News

Abstract

This article conducts an in-depth discussion on the maintenance and management of the electrolyte in forklift lead-acid batteries, elaborating in detail on the composition of the electrolyte and its significant role in the operation of the battery. Combined with the actual application scenarios, this paper systematically analyzes the common problems of the electrolyte in forklift lead-acid batteries during daily use, and specifically proposes effective maintenance and management measures, fault diagnosis and handling methods. At the same time, it looks forward to the future development trend of electrolyte management, aiming to provide scientific and practical guidance for the efficient operation and extended service life of forklift lead-acid batteries.

1. Introduction

Forklifts, as indispensable and important equipment in the modern logistics industry, are widely used in various links such as warehousing, transportation and loading and unloading. Lead-acid batteries have become the main power source for forklifts due to their advantages such as mature technology, low cost, and good high-current discharge performance. As the key medium for lead-acid batteries to convert electrical energy into chemical energy, the performance and state of the electrolyte directly affect the charging and discharging efficiency of the battery, its service life, and the working performance of forklifts. With the rapid development of the logistics industry, the usage frequency and intensity of forklifts are constantly increasing, which puts forward higher requirements for the maintenance and management of lead-acid battery electrolyte. Therefore, in-depth research on the maintenance and management of the electrolyte of forklift lead-acid batteries has important practical significance.

2. Composition of Electrolyte for Forklift Lead-Acid Batteries

2.1 Composition of the electrolyte

The electrolyte of forklift lead-acid batteries is mainly composed of pure sulfuric acid and distilled water in a certain proportion. Among them, sulfuric acid is a key substance involved in the electrochemical reaction. It dissociates into hydrogen ions and sulfate ions in water, providing an ionic conductive environment for the charging and discharging process of the battery. Distilled water plays a role in diluting sulfuric acid, regulating the density of the electrolyte, and participating in electrochemical reactions at the same time. The density of the electrolyte is usually between 1.28 and 1.30g/cm³. For batteries of different specifications and usage environments, the requirements for the density of the electrolyte may vary slightly.

3. The Importance of Maintenance and Management of Electrolyte in Forklift Lead-Acid Batteries

3.1 Affect the charging and discharging performance of the battery

The density and concentration of the electrolyte directly affect the charging and discharging efficiency of the storage battery. If the density of the electrolyte is too high or too low, it will lead to a slowdown in the electrochemical reaction rate, a decrease in the charging and discharging capacity, and a weakening of the forklift's endurance and working power. For instance, when the density of the electrolyte is too low, the concentration of sulfuric acid is insufficient, the electrochemical reaction is not thorough, the battery cannot be fully discharged, and the forklift may encounter problems such as insufficient power and slow operation during operation. If the density of the electrolyte is too high, it will accelerate the sulfation and corrosion of the plates, shortening the service life of the battery.

3.2 It is related to the service life of the battery

Good maintenance and management of the electrolyte can effectively slow down the sulfidation, corrosion and aging rate of the plates. When the electrolyte level is too low, the upper part of the plates is exposed to the air, which is prone to oxidation and sulfidation, resulting in a reduction of the active material on the plates and a decrease in the capacity of the battery. Impurities mixed in the electrolyte can cause self-discharge, accelerating the power loss of the battery. At the same time, impurities may undergo chemical reactions with the plates, corroding them and shortening the service life of the battery. Therefore, scientifically and reasonably maintaining and managing the electrolyte is the key to extending the service life of lead-acid batteries in forklifts.

3.3 Ensure the safe operation of forklifts

During the operation of a forklift, if there is a problem with the battery electrolyte, it may cause a series of safety hazards. For instance, electrolyte leakage may corrode the metal parts of forklifts, causing structural damage. During the charging process, if the temperature of the electrolyte is too high, a large amount of flammable and explosive gas may be produced, posing an explosion risk. Through regular maintenance and management of the electrolyte, potential safety issues can be identified and resolved in a timely manner, ensuring the safe operation of forklifts.

4. Daily Maintenance and Management Measures for Lead-acid Battery Electrolyte of Forklifts

4.1 Check the height of the electrolyte level

Regularly checking the height of the electrolyte level is an important part of daily maintenance. Under normal circumstances, it should be checked once every 1 to 2 weeks. When conducting the inspection, the cover plate on the battery should be opened to observe whether the electrolyte level is between the upper and lower scale lines on the plate protection net or the casing. If the liquid level is below the lower mark, distilled water or special lead-acid battery replenishment fluid should be added in time. It should be noted that the addition of sulfuric acid or other untreated water is strictly prohibited to avoid affecting the composition and performance of the electrolyte. After adding the liquid, it should be ensured that the liquid level height is within an appropriate range.

4.2 Measurement of Electrolyte density

The density of the electrolyte is an important indicator reflecting the charging and discharging state and performance of the storage battery. Regularly measuring the density of the electrolyte with a hydrometer can help to promptly understand the working status of the battery. It is generally recommended to measure once a week. The measurement should be carried out after charging is completed or after discharging and left to stand for a period of time to ensure the accuracy of the measurement results. Under normal circumstances, the density of the electrolyte in a fully charged battery should be within the specified range. If the measured value deviates too much from the standard value, the cause should be analyzed and adjustments made. For example, when the density of the electrolyte is too low, it can be increased by supplementing sulfuric acid. If the density is too high, add distilled water for dilution. However, during the adjustment process, it is necessary to operate slowly, adding and stirring simultaneously to avoid damaging the battery due to rapid density changes.

