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In the field of modern industrial logistics, forklifts, as indispensable handling equipment, are widely used in warehouses, factories and other places. Lead-acid batteries, as the core power source of forklifts, once they are discharged from power, will not only prevent the forklift from operating normally but also may interrupt the entire production or logistics operation process, causing serious economic losses and time waste. Therefore, formulating a scientific, efficient and feasible emergency plan for the depletion of lead-acid batteries in forklifts is of vital importance for ensuring the normal operation of enterprises.

1. Analysis of the Causes of Power Loss

Before formulating an emergency plan, we need to have a thorough understanding of the common causes of lead-acid battery depletion in forklifts, so as to take more targeted measures.

(1) Improper use

1.Excessive discharge: The operator did not strictly follow the regulations and continued to use the forklift when the battery power was too low, resulting in excessive discharge of the battery. Excessive discharge can cause sulfation of the battery plates, reducing the battery's capacity and service life. At the same time, it is also more likely to result in a situation where the battery cannot be started due to low power.

2. Failure to charge in time: After the operation is completed, the forklift is not promptly sent to the charging area for charging. Especially after continuous high-intensity operation, the battery cannot be replenished in time, and it is very likely to be discharged when used next time.

(2) Equipment failure

1. Charging system failure: The charger malfunctions, such as being unable to output voltage normally or having unstable current, which causes the battery to fail to be fully charged. In addition, problems such as aging charging lines and poor contact can also affect the charging effect, preventing the battery power from being effectively replenished.

2. Problems with the battery itself: As the usage time increases, the internal plates of lead-acid batteries gradually age, the active substances decrease, and the electrolyte also wears out, resulting in a decline in battery capacity and making it more prone to battery depletion. At the same time, faults such as short circuits and open circuits inside the battery can also cause a loss of power.

(3) Environmental factors

1. Temperature influence: In low-temperature environments, the viscosity of the electrolyte in lead-acid batteries increases, and the ion diffusion rate slows down, resulting in a decline in the battery's charging and discharging performance and a reduction in its actual available capacity. For instance, when the ambient temperature drops below -10℃, the capacity of the battery may decrease by more than 30%, making it more prone to failure to start due to low power.

2. Humid environment: If forklifts are used or stored in a humid environment for a long time, the terminals and connecting wires of the battery are prone to corrosion, resulting in poor contact, which affects the charging and discharging processes and eventually leads to power loss.

2. Emergency Response Procedures

When it is found that the lead-acid battery of a forklift is discharged, emergency handling should be carried out promptly and orderly in accordance with the following procedures to restore the normal operation of the forklift as soon as possible.

(1) On-site assessment

1. Confirm the battery depletion situation: When the operator finds that the forklift has insufficient power, difficulty in starting or cannot start at all, they should first check the battery power indicator light or use a professional battery detector to confirm whether the battery is depleted and the extent of the depletion.

2. Determine the cause of power loss: Based on daily usage conditions and the status of the equipment, initially determine the cause of power loss. For instance, if a newly replaced battery is discharged, it might be necessary to check whether the charging system is functioning properly. If it is a battery that has been in use for many years, it might be due to its own aging problem.

3. Assess the impact of operations: Based on the power loss situation and the urgency of the current operation tasks, evaluate the impact on production or logistics operations, determine whether immediate emergency measures are needed, and to what extent such measures should be taken.

(2) Emergency Activation

1. Cross-connection start-up: If there are other forklifts or vehicles with normal batteries on site, the start-up can be carried out by cross-connection cables. The specific operation is as follows:

Make sure the engines of both vehicles are turned off. Connect the red clip of the jumper cable to the positive terminal of the undercharged battery and the other end to the positive terminal of the normal battery.

- Connect the black clip to the negative terminal of a normal battery, and the other end to the grounding metal part of the cylinder block of the undercharged forklift engine (note: Do not connect to the negative terminal of the undercharged battery to avoid generating sparks and causing an explosion).

Start the engine of a normal vehicle and let it run for a few minutes, then try to start a forklift that has lost power.

After the forklift is successfully started, remove the jumper cables in the reverse order of the connection.

Precautions: When performing the jumper start-up, ensure that the specifications of the jumper cables are appropriate and the connection is firm to avoid sparks caused by poor contact. At the same time, do not let the positive and negative poles of the jumper cables come into direct contact to prevent short circuits.

2. Use an emergency start power supply: If there are no other vehicles available for cross-starting, a dedicated emergency start power supply can be used. The emergency start power supply is compact in size, portable and easy to operate. Connect the clips of the emergency start power supply to the battery in accordance with the positive and negative poles, and then press the start button to attempt to start the forklift. When using the emergency start power supply, make sure the power is fully charged and operate strictly in accordance with the requirements of the manual.

(3) Temporary power supply

1.If the forklift needs to continue operating for a short period of time and cannot be charged in time, temporary power supply can be considered.

Mobile power generation equipment: Portable generators or vehicle-mounted generators are used. Through a dedicated power conversion device, the output voltage of the generator is converted into a voltage suitable for charging the forklift battery, providing a temporary power supply for the forklift. When using mobile power generation equipment, pay attention to the power matching of the generator to avoid damage to the forklift and the generator due to insufficient or excessive power.

