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In modern logistics warehousing and industrial production, forklifts, as important handling equipment, the performance and lifespan of their power source - lead-acid batteries - directly affect operational efficiency and operating costs. If the lead-acid batteries of forklifts experience problems such as capacity attenuation and plate sulfation too early, it will not only increase the downtime of the equipment, but also significantly raise the operating expenses of the enterprise due to frequent battery replacement. Therefore, it is of vital importance for both enterprises and operators to master scientific and practical methods to extend the lifespan of lead-acid batteries in forklifts.

1. Correct daily usage habits

(1) Avoid excessive discharge

The depth of discharge of lead-acid batteries is closely related to their service life. Excessive discharge can cause the active substances on the surface of the plates to overreact, accelerate the sulfation of the plates and shorten the battery life. Generally speaking, when the forklift dashboard shows that the battery level remains at 20% to 30%, it should be charged in time to avoid running out of power. Operators should strictly follow the operating procedures. When the battery level reaches the warning value, they should immediately stop the operation and drive the forklift to the charging area. Meanwhile, enterprises can establish a strict power monitoring system. By installing a power monitoring system, they can keep track of the power status of each forklift battery in real time, thus avoiding excessive discharge caused by human negligence.

(2) Reasonably control the load

During the operation of a forklift, the size of the load has a direct impact on the discharge current of the battery. Excessive load can cause the battery to have an overly large instantaneous discharge current, leading to problems such as plate bending and active material shedding. Therefore, operators must strictly operate the forklift in accordance with its rated load and are strictly prohibited from overloading. In addition, when handling goods, operations such as sudden acceleration, sudden braking and frequent steering should be avoided as much as possible. These operations can cause excessive fluctuations in battery current and accelerate battery wear.

2. Scientific Charging Management

(1) Choose the appropriate charger

Lead-acid batteries of different models and specifications have different requirements for charging voltage and current, so it is crucial to choose a charger that matches the battery. Poor-quality or mismatched chargers may cause the charging voltage to be too high or too low, and the current to be unstable, thereby affecting the charging effect and lifespan of the battery. When choosing a charger, it is necessary to select based on parameters such as the rated voltage and capacity of the battery to ensure that the output voltage and current of the charger meet the charging requirements of the battery. At the same time, it is necessary to choose a charger with reliable quality and overcharge, overcurrent and short-circuit protection functions to ensure the safety and stability of the charging process.

(2) Follow the correct charging process

Pre-charging inspection: Before starting charging, conduct a comprehensive inspection of the battery, including checking if the battery casing is damaged or leaking, and if the connecting wires are loose or oxidized, etc. If any problems are found, they should be repaired or replaced in time to ensure the safety of charging. At the same time, the density of the electrolyte and the liquid level height of the battery should be measured. If the density of the electrolyte is too low or the liquid level is insufficient, an appropriate amount of distilled water or special lead-acid battery replenishment liquid should be added first to adjust the density of the electrolyte to the normal range.

Charging process control: The charging process is generally divided into two stages: constant current charging and constant voltage charging. During the constant current charging stage, the charger charges the battery with a constant current. When the battery voltage rises to a certain value, it enters the constant voltage charging stage. The charger maintains a constant voltage while the current gradually decreases. During the charging process, it is necessary to closely monitor the changes in charging current, voltage and battery temperature. When the battery temperature exceeds 45℃, charging should be suspended. Wait until the temperature drops before resuming charging to avoid problems such as deformation of the battery plates and rapid evaporation of the electrolyte due to excessive temperature. In addition, each charging time should not be too long, generally controlled at around 8 to 10 hours, to avoid overcharging. Overcharging can cause the battery to heat up, accelerate the aging of the plates and shorten the battery's lifespan.

Post-charging treatment: After charging is completed, do not use the forklift immediately. Let the battery stand for 30 minutes to 1 hour to ensure that the electrolyte inside the battery is fully mixed and the voltage stabilizes. At the same time, the density of the electrolyte and the liquid level height of the battery should be checked again. If necessary, appropriate adjustments should be made. In addition, it is necessary to clean the dust and electrolyte residue on the battery surface in a timely manner, keep the battery surface clean and dry, and prevent the battery from self-discharging.