4.3 Electrolyte temperature Monitoring

The temperature of the electrolyte has a significant impact on the performance and lifespan of the storage battery. During the charging process, the temperature of the electrolyte will gradually rise. If the temperature is too high (generally exceeding 45℃), it will accelerate the aging and corrosion of the plates, reduce the service life of the battery, and may also cause safety accidents. Therefore, during the charging process, the temperature of the electrolyte should be monitored in real time. A thermometer can be inserted into the electrolyte for measurement. When the temperature approaches or exceeds 45℃, the charging current should be immediately reduced or charging should be suspended. Charging can be resumed only after the temperature drops to the normal range. In addition, when using forklifts in high-temperature environments, appropriate cooling measures should be taken, such as adding ventilation and heat dissipation equipment to prevent the battery from being exposed to high temperatures for a long time.

4.4 Impurity cleaning of the electrolyte

Impurities mixed in the electrolyte can cause serious damage to the battery. Regularly cleaning the impurities inside the battery can effectively extend its service life. When cleaning, first extract the electrolyte from the battery, then rinse the interior of the battery with distilled water to remove sediment and impurities on the surface and bottom of the plates. After rinsing thoroughly, refill with the electrolyte that meets the requirements. During daily use, it is important to keep the battery clean to prevent dust, metal debris and other impurities from entering the interior of the battery. For example, when loading and unloading goods, prevent metal parts on the goods from falling into the battery; Regularly wipe the battery casing to keep its surface clean and dry.

5. Common Problems and Solutions of Electrolyte in ForkLift Lead-Acid Batteries

5.1 The electrolyte level drops too quickly

The main reasons for the rapid drop in the electrolyte level are twofold: First, normal water evaporation, especially in high-temperature environments or when forklifts are frequently used, the rate of water evaporation increases. The second is that there is leakage in the battery, such as damaged casing and poor sealing at the connection points of the plates. For the rapid drop of the liquid level caused by water evaporation, it can be solved by regularly adding distilled water or supplementary liquid. If battery leakage is found, the forklift should be stopped immediately and a comprehensive inspection of the battery should be carried out to identify the leaking area. For minor shell damage, special battery repair glue can be used for repair. If the leakage is severe, such as the connection parts of the plates being severely damaged, a new battery needs to be replaced.

5.2 Abnormal electrolyte density

Abnormal electrolyte density includes two situations: excessively high density and excessively low density. Excessively high density might be due to insufficient added distilled water or overly long charging time and excessive charging current, which leads to excessive evaporation of water and a relative increase in the concentration of sulfuric acid. If the density is too low, it may be due to the addition of too much distilled water or the self-discharge of the battery, which dilutes the sulfuric acid. When the density of the electrolyte is found to be too high, distilled water can be slowly added for dilution, and it should be thoroughly stirred evenly. Then, the density should be measured again until it reaches the normal range. If the density of the electrolyte is too low, an appropriate amount of concentrated sulfuric acid can be added for adjustment, but it is necessary to pay attention to the control of the addition amount to avoid excessive adjustment. At the same time, for cases where the density is too low due to self-discharge, it is necessary to check whether the battery has problems such as short circuit and plate sulfation, and repair them in a timely manner.

5.3 The electrolyte is turbid

The turbidity of the electrolyte is usually caused by sulfation of the plates, shedding of active substances or the mixture of a large amount of impurities in the electrolyte. Sulfation of the plates can lead to the formation of hard lead sulfate crystals on the surface of the plates. These crystals gradually fall off in the electrolyte, making the electrolyte turbid. The shedding of active substances is due to the aging of the plates or excessive charging current, which causes the active substances on the plates to loosen and fall off into the electrolyte. Impurities such as metal shavings and dust mixed into the electrolyte can also cause the electrolyte to become turbid. When the electrolyte is found to be turbid, all the electrolyte in the battery should be drained first. Then, the interior of the battery should be rinsed multiple times with distilled water to remove as much sediment and impurities as possible from the surface and bottom of the plates. If the sulfation of the plates is severe, it can be repaired by charging with a small current for a long time. If too much active material falls off or the plates are severely damaged, a new battery needs to be replaced.

6. Conclusion

The maintenance and management of the electrolyte in forklift lead-acid batteries is a key link to ensure the normal operation of forklifts and extend the service life of the batteries. Through an in-depth understanding of the composition of the electrolyte, we have recognized the significant role of the electrolyte in the operation of the storage battery. During daily use, strictly implementing maintenance and management measures such as checking the liquid level height of the electrolyte, measuring its density, monitoring its temperature and cleaning up impurities can promptly identify and solve problems existing in the electrolyte, ensuring the performance and safety of the battery. For common problems such as the rapid drop of the electrolyte level, abnormal density and turbidity, mastering the corresponding treatment methods can effectively reduce the impact of faults on the operation of forklifts. With the continuous advancement of technology, the management of electrolyte for forklift lead-acid batteries will develop in the direction of intelligence, research and application of new types of electrolyte, and environmental protection. In the future, we need to constantly learn and apply new technologies and methods to further enhance the maintenance and management level of lead-acid battery electrolyte for forklifts, providing strong support for the efficient and sustainable development of the logistics industry.