2. Spare battery packs: Enterprises can prepare one or more sets of spare battery packs in advance. When a power shortage occurs, the spare battery packs should be replaced promptly to ensure that the forklift can continue to operate. When replacing the battery pack, first turn off the power of the forklift. Then, follow the correct operation procedures to disassemble and install the battery, ensuring a firm connection to avoid poor contact affecting the operation of the forklift.

(4) Professional Rescue

If the forklift still fails to start or operate normally after taking the above emergency measures, professional maintenance personnel or battery suppliers should be contacted for rescue in a timely manner. While waiting for rescue, make sure the forklift is in a safe position and set up warning signs to prevent any accidents. After professional maintenance personnel arrive at the site, they will use professional detection equipment to conduct a comprehensive inspection of the battery and charging system, identify the root cause of the battery depletion, and carry out repairs or replacements.

3. Preventive Measures

To reduce the occurrence of lead-acid battery depletion in forklifts, in addition to formulating emergency plans, a series of effective preventive measures should also be taken.

(1) Standardize the operation procedures

1. Develop a detailed forklift operation manual, clearly stipulating the usage norms of the battery, including the handling methods after the battery level alarm and the prohibition of excessive discharge, etc. Strengthen the training of operators to ensure that they are familiar with and strictly abide by the operation procedures.

2. Establish a charging management system, stipulating that forklifts must be charged within the prescribed time after completion of operations, and assign a dedicated person to supervise the charging process to ensure that the charging time and charging method meet the requirements.

(2) Regular maintenance and servicing

1. Regularly inspect and maintain the battery, including checking the electrolyte level and specific gravity, cleaning the battery terminals and connecting wires to prevent corrosion and oxidation. When the electrolyte level is below the minimum scale line, special distilled water or lead-acid battery replenishment fluid should be added.

2. Regularly inspect the charging system to check if the output voltage and current of the charger are normal and if there are any issues such as aging or damage to the charging lines. Replace damaged chargers and aging circuits in a timely manner to ensure the normal operation of the charging system.

3. According to the user manual of the battery, regularly perform deep discharge and charging maintenance on the battery to activate the active substances on the plates and extend the service life of the battery.

(3) Environmental Management

1.In cold seasons, provide insulation measures for forklifts and batteries, such as storing forklifts in a warm indoor environment or installing insulation covers on batteries. Meanwhile, adjust the charging time and current appropriately to meet the charging requirements in low-temperature environments.

2. Avoid parking and using forklifts for long periods in damp environments. If it is unavoidable, enhance the protection of the battery and electrical system, regularly inspect the corrosion of terminals and connecting wires, and promptly carry out cleaning and protective treatment.

(4) Monitoring and Early Warning

1.Install a battery power monitoring system to monitor parameters such as battery power, voltage and current in real time, and send real-time data and early warning information to operators and managers through display screens or mobile phone apps, etc. When the battery level drops below the set threshold, the system automatically issues an alarm to remind the operator to charge it in time.

2. Establish an equipment maintenance management system to record information such as the usage time, charging frequency, and maintenance status of the battery. Through data analysis, predict the service life of the battery and possible faults, and take preventive measures in advance.

4. Technological Upgrading and Improvement

With the continuous development of technology, some new technologies and products can effectively enhance the performance and reliability of lead-acid batteries in forklifts and reduce the occurrence of battery depletion.

(1) Intelligent charging technology

By adopting an intelligent charger, it can automatically adjust the charging voltage and current according to the actual state of the battery, achieving multiple charging modes such as constant current, constant voltage, and float charging, avoiding overcharging and undercharging phenomena, and improving the charging efficiency and the service life of the battery. Meanwhile, the smart charger also has fault diagnosis and protection functions, which can promptly detect abnormal situations during the charging process and take corresponding protective measures.

(2) New battery technology

Pay attention to the development of new lead-acid battery technologies, such as lead-acid batteries made of graphene materials. Compared with traditional lead-acid batteries, they have higher energy density, faster charging speed and longer service life. Enterprises can gradually introduce new types of batteries based on their own needs and economic strength to enhance the power performance and reliability of forklifts.

(3) Substitution by new energy forklifts

Consider gradually replacing some forklifts with new energy forklifts, such as lithium battery forklifts or electric forklifts. Lithium batteries have the advantages of high energy density, fast charging speed, long service life and no maintenance required, which can effectively reduce the problems caused by battery depletion. Although the initial purchase cost of new energy forklifts is relatively high, in the long run, their operating and maintenance costs are low, and they have good economic and environmental benefits.

In conclusion, the emergency plan for the depletion of lead-acid batteries in forklifts is a systematic project, covering multiple aspects such as cause analysis, emergency response, preventive measures, and technological upgrades. Enterprises should, based on their own actual conditions, formulate detailed and feasible emergency plans, and constantly improve and optimize them to ensure that they can respond promptly and handle effectively when encountering battery depletion, minimize the impact on production and logistics operations, and guarantee the normal operation of the enterprise.