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In modern logistics and industrial production, forklifts, as key material handling equipment, the selection of their power sources is of vital importance. Lead-acid batteries have become the preferred power source for many forklifts due to their cost-effectiveness, reliability and wide applicability. However, forklifts of different tonnages have significant differences in operation intensity, running time and power requirements. Therefore, it is necessary to be equipped with lead-acid batteries of corresponding specifications to ensure the efficient and stable operation of forklifts. This article will delve deeply into the compatibility relationship between forklifts of different tonnages and lead-acid batteries, providing users with a practical selection guide.

Analysis of Forklift Tonnage and Operation Requirements

The tonnage of a forklift is one of its core specifications, directly determining its load-carrying capacity and applicable scenarios. Generally speaking, the tonnage of forklifts can be classified into light-duty forklifts of 1 to 3 tons and those of 3 to 5 tons

Medium-sized forklifts and heavy-duty forklifts over 5 tons.

Light-duty forklifts (1-3 tons)

This type of forklift is mainly used for operations such as goods handling, shelving and unloading inside the warehouse. The working environment is usually quite narrow, which places high demands on the maneuverability of forklifts. Its working intensity is relatively low, with a single continuous working time generally ranging from 2 to 4 hours, but it may require frequent starts, stops and turns. For instance, in an e-commerce warehouse, light forklifts need to quickly move small items from the shelves to the sorting area, which imposes certain requirements on the flexibility of the forklifts and the instantaneous discharge capability of the batteries.

Medium-sized forklift (3-5 tons)

Medium-sized forklifts are often used in logistics centers, factory workshops and other places, responsible for moving heavy pallets of goods, such as raw materials and finished products. The working environment space is relatively large, but the handling distance may be long. The working intensity is moderate, and the single continuous working time can reach 4 to 6 hours. For instance, in an auto parts factory, medium-sized forklifts need to transport boxes of parts from the warehouse to the production line, which places high demands on the forklift's endurance and the continuous power supply stability of the battery.

Heavy-duty forklifts (over 5 tons)

Heavy-duty forklifts are mainly used in large logistics and industrial enterprises such as ports, steel mills, and wood factories, for handling super-heavy goods like large containers, steel coils, and logs. Its working environment is complex, the handling tasks are arduous, the single continuous working time is often more than 6 hours, and it needs to frequently start and climb slopes under heavy load. For instance, at port terminals, heavy-duty forklifts need to load, unload and transport containers weighing tens of tons, which places extremely high demands on the power output of the forklifts and the high-capacity and high-rate discharge performance of the batteries.

Interpretation of Lead-acid Battery Types and Parameters

Lead-acid battery type

REDOX lead-acid battery: Also known as open-type lead-acid battery, it is the most traditional type of lead-acid battery. It contains a liquid electrolyte inside, which is a mixture of sulfuric acid and water. This type of battery has the advantages of low cost, large capacity and high reliability, and is suitable for use in places with good battery maintenance conditions, such as fixed factory workshops. However, it is necessary to regularly check and replenish the electrolyte to maintain the performance and lifespan of the battery.

Maintenance-free lead-acid batteries: including gel batteries and AGM (Absorbent Glass Fiber Separator) batteries. The electrolyte of colloid batteries is gel-like, while AGM batteries use glass fiber separators to adsorb the electrolyte. Both achieve sealed maintenance-free operation. Maintenance-free lead-acid batteries are easy to use and do not require regular water addition. They are suitable for places with low requirements for battery maintenance, such as logistics distribution centers. However, its cost is relatively high, and its capacity and lifespan may be slightly lower than those of REDOX lead-acid batteries.

Key parameter interpretation: Vehicle voltage: The voltage of lead-acid batteries usually includes 24V, 48V, 72V, 80V, etc. Voltage determines the working efficiency and power output of the forklift motor. Generally speaking, the larger the tonnage of a forklift, the higher the voltage it requires to provide sufficient power to drive the motor to operate. For instance, light forklifts weighing 1-2 tons may use 24V or 48V batteries, while heavy forklifts weighing over 5 tons mostly employ 72V or 80V batteries.

Capacity: Battery capacity is measured in ampere-hours (Ah), indicating the amount of charge that the battery can release under certain discharge conditions. The larger the capacity, the more energy the battery can store, and the stronger the forklift's endurance will be. The operation intensity and working hours of forklifts determine the size of the required battery capacity. For instance, a light forklift that operates for 2 to 4 hours a day may require a battery capacity of 200 to 400Ah. Heavy-duty forklifts that operate for more than six hours a day require large-capacity batteries of over 600Ah.