3. Regular maintenance and upkeep

(1) Maintenance of electrolyte

Electrolyte is a key substance for the normal operation of lead-acid batteries. Its density and liquid level height directly affect the performance and lifespan of the battery. Therefore, the density and liquid level height of the electrolyte should be checked regularly, usually once a week. When the electrolyte level is below the minimum scale line, distilled water or special lead-acid battery replenishment fluid should be added to restore the level to the normal range. Be careful not to add tap water or other water containing impurities to prevent impurities from entering the battery and affecting its performance. At the same time, the density of the electrolyte should be adjusted in a timely manner according to the changes in seasons and usage environments. In winter, the density of the electrolyte can be appropriately increased to enhance the battery's anti-freezing performance. In summer, the density of the electrolyte can be appropriately reduced to prevent the battery from overheating.

(2) Inspection and maintenance of the plates

The plates are the core components of lead-acid batteries, and their condition directly determines the battery's capacity and lifespan. Regularly checking the condition of the plates can help identify problems in a timely manner and take corresponding measures. Generally, a thorough inspection of the battery should be carried out every 3 to 6 months. Open the battery cover and observe whether there are any issues such as sulfation on the surface of the plates or the shedding of active substances. If slight vulcanization of the plates is found, it can be repaired by charging with a small current for a long time or by using a vulcanization removal charging device. If the plates are severely sulfated or a large amount of active substances fall off, the plates or the entire battery need to be replaced. In addition, when inspecting the plates, be careful to avoid damaging them and prevent short circuits.

(3) Maintenance of connecting wires and terminals

The connection wires and terminals of the battery are important components for connecting the battery to the electrical system of the forklift. The reliability of their connection directly affects the charging and discharging performance of the battery. Regularly check whether the connecting wires and terminals are loose or oxidized. If any looseness is found, tighten them in time. If oxidation is found, it can be cleaned with sandpaper or a special terminal cleaner to ensure a good connection. At the same time, a layer of Vaseline or a special conductive paste can be applied to the surface of the terminal to prevent oxidation of the terminal, reduce contact resistance and improve charging and discharging efficiency.

4. Appropriate storage and environmental management

(1) Correct storage method

When forklifts are not in use for a long time, lead-acid batteries need to be properly stored. First, fully charge the battery. Then, perform a supplementary charge every two weeks to prevent the battery from self-discharging and causing a loss of power. During storage, the battery should be placed in a dry, well-ventilated and cool place, avoiding direct sunlight and damp environments. At the same time, it is necessary to avoid squeezing or colliding the battery to prevent damage to the battery casing and deformation of the plates. In addition, if the battery needs to be stored for a long time (more than three months), the electrolyte of the battery can be extracted, sealed and stored. When it is needed, the electrolyte can be refilled and the battery recharged. This can effectively extend the storage life of the battery.

(2) Control of ambient temperature

The performance of lead-acid batteries is relatively sensitive to ambient temperature, and the suitable operating temperature range is generally 20℃ to 25℃. When the ambient temperature is too high, the chemical reaction rate of the battery increases, the evaporation of the electrolyte intensifies, and the aging speed of the plates also speeds up. When the ambient temperature is too low, the chemical reaction rate of the battery slows down, the battery capacity decreases, and the starting performance deteriorates. Therefore, during the hot summer weather, shading facilities should be provided for forklifts and batteries to prevent direct sunlight from hitting the batteries. If necessary, forced ventilation or water cooling can be adopted to lower the battery temperature. In the cold winter weather, it is necessary to take insulation measures for the battery, such as wrapping the battery with an insulation cover or parking the forklift in a warm room, to ensure that the battery operates within an appropriate temperature range and extend its lifespan.

5. Establish a complete battery management system

Enterprises should establish a complete management system for lead-acid batteries to manage the entire process of battery procurement, use, maintenance and replacement. By establishing battery files, recording information such as the purchase time, usage, maintenance records, and charge and discharge cycles of each battery, it is convenient to promptly grasp the status and performance changes of the batteries. At the same time, a scientific battery replacement strategy should be formulated. Based on the actual usage and life cycle of the battery, the battery replacement time should be reasonably arranged to avoid equipment failure and production efficiency decline caused by excessive battery use. In addition, enterprises can also introduce an intelligent battery management system to achieve remote monitoring and data analysis of batteries, promptly identify problems existing in batteries, and provide corresponding solutions, further enhancing the management level and service life of batteries.

In conclusion, to extend the lifespan of lead-acid batteries in forklifts, efforts should be made from multiple aspects, including daily usage habits, charging management, maintenance and care, storage and environmental management, as well as the establishment of a complete management system. Only by organically integrating these methods and strictly implementing them can the battery life be effectively prolonged, operating costs be reduced, and the economic benefits and production efficiency of enterprises be enhanced. Operators and enterprise managers should fully recognize the significance of maintaining lead-acid batteries, constantly learn and master scientific maintenance methods, and ensure that the lead-acid batteries of forklifts are always in good working condition.