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Abstract

This article delves deeply into the common problem of active material shedding in forklift lead-acid batteries, analyzes in detail the hazards it causes to battery performance, forklift operation, and usage costs, and proposes practical and feasible solutions from multiple dimensions such as battery design, usage and maintenance, and production and manufacturing. It aims to provide comprehensive theoretical basis and practical guidance for the scientific management and efficient use of lead-acid batteries in forklifts, helping to enhance the operational efficiency of forklifts and reduce operating costs.

1. Introduction

Forklifts, as indispensable handling equipment in modern logistics and warehousing industries, are widely used in factories, warehouses, ports and other places. Lead-acid batteries have become the mainstream choice for forklift power systems due to their advantages such as mature technology, low cost, and good high-current discharge performance. However, during the use of lead-acid batteries in forklifts, the shedding of active substances is a rather common and thorny problem. The active material is the key substance for lead-acid batteries to achieve the mutual conversion of electrical energy and chemical energy. Once it falls off, it will have a serious impact on the performance and service life of the battery, and further interfere with the normal operation of forklifts. An in-depth study on the hazards of active material shedding in forklift lead-acid batteries and the solutions is of great practical significance for ensuring the safe and efficient operation of forklifts and reducing the operating costs of enterprises.

2. The Principle of Active Material Shedding in Forklift Lead-Acid Batteries

During the charging and discharging process of lead-acid batteries, lead dioxide on the positive plate and spongy lead on the negative plate undergo chemical reactions with sulfuric acid in the electrolyte, achieving the conversion of electrical energy to chemical energy. During this process, the active substances on the plates will undergo changes of volume expansion and contraction. When the battery is frequently charged and discharged, overcharged or overdischarged, used in harsh environments, or has its own quality defects, the bonding force between the active substances on the plates and the grids will gradually weaken, causing the active substances to fall off the plates. In addition, when batteries are subjected to external forces such as vibration and shock during use, the shedding process of active substances will also be accelerated.

3. Hazards of Active Material Shedding in Forklift Lead-Acid Batteries

(1) Battery performance declines

Capacity reduction: Active substances are the main components involved in electrochemical reactions. Their shedding directly leads to a decrease in the substances involved in the reaction, and the actual capacity of the battery decreases accordingly. For instance, a battery that was originally capable of supporting a forklift to operate continuously for 8 hours may only last for 4 to 5 hours after a large amount of active substances fall off, which seriously affects the operational efficiency of the forklift and hinders the progress of logistics handling and other tasks.

Reduced charging and discharging efficiency: The active substances that fall off accumulate at the bottom of the battery, which hinders the diffusion of the electrolyte and ion migration, and increases the internal resistance of the battery. This not only prolongs the charging time but also causes the voltage to drop too rapidly during the discharging process, preventing the battery from fully exerting its due performance. According to statistics, the charging and discharging efficiency of batteries with severe shedding of active substances may decrease by 30% to 50%.

(2) The risk of forklift operation failure increases

Insufficient power: Due to the decline in battery capacity and charging and discharging efficiency, forklifts may experience insufficient power during operation. For instance, when moving heavy objects up a slope, the forklift's speed significantly slows down, and in some cases, it may even fail to move normally, affecting the safety of the operation and the timeliness of goods transportation.

Electrical system failure: Fallen active substances accumulate at the bottom of the battery. If too much accumulates, it may cause a short circuit in the plates. Once a short circuit occurs, the battery will heat up rapidly, not only damaging the battery itself but also potentially causing electrical system failures in forklifts, such as burning out fuses and damaging controllers. In severe cases, it may even lead to fires and other safety accidents, posing a huge safety hazard to enterprises and personnel.

(3) Increase the cost of use

Frequent battery replacement: The shedding of active substances will significantly shorten the battery's service life. Enterprises need to replace batteries frequently, which increases the cost of equipment procurement. Take a set of ordinary forklift lead-acid batteries as an example. Their price is usually several thousand or even tens of thousands of yuan. Frequent replacement will undoubtedly bring a heavy economic burden to the enterprise.

Rising maintenance costs: In addition to the replacement cost of the battery itself, problems such as electrical system failures of forklifts caused by the shedding of active substances will also increase maintenance costs. This includes costs such as parts replacement and maintenance labor, which further increase the operating costs of enterprises.

