Time:2025-03-03 14:15:09
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In high-intensity operation scenarios such as warehousing logistics and port loading and unloading, the endurance capacity of lead-acid batteries used in forklifts directly affects the operation efficiency of enterprises. However, due to improper operation, equipment aging or management omissions caused by the battery power depletion (deep discharge) ** frequent problems, light shutdown delay production, heavy permanent damage to the battery. According to the statistics of the China Warehousing Association, in 2023, 67% of the forklift shutdown accidents caused by battery exhaustion, a single loss of more than 10,000 yuan.
The dangers of running out of power: More than just "downtime"
After the lead-acid battery is completely exhausted, if it is not scientifically treated, it will cause serious consequences:
1.Irreversible damage:
◆Plate sulfation: the lead sulfate in the electrolyte crystallizes and hardens, and the capacity loss is up to 70%;
◆Internal resistance surge: the discharge efficiency of the battery decreases by 30%-50% after recovery, accelerating aging.
2.Security risks:
◆Excessive discharge leads to electrolyte delamination, which may cause leakage and corrosion of equipment.
◆When the low-voltage protection of some forklifts fails, the power may be exhausted and the controller may burn.
Three-step First aid: Science "resurrects" Drained batteries
Step 1: Stop using immediately
◆When the forklift instrument shows that the power is below 20%, stop the operation immediately to avoid forced discharge to 0%;
◆If the battery is exhausted, disconnect the battery from the circuit of the forklift to prevent reverse current from damaging the device.
Step 2: Professional charging equipment intervention
◆Use a pulse repair charger (not an ordinary charger) : charge slowly at 0.1C current (such as 20A for 200Ah batteries) until the voltage is restored to 12V (12V battery);
◆"Quick charge rescue" is strictly prohibited! High current charging will intensify plate vulcanization and lead to battery obsolescence.
The third step: capacity detection and decision
◆After charging is completed, test the actual capacity with the discharge meter:
●If the capacity is more than 80% of the nominal value, it can continue to use, but the maintenance period needs to be shortened;
●If the capacity is less than 50%, it is recommended to replace the old with the new to avoid repeated exhaustion and accidents.
Long-term prevention: from "fire fighting" to "fire prevention"
1. Technology upgrade: intelligent monitoring system
◆Forklift power warning module: real-time display of remaining power and estimated working time, less than 30% automatic alarm;
◆Cloud management platform: enterprises can remotely monitor the battery status of multiple forklifts and schedule the timely replacement of low-power equipment.
2. Management norms: enterprises must do the list
◆Formulate the "double 20%" rule: the power must be charged below 20%, and the charge can be put into use above 80%;
◆Shift handover record: operators need to fill in the "Battery Status Handover form" to clarify the remaining power and abnormal conditions;
◆Monthly health test: Use the internal resistance tester to check the "sub-health" battery, and replace the hidden unit in advance.
3. Equipment adaptation: anti-exhaustion technology
◆Deep cycle lead-acid battery: designed for frequent charge and discharge, supporting 600 deep discharges (ordinary batteries only 300 times);
◆Intelligent charging pile networking: the forklift truck automatically identifies the low-power battery after returning, and prioritizes the charging queue.
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