Discharge rate: The discharge rate refers to the ratio of the discharge current to the rated capacity of the battery when it discharges within a specified period of time. For forklifts, a large current output is required at moments such as starting, accelerating and climbing, so the battery is required to have a high discharge rate. Under normal circumstances, heavy-duty forklifts have higher requirements for battery discharge rates than light-duty and medium-duty forklifts.

Recommendations for lead-acid battery models suitable for forklifts of different tonnages

Light-duty forklifts (1-3 tons)

1-1.5-ton forklifts: For such small forklifts, commonly compatible lead-acid battery models include 24V-210Ah (such as 3DB210 type), 24V-280Ah (such as 4DB280 type), etc. Take the Heli CDD12l forklift as an example. It can be matched with the 3DB210 lead-acid traction battery pack of Zibo Torch, with a single cell voltage of 2V and a rated capacity of 210Ah. The entire pack consists of 12 cells, and the peripheral dimensions of the power box are 655198574mm. These batteries are suitable for light material handling in warehouses and can meet the frequent start-stop needs of forklifts in narrow Spaces.

1.5-3 ton forklifts: The battery models that are compatible are more diverse, such as 48V-400Ah (like the 8PZB400 model), 48V-440Ah (like the 48V8PZB440 model), 48V-450Ah (like the D-450S model), etc.

Medium-sized forklift (3-5 tons)

For 3-4 ton forklifts: Commonly compatible lead-acid batteries include 48V-500Ah (such as 5PZS500 model), 48V-550Ah (such as 10DB550 model), etc.

4-5 ton forklifts: Compatible battery models include 48V-600Ah (such as 24-6DB600AH type), 80V-480Ah, etc.

Heavy-duty forklifts (over 5 tons)

For 5-8 ton forklifts: 80V-600Ah (such as 40-4pzs600 model), 80V-700Ah and other models of lead-acid batteries can be selected.

Forklifts over 8 tons: For super heavy-duty forklifts, lead-acid batteries with a capacity of 80V-800Ah or more may be required, and even custom-made batteries of special specifications may be needed to meet their powerful power demands. In practical applications, based on the specific model and operation requirements of the forklift, professional battery suppliers can be consulted to obtain the most suitable battery solution.

Precautions for Selecting lead-acid batteries

Forklift compatibility: When choosing lead-acid batteries, it is essential to ensure that the battery's size, voltage, interface and other parameters are fully compatible with the forklift. The requirements for batteries may vary among different brands and models of forklifts. Therefore, it is essential to consult the forklift's user manual or consult the forklift manufacturer before making a selection to determine the appropriate battery specification.

Working environment: Consider the impact of the forklift's working environment on the battery. If the battery operates in a high-temperature environment, its heat dissipation performance and the evaporation rate of the electrolyte will be affected. Batteries with good heat dissipation design and high-temperature resistance should be selected. In low-temperature environments, the capacity of batteries will decline. It is necessary to choose batteries suitable for low-temperature conditions or take necessary insulation measures. In addition, if the working environment is humid or dusty, maintenance-free lead-acid batteries with good sealing performance should be selected to prevent internal short circuits or corrosion of the batteries.

Cost-effectiveness: The cost of lead-acid batteries includes procurement cost, usage cost and maintenance cost. Although the purchase cost of liquid-rich lead-acid batteries is relatively low, they require regular maintenance, including checking the electrolyte level, adding distilled water, and cleaning the battery surface, etc., and the maintenance cost is relatively high. Although maintenance-free lead-acid batteries have a slightly higher procurement cost, they do not require maintenance during use, which can save maintenance time and labor costs. Therefore, when selecting a model, it is necessary to comprehensively consider the full life cycle cost of the battery and choose the battery with the best cost performance based on the actual situation of the enterprise.

Brand and Quality: Choose lead-acid batteries from well-known brands, as their product quality and performance are more guaranteed. Well-known brands usually adopt advanced production techniques and high-quality raw materials. The batteries they produce have the advantages of sufficient capacity, long service life and high reliability. Meanwhile, the after-sales service of brand batteries is also more complete, capable of providing users with technical support and maintenance services in a timely manner, reducing the downtime caused by battery malfunctions.

Lead-acid batteries, as an important power source for forklifts, their selection is directly related to the performance, efficiency and operating costs of forklifts. Through the analysis of the operation requirements of forklifts of different tonnages and the understanding of the types and parameters of lead-acid batteries, users can select the most suitable battery model based on the actual situation. During the selection process, factors such as forklift compatibility, working environment, cost-effectiveness and brand quality are fully considered to ensure that the forklift can operate stably and efficiently under various working conditions, providing strong support for the production and logistics activities of enterprises.