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The characteristics of lead-acid batteries

This kind of battery has many characteristics. Its voltage is stable. The nominal voltage of each individual lead-acid battery is 2V, which can provide a relatively smooth power output for forklifts. Meanwhile, it has a relatively high specific energy and can store a considerable amount of electrical energy under a certain mass and volume, meeting the demand for high-current discharge of forklifts within a short period of time, and providing sufficient power for the start-up, acceleration and heavy object handling of forklifts. However, lead-acid batteries also have some drawbacks. For instance, their energy density is relatively low, which means they are heavier and larger in volume for the same amount of electricity. The charging time is relatively long, usually taking several hours to fully charge. Moreover, the cycle life is limited. After a certain number of charge and discharge cycles, the battery capacity will gradually decline.

Key points for configuring lead-acid battery packs in forklifts

Determination of voltage and capacity

Voltage matching: The electrical system of forklifts has specific requirements for voltage. Common forklift voltages include 24V, 36V, 48V, etc. When determining the voltage of the battery pack, it is necessary to follow the design standards of the forklift to ensure that the two are completely matched. If the voltage does not match, a voltage that is too low will cause insufficient power for the forklift and prevent it from working normally. Excessively high voltage may damage the electrical components of the forklift.

Capacity calculation: The selection of battery pack capacity is of vital importance as it directly affects the forklift's endurance. The calculation of capacity needs to comprehensively consider factors such as the working intensity, working time and load weight of the forklift. In practical applications, it is also necessary to take into account the instantaneous large current demand when the forklift starts and accelerates, and appropriately increase the reserved capacity to ensure the stable operation of the forklift under various working conditions.

Selection of battery types and specifications

Type considerations: There are various types of lead-acid batteries, such as common open-type lead-acid batteries and valve-regulated sealed lead-acid batteries. Ordinary open-type batteries have a relatively low cost, but they require the regular addition of distilled water, resulting in a large amount of maintenance work. Moreover, they produce acid mists during use, causing certain pollution to the environment. VRLA batteries have the advantages of being maintenance-free, having good sealing performance, and no acid mist leakage. Although their cost is relatively high, they are more widely used in places with high environmental protection and maintenance requirements. When making a choice, it should be determined based on the usage environment and maintenance conditions of the forklift.

Specification compatibility: Lead-acid batteries of different specifications vary in terms of size, weight, capacity, etc. When choosing battery specifications, it is necessary to ensure that they can fit the battery installation space of the forklift and meet the performance requirements of the forklift at the same time. Batteries that are too large may not be installed, while those that are too small may not be able to provide sufficient energy. In addition, the weight of the battery should also be taken into account. A battery that is too heavy may affect the overall balance and handling performance of the forklift. Therefore, under the premise of meeting the capacity requirements, it is necessary to choose a battery specification with an appropriate weight as much as possible.

Battery quantity and combination method

Quantity determination: The number of batteries is determined by the total required voltage and the voltage of each individual battery. At the same time, it is also necessary to calculate based on the capacity of the selected batteries and the total required capacity to ensure that the number of batteries can not only meet the voltage requirements but also provide sufficient power.

Combination methods: The main battery combination methods are series connection and parallel connection. Series connection is used to increase voltage. When the positive and negative terminals of multiple batteries are connected in sequence, the total voltage is equal to the sum of the voltages of each battery. For example, as mentioned above, 24 2V batteries are connected in series to obtain a 48V voltage. Parallel connection is used to increase capacity. The positive terminals of multiple batteries are connected to each other, and the negative terminals are connected to each other. The total capacity is equal to the sum of the capacities of each battery. In actual configuration, it is often the case that battery packs of a certain voltage are first connected in series, and then multiple such battery packs are connected in parallel to simultaneously meet the requirements of voltage and capacity.

