 24 hours, which places extremely high demands on the capacity and endurance of lead-acid batteries in forklifts. In such scenarios, it is usually necessary to select large-capacity batteries and adopt a double-shift or multi-shift battery swapping system to ensure the continuous operation of the forklift. In fact, considering the particularity of port operations, large-capacity lead-acid batteries are generally chosen. At the same time, to ensure that the forklift can quickly resume operation when the battery power is insufficient, it is also necessary to be equipped with a sufficient number of spare batteries and establish a complete battery swapping process and management system. In addition, due to the harsh environment of the port, it is also necessary to select batteries with good sealing and corrosion resistance to extend the service life of the batteries.

(3) Capacity matching of factory production workshop operations

For light industrial production workshops, due to the relatively light weight of the goods and the relatively good working environment, the working intensity of forklifts is moderate. The battery capacity can be selected relatively appropriately based on the specific operation time and load conditions. Regular maintenance and care of the battery should be carried out, and various performance indicators of the battery should be checked in a timely manner to ensure that the battery can work normally in harsh environments.

4. Other Supporting Measures and Precautions

In addition to reasonably matching battery capacity, a series of supporting measures also need to be taken to ensure the normal operation of forklift lead-acid batteries in different working scenarios. First of all, it is necessary to select the appropriate charging equipment and charging method based on different working scenarios and battery capacity. For example, for large-capacity batteries, chargers with fast charging functions should be chosen to shorten the charging time. At the same time, overcharging and undercharging should be avoided. An intelligent charging management system should be adopted to automatically adjust the charging parameters according to the actual state of the battery.

Secondly, strengthen the training of forklift operators to enable them to understand the working principle, performance characteristics, as well as the correct usage and maintenance methods of lead-acid batteries. Operators should strictly follow the operating procedures when using forklifts and avoid improper operations such as sudden acceleration and sudden braking to reduce battery energy loss and the impact on battery life.

In addition, it is also crucial to establish a sound battery maintenance and monitoring system. Regularly inspect and maintain the battery, including measuring the specific gravity of the electrolyte, checking the condition of the plates, and cleaning the battery surface, etc. The battery monitoring system is used to monitor parameters such as voltage, current and temperature of the battery in real time, promptly identify problems existing in the battery and take corresponding measures to deal with them.

Reasonable matching of the capacity of lead-acid batteries for forklifts is the key to improving the operational efficiency of forklifts, reducing operating costs and ensuring operational safety. In practical applications, it is necessary to fully consider the characteristics and demands of different operation scenarios, combine the performance and influencing factors of the battery, scientifically and reasonably select the battery capacity, and take corresponding supporting measures and management methods to ensure that the lead-acid batteries of forklifts can perform at their best in various operation scenarios, providing strong support for the production and operation of enterprises.