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Abstract

This article delves deeply into the issue of water loss in lead-acid batteries of forklifts, systematically analyzing various reasons for the occurrence of water loss during their use, including factors such as the battery's own chemical reactions, usage environment, and operating habits. At the same time, it elaborates in detail on the scientific and effective water replenishment methods, providing comprehensive and practical technical references for the maintenance and management of forklift lead-acid batteries. The aim is to help enterprises and operators extend the battery life, reduce operating costs, and ensure the efficient and stable operation of forklifts.

1. Introduction

Lead-acid batteries have been widely used in the forklift field 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, water loss is a relatively common problem, which seriously affects the performance and service life of the batteries. If the water loss problem cannot be detected and properly handled in time, it will lead to sulfation of the battery plates, shedding of active substances, and even battery scrapping, increasing the equipment maintenance costs of enterprises and affecting the normal operation efficiency of forklifts. Therefore, a thorough analysis of the causes of water loss in forklift lead-acid batteries and the mastery of the correct water replenishment methods are of great significance for ensuring the stable operation of forklifts.

2. Analysis of the Causes of Water Loss in Forklift Lead-Acid Batteries

(1) Chemical reactions inside the battery cause water loss

During the charging and discharging process of lead-acid batteries, a series of complex electrochemical reactions occur. During the charging process, when the battery is nearly fully charged, the current will cause the water in the electrolyte to undergo an electrolytic reaction, decomposing into hydrogen and oxygen that escape from the battery interior, thereby resulting in a reduction in water content.

This electrolytic water reaction is one of the main internal reasons for water loss in lead-acid batteries. As the number of charge and discharge cycles of the battery increases, water is constantly consumed. If not replenished in time, the concentration of the electrolyte inside the battery will gradually rise, thereby affecting the performance of the battery.

(2) Environmental factors of use

High-temperature environment: When forklifts operate outdoors or in high-temperature workshop environments, the battery is exposed to a relatively high temperature. An increase in temperature will accelerate the evaporation rate of water in the electrolyte. According to relevant research, for every 10℃ increase in ambient temperature, the self-discharge rate of batteries doubles and the evaporation rate of water also significantly accelerates. High temperatures will also intensify the chemical reactions inside the battery, further promoting the electrolysis of water and accelerating the consumption of water.

Poor ventilation: If the forklift's working environment has poor ventilation conditions, the hydrogen and oxygen produced by the battery during charging and discharging cannot be discharged in time and will accumulate inside the battery, causing the internal pressure of the battery to rise. Excessive pressure will cause the battery's sealing performance to decline, increasing the risk of electrolyte leakage and water evaporation. In addition, poor ventilation will also make it difficult for the heat around the battery to dissipate, further raising the battery temperature and exacerbating the water loss problem.

(3) Charging factors

Overcharging: Overcharging is one of the important reasons for water loss in forklift lead-acid batteries. When the battery is fully charged, if the charging device continues to charge the battery, it will intensify the electrolytic water reaction inside the battery, generating a large amount of hydrogen and oxygen, which leads to rapid water consumption. At the same time, overcharging will also cause the battery to heat up severely, further accelerating the evaporation of water and the chemical reactions inside the battery, causing irreversible damage to the battery.

Excessive charging current: During the charging process, if the selected charging current is too large, it will accelerate the chemical reaction speed inside the battery, causing the battery to heat up significantly, the temperature of the electrolyte to rise, and the evaporation of water to intensify. In addition, excessive charging current may cause the active substances on the surface of the battery plates to fall off due to intense reactions, affecting the battery's service life and also accelerating the loss of moisture.

(4) Improper use and maintenance

Frequent high-current discharge: In actual operation, forklifts often need to perform frequent starts, accelerations, and heavy object handling, which can lead to frequent high-current discharge of the battery. High current discharge will cause the active substances on the surface of the battery plates to rapidly participate in the reaction, generating a large amount of heat, which in turn raises the temperature of the electrolyte and accelerates the evaporation of water. Moreover, frequent high-current discharges will also shorten the battery's service life and make it more prone to problems such as water loss.