The connection method of lead-acid battery packs for forklifts

Series connection methods and precautions

Connection steps: When making a series connection, first prepare the appropriate connection cable. The specification of the cable should be able to carry the maximum current of the battery pack during operation. Generally, the cross-sectional area of the cable can be selected based on the battery capacity and working current. Then, determine the positive and negative terminals of each battery. Generally, the positive terminal of a battery is marked with a "+" sign and the negative terminal with a "-" sign. The positive terminal is usually red and the negative terminal is usually black. Connect the negative terminal of the first battery to the positive terminal of the second battery with a connecting cable. Use an appropriate tool to tighten the connecting nut to ensure a firm connection and good contact to reduce contact resistance. In the same way, all the batteries are connected in series in sequence, and finally a battery pack with a total voltage of the sum of the voltages of each battery is obtained. Therefore, carefully check the polarity of each battery before connection. At the same time, ensure that the connecting cables are tightly connected to the battery terminals to avoid loosening or poor contact. Loose connections will increase the contact resistance. During the battery charging and discharging process, the contact resistance generates heat, causing the temperature at the connection points to rise. This not only affects the battery performance but may also damage the connection components and even cause a fire. In addition, after the connection is completed, use a multimeter or other tools to measure the total voltage of the battery pack, and check whether the connection is correct and whether the total voltage meets expectations.

Parallel connection methods and precautions

Connection steps: When connecting in parallel, prepare the connection cables that meet the current carrying requirements in advance as well. Connect the positive terminals of all the batteries together with cables to form a common positive terminal. Then connect the negative terminals of all the batteries together with cables to form a common negative terminal. During the connection process, it is necessary to ensure that each connection point is firm and reliable, and that the positive and negative terminals of each battery are correctly connected to the corresponding common terminal.

When participating in parallel connection, batteries from the same manufacturer, model and batch should be selected as much as possible to ensure the consistency of battery performance. When batteries of different performances are connected in parallel, there may be an imbalance in charging and discharging. Batteries with better performance will overcharge and discharge, while those with poorer performance cannot fully function. In the long run, this will shorten the service life of the entire battery pack. At the same time, attention should be paid to the layout of the connecting cables. Try to make the cable lengths from each battery to the common terminal equal to reduce the impact of cable resistance differences on battery charging and discharging. In addition, after the connection is completed, check the total capacity and voltage of the battery pack to ensure they meet expectations. The working state of the battery pack can be determined as normal by measuring the changes in voltage and current during the charging and discharging process.

Key points for the connection between the battery pack and the forklift's electrical system

Connection position and method: The connection between the battery pack and the electrical system of the forklift is generally carried out through dedicated terminal posts or connectors. At the battery installation area of the forklift, there will be corresponding terminal blocks. The positive and negative output lines of the battery pack need to be connected to these terminals. The connection methods usually adopt bolt fastening or plug-and-pull connection. For bolted connections, it is necessary to use an appropriate wrench to tighten the bolts to ensure a firm connection. For plug-and-pull connections, it is necessary to ensure that the plug and socket fit tightly without any looseness. When connecting, it is necessary to distinguish between the positive and negative poles. Connect the positive pole wire of the battery pack to the positive pole input terminal of the forklift's electrical system, and the negative pole wire to the negative pole input terminal. Avoid reversing the connection.

Safety protection and inspection: After the connection is completed, safety protection should be carried out on the connection parts. Insulating tape or insulating covers can be used to wrap the exposed wiring parts to prevent electric shock and short circuit accidents. At the same time, it is necessary to check whether the entire connection line is damaged or aged. If there are any problems, they should be replaced in time. Before using the forklift, it is necessary to check again whether the connection between the battery pack and the electrical system is firm, and measure whether the voltage output from the battery pack to the electrical system is normal, to ensure that the electrical system of the forklift can receive the electrical energy provided by the battery pack normally and guarantee the safe operation of the forklift. In addition, during the operation of the forklift, it is necessary to regularly inspect the connection points between the battery pack and the electrical system to check for any abnormal phenomena such as loosening or overheating. Timely identification and resolution of problems should be carried out to ensure the stable operation of the forklift and the normal service life of the battery pack.