4. Solutions to the Shedding of Active Substances in Forklift Lead-Acid Batteries

(1) Reasonable use and maintenance

Standardize charging and discharging operations: Charge and discharge strictly in accordance with the requirements of the battery user manual to avoid overcharging and overdischarging. Generally speaking, when the battery power remains at 20% to 30%, it should be charged in time. During the charging process, when the battery is fully charged, charging should be stopped in time to prevent the active material from expanding excessively and falling off due to long-term overcharging. At the same time, avoid high current discharge. When the forklift starts, accelerates, climbs slopes and other operations, they should be carried out smoothly to prevent sudden high current discharge from damaging the battery.

Regular inspection and maintenance: Establish a complete battery regular inspection system to regularly check the electrolyte level, density and temperature of the battery. When the electrolyte level is too low, distilled water or special lead-acid battery replenishment fluid should be added in time. Regularly measure the density of the electrolyte to ensure it is within the normal range. If the density is abnormal, adjustments should be made. In addition, it is necessary to regularly check whether the connection terminals of the battery are loose or oxidized, and tighten and clean them in time to ensure the good electrical conductivity of the battery.

Control the usage environment: Try to create a good usage environment for the lead-acid batteries of forklifts, and avoid the batteries working in high-temperature, humid and overly vibrated environments. In a high-temperature environment, the chemical reaction rate inside the battery increases, and the active substances are more likely to fall off. A humid environment can cause corrosion of the battery casing and connecting components, affecting battery performance. Excessive vibration will accelerate the shedding of active substances. Therefore, forklifts should be parked in dry, well-ventilated and temperature-appropriate places. If necessary, measures such as cooling, moisture-proofing and shock absorption can be taken.

(2) Optimize battery design and manufacturing processes

Improve the plate structure: Develop and adopt new plate structures to enhance the binding force between the active substances on the plates and the grid. For instance, measures such as thickening the grid, increasing the density of the grid ribs, and improving the grid material can be adopted to enhance the supporting effect of the grid on the active substances and reduce the risk of active substances falling off during the charging and discharging process. In addition, a special coating process can be adopted on the surface of the plates to enhance the adhesion between the active substances and the plates.

Select high-quality raw materials: During the battery production process, strictly select high-quality raw materials. For instance, use lead with high purity and low impurities as the plate material, and select electrolyte with stable performance and reliable quality, etc. High-quality raw materials can enhance the overall performance and stability of batteries and reduce the probability of active substance shedding. Meanwhile, strengthen the management and screening of raw material suppliers, establish a strict raw material quality inspection system, and ensure that every batch of raw materials meets the production standards.

Optimize production processes: Continuously optimize the production process of batteries and strictly control every link in the production process. For example, during the process of applying paste to the plates, precisely control the thickness and uniformity of the paste application to ensure that the active substances are evenly distributed on the plates. During the curing and drying process of the plates, it is necessary to reasonably control parameters such as temperature, humidity and time to ensure that the active substances fully combine with the plates, thereby enhancing the strength and stability of the plates.

(3) Adopt advanced monitoring and repair technologies

Real-time monitoring of battery status: By using advanced sensors and monitoring technologies, various parameters of forklift lead-acid batteries are monitored in real time, such as voltage, current, temperature, and electrolyte density. Through data analysis and processing, abnormal conditions of the battery can be detected in a timely manner, such as capacity reduction caused by the shedding of active substances and increased internal resistance, and early warnings can be issued in advance so that measures can be taken promptly to handle the situation and prevent the problem from worsening further.

Battery repair techniques: For batteries that have already experienced the problem of active material shedding, some advanced repair techniques can be adopted for handling. For instance, pulse repair technology restores part of the battery's performance by sending high-frequency pulse currents to the battery, breaking the lead sulfate crystals inside the battery and allowing the detached active substances to reparticipate in the electrochemical reaction. In addition, there are also chemical repair technology, ultrasonic repair technology, etc. Enterprises can choose the appropriate repair method based on the actual situation of the battery to extend the service life of the battery and reduce the usage cost.

5. Conclusion

The shedding of active substances in forklift lead-acid batteries is a problem that seriously affects battery performance, forklift operation and enterprise costs. By thoroughly understanding its detachment principle and hazards, we can take effective solutions from multiple aspects such as rational use and maintenance, optimizing battery design and manufacturing processes, and adopting advanced monitoring and repair technologies. In practical applications, enterprises should attach great importance to the management and maintenance of lead-acid batteries in forklifts. They should formulate scientific and reasonable maintenance plans based on their own actual situations. At the same time, they should pay attention to the development trends of battery technology and actively adopt new technologies and new processes to reduce the occurrence of active material shedding, increase the service life and performance of batteries, and ensure the safe and efficient operation of forklifts. Reduce the operating costs of enterprises and promote the healthy development of the logistics and warehousing industry.