Lack of regular inspection and maintenance: Some enterprises or operators do not attach enough importance to the maintenance of lead-acid batteries in forklifts and lack the awareness of regularly checking the electrolyte level. If the problem of battery water loss is not detected in time, water cannot be replenished promptly, causing the battery to continue working in a water-deficient state, further deteriorating battery performance and accelerating battery damage.

3. Methods for Replenishing Water to Forklift Lead-Acid Batteries

(1) Preparations before replenishing water

Tool preparation: Prepare a dedicated plastic funnel, rubber dropper, distilled water or dedicated lead-acid battery replenishment solution, clean cloth and other tools. Avoid using metal tools to prevent metal impurities from mixing into the electrolyte and affecting battery performance.

Battery inspection: Before replenishing water, first check whether the battery casing is damaged, deformed or leaking. If there is any abnormality, the battery should be repaired or replaced first to ensure that it is in a safe and water-replenishing state. Meanwhile, check the battery voltage and the density of the electrolyte, and record the relevant data for subsequent comparison and analysis.

Environmental preparation: Select a well-ventilated, clean and tidy environment for the water replenishment operation. Avoid conducting it in flammable, explosive or dusty areas. Ensure that the operation area is far away from fire sources and high-temperature sources to prevent dangers such as explosions caused by hydrogen gas produced by batteries.

(2) Judging the timing of water replenishment

When the electrolyte level of the battery drops below the minimum level line, water replenishment operation is required. In addition, whether water replenishment is needed can also be determined by detecting the density of the electrolyte. Generally speaking, when the density of the electrolyte is significantly higher than the standard value, it indicates insufficient moisture and water needs to be replenished to adjust the concentration of the electrolyte.

(3) Steps for water replenishment operation

Open the battery cover: Carefully open the liquid injection hole cover on the battery, and be careful not to let dust, impurities, etc. fall into the battery interior. For some batteries with safety valves, it is necessary to first confirm whether the safety valve is normal. If it is blocked or damaged, it should be cleaned or replaced first.

Replenishment: Use a rubber dropper or plastic funnel to slowly inject distilled water or special lead-acid battery replenishment solution into the battery. When replenishing water, pay attention to observing the liquid level of the electrolyte to make it reach the appropriate position between the highest and lowest liquid level lines to avoid excessive water replenishment causing the electrolyte to overflow. For batteries of different specifications and capacities, the amount of water replenished also varies. Generally, the amount of water replenished per cell is about 10 to 15 milliliters. For specific details, please refer to the battery user manual.

Close the battery cover: After the water replenishment is completed, wipe the battery surface with a clean cloth to ensure there is no electrolyte remaining. Then reinstall the liquid injection hole cover or safety valve back to its original position, tighten or fasten it to ensure the battery is well sealed.

(4) Precautions after hydration

Charging treatment: After replenishing water, the battery should be charged promptly to ensure that the replenished water is thoroughly and evenly mixed with the electrolyte. During the charging process, it is necessary to pay close attention to the changes in the battery's charging voltage, current and temperature to ensure a normal charging process. Avoid performing a high-current discharge immediately after water replenishment to allow the battery sufficient time to restore its performance.

Regular monitoring: During the period after water replenishment, it is necessary to strengthen the monitoring of the battery, regularly check the liquid level and density of the electrolyte, and observe whether the battery's performance has improved. If any abnormalities are found in the battery, such as severe heating during charging or unstable voltage, further inspection and handling should be carried out in a timely manner.

4. Conclusion

The water loss of forklift lead-acid batteries is caused by the combined effect of multiple factors, including internal chemical reactions of the battery, usage environment, charging methods, and usage and maintenance habits, etc. Understanding these causes of water loss can help us take targeted preventive measures in actual use and reduce the occurrence of battery water loss. At the same time, mastering the correct method of replenishing water can enable timely and effective handling when the battery loses water, extend the battery's service life, and ensure the normal operation of the forklift. Enterprises and operators should attach great importance to the maintenance of lead-acid batteries in forklifts, strengthen daily inspection and management, improve the reliability and economy of the equipment, reduce operating costs, and promote the efficient development of logistics and warehousing operations.