During the connection process, operations should be carried out strictly in accordance with the series and parallel connection methods. When connecting in series, carefully check the polarity of each battery to ensure correct connection, and tighten the connecting nuts with an appropriate wrench. When in parallel, select batteries from the same manufacturer and the same batch to ensure consistent battery performance. Firmly connect the positive and negative terminals of each battery pack to the common positive and negative terminal cables respectively. After the connection is completed, conduct a comprehensive inspection of the entire battery pack, measure the total voltage and total capacity, and install it on the forklift after confirming that there are no errors.

After upgrading the configuration and correct connection, the forklift's endurance has been significantly enhanced, capable of meeting the high-intensity work demands throughout the day. This has effectively improved the operational efficiency of the logistics warehouse, reduced downtime caused by insufficient battery power, and lowered operating costs. Meanwhile, due to the more stable performance of the new battery pack, the number of charge and discharge cycles is relatively reduced, which also extends the service life of the battery pack and brings good economic benefits to the enterprise.

The impact of maintenance and upkeep on the performance of battery packs

Key points of daily maintenance

Cleaning and Inspection: Regularly clean the battery pack. Use a clean damp cloth to wipe the battery surface to remove dust, dirt and acid residue, preventing these impurities from causing corrosion of the battery terminals and short circuits. At the same time, check whether the battery casing has any damage, cracks or leakage. If any problems are found, replace the battery in time to avoid environmental pollution and safety hazards caused by electrolyte leakage. Check whether the connection between the battery terminals and the connecting cables is loose. If it is loose, tighten it in time to ensure a reliable connection and reduce contact resistance.

Electrolyte inspection: For ordinary open-type lead-acid batteries, the liquid level and density of the electrolyte should be checked regularly. The electrolyte level should be maintained between the upper and lower limits marked on the battery casing. If the level is too low, distilled water or special lead-acid battery replenishment fluid should be added. Do not add tap water or sulfuric acid solution, as it may affect the battery performance. Use a hydrometer to measure the density of the electrolyte. Under normal circumstances, the density of the electrolyte in a fully charged lead-acid battery is 1.28g/cm³ (at 25℃). If the density deviation is too large, it indicates that the battery charging state is abnormal or there is a problem with the electrolyte, and corresponding measures should be taken, such as supplementary charging or adjusting the density of the electrolyte.

Charging and discharging management

The correct charging method: Use an appropriate charger to charge the battery pack. The output voltage and current of the charger should match the specifications of the battery pack. Avoid overcharging and undercharging. Overcharging can cause the battery to heat up, accelerate water loss and plate aging, and shorten the battery's lifespan. Undercharging will lead to a decrease in battery capacity. During the charging process, it is necessary to follow the charging mode of constant current first and then constant voltage. At the initial stage, charge with a constant current. When the battery voltage rises to a certain value, switch to constant voltage charging until the battery is fully charged. At the same time, control the charging time. Generally, the charging time for lead-acid batteries is 6 to 8 hours. The specific time can be adjusted according to the battery capacity and charger parameters. ​

Reasonable discharge depth: Control the discharge depth of the forklift to avoid excessive discharge. The optimal discharge depth of lead-acid batteries is generally between 50% and 80%. Excessive discharge can cause sulfation of the battery plates, reducing the battery's capacity and service life. During the operation of a forklift, it is necessary to charge the battery in a timely manner according to the battery power indicator. When the battery power drops to a certain level, the forklift should be stopped from use and charged to prevent excessive battery discharge. In addition, try to avoid frequent high-current discharges, such as sudden acceleration and sudden braking, as these operations will increase the burden on the battery and affect its performance. ​

The role of maintenance and care in extending the lifespan of battery packs

By strictly implementing daily maintenance and reasonable charging and discharging management, the service life of lead-acid battery packs can be effectively prolonged. Regular cleaning and inspection can promptly identify and resolve issues on the battery surface and connection points, preventing the faults from escalating. Reasonable inspection and replenishment of the electrolyte can ensure the normal progress of the chemical reactions inside the battery. The correct charging method and reasonable depth of discharge can reduce sulfation and aging of battery plates, maintaining the battery's capacity and performance.