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Introduction

In modern logistics and industrial production, forklifts, as key material handling equipment, their efficient and stable operation is of vital importance. As the power core of forklifts, the performance of lead-acid batteries in different working environments directly affects the working efficiency, service life and operating costs of forklifts. Understanding these performance differences and taking targeted measures are of great significance for enterprises to optimize forklift operations and reduce costs.

Performance under normal temperature and dry conditions

Performance advantage

In a normal temperature and dry environment, forklift lead-acid batteries can demonstrate relatively stable and good performance. From the perspective of capacity retention, the chemical reactions inside the battery can proceed relatively smoothly. The reaction efficiency between the active substances on the positive and negative plates and the electrolyte is high, enabling the battery to maintain an output close to its rated capacity for a long time.

In terms of charging and discharging efficiency, a dry environment at normal temperature is conducive to the migration and reaction of ions inside the battery. When charging, electrical energy can be efficiently converted into chemical energy and stored, with a charging efficiency of 80% to 90%. Compared with other harsh environments, it can fully charge the battery more quickly. During discharge, chemical energy can also be relatively fully converted into electrical energy output, providing strong and stable power support for the lifting and handling actions of the forklift. This ensures that the forklift can maintain a relatively stable speed and power response when handling goods of different weights, reducing the operation lag caused by insufficient power.

Key points for performance maintenance

To maintain good performance, daily maintenance is indispensable. Regularly checking the density of the electrolyte is one of the key steps, as the sulfuric acid in the electrolyte participates in the reaction during charging and discharging, and its density will change. Under normal circumstances, the density of the electrolyte should be maintained at 1.28g/cm³. Regular measurements should be made with a dedicated hydrometer. If the density deviates from the normal range, timely adjustments can be made, such as adding an appropriate amount of distilled water or sulfuric acid solution to restore the normal density and ensure the normal progress of chemical reactions inside the battery.

At the same time, the inspection of the battery's appearance and connection parts should not be ignored. Check whether the battery casing is damaged or leaking electrolyte, etc. Once the casing is found to be damaged, the battery should be replaced in time to prevent electrolyte leakage from corroding surrounding equipment and affecting battery performance. Check whether the connection between the battery terminals and the connecting wires is firm, and whether there is any loosening or oxidation. If the connection parts are loose, it will increase the resistance, causing heat generation during charging and discharging, affecting the battery performance and even posing safety hazards. If oxidation occurs, the oxide can be removed with special tools and protective grease can be applied to ensure good connection, reduce resistance and improve charging and discharging efficiency.

Performance changes in high-temperature environments

Negative impact on battery performance

When the working environment temperature rises and exceeds the suitable operating temperature range of lead-acid batteries, the battery performance will be negatively affected in many aspects. In terms of capacity, high temperatures accelerate the chemical reaction rate inside the battery, causing the active substance lead dioxide on the positive plate to soften and fall off more quickly, and the lead on the negative plate is also more prone to oxidation, resulting in a reduction in the effective reaction area of the plates and a rapid decline in battery capacity. Studies show that for every 10℃ increase in ambient temperature, battery capacity may decrease by approximately 10% to 15% during long-term use. For instance, in high-temperature outdoor working environments such as construction sites or steel mills during summer, the lead-acid batteries of forklifts, which were originally fully charged and could operate for 8 hours, may only last for 4 to 6 hours under continuous high-temperature conditions, seriously affecting the working efficiency of forklifts.

High temperatures will also greatly shorten the cycle life of batteries. On the one hand, high temperature accelerates the corrosion rate of the positive plate, damages the grid structure of the plate, affects the adhesion of active substances, and thereby reduces the charging and discharging performance of the battery. On the other hand, high temperatures accelerate the evaporation of water inside the battery, dry up the electrolyte, increase the internal resistance of the battery, and further accelerate the aging of the battery. Under normal circumstances, the cycle life of lead-acid batteries can reach 300 to 500 charge and discharge cycles. However, in high-temperature environments, this number of cycles may decrease to 150 to 250, significantly increasing the battery replacement frequency and usage cost.

Measures to deal with high temperatures

To address the impact of high temperatures on the performance of lead-acid batteries in forklifts, a variety of measures can be taken. From the perspective of hardware facility improvement, installing a battery cooling system is a relatively effective method. For instance, installing an air-cooled cooling device in the battery compartment of a forklift, through forced convection by fans, can promptly dissipate the heat generated by the battery and lower its temperature. Or a liquid cooling system can be adopted, where the coolant circulates to remove the battery's heat. This method has a more significant cooling effect, but the system is relatively complex and the cost is higher. In the forklifts of some large logistics centers, after installing liquid-cooled cooling systems, even in the hot summer, the battery temperature can be effectively controlled within an appropriate range, and the problems of battery capacity attenuation and shortened cycle life have been significantly improved.

It is also crucial to adjust the charging strategy reasonably. In high-temperature environments, appropriately reducing the charging current can decrease the heat generated by the battery during the charging process and prevent further deterioration of battery performance due to overheating during charging. At the same time, shortening the charging interval and adopting a "small meals frequently" charging method can prevent the battery from being over-discharged before long-term charging, which is conducive to maintaining battery performance. For instance, originally, forklift batteries could be discharged to 20% of their capacity at normal temperature before recharging. However, in high-temperature environments, charging can be adjusted to start when the battery capacity remains at 30% to 40%, with each charging time correspondingly shortened to reduce the battery's heat generation time at high temperatures.

Performance challenges in low-temperature environments

Performance degradation manifestation

Low-temperature environments also pose severe challenges to lead-acid batteries in forklifts. At low temperatures, the viscosity of the electrolyte increases, and the migration speed of ions in the electrolyte slows down, resulting in a significant increase in the internal resistance of the battery. This makes it difficult for the battery to output electrical energy during discharge, causing the forklift to start slowly and significantly lacking power when lifting goods. Research data shows that when the ambient temperature drops to -10 ℃, the internal resistance of lead-acid batteries may increase to 2 to 3 times that at room temperature, and the actual discharge capacity of the battery may only be 50% to 60% of the rated capacity. In the low-temperature working environments such as outdoor warehouses or cold storage facilities in cold regions during winter, forklifts often encounter problems such as difficulty in starting, slower running speed, and insufficient lifting height of goods, which seriously affect the normal operation.

Low temperatures can also lead to a decline in the battery's charging acceptance capacity. During charging, the internal chemical reaction rate of the battery slows down. The process of lead sulfate converting to lead dioxide on the positive plate and lead sulfate converting to lead on the negative plate is hindered, resulting in a significant reduction in charging efficiency. Originally, it took 8 to 10 hours to fully charge the battery at normal temperature. In low-temperature environments, it may take 12 to 15 hours or even longer, and it is also difficult to fully charge the battery, further limiting the usage time and working efficiency of the forklift.

In addition, optimizing the forklift operation process is also helpful for adapting to low-temperature environments. Before forklift operation, carry out appropriate preheating operations. For instance, run the forklift empty for a period of time to allow the battery to generate a certain amount of heat under a small current discharge state, thereby increasing its own temperature. At the same time, plan the forklift operation tasks reasonably, avoid long-term continuous heavy-load operation, and give the battery appropriate rest time to maintain battery performance. In low-temperature environments, try to minimize sudden acceleration and braking of forklifts and other violent operations. These operations can cause the battery to discharge a large current instantly, further accelerating the decline in battery performance. Smooth driving operation helps to extend the battery's service life in low-temperature conditions.

Performance risks and protection in Damp environments

The risks brought by a humid environment

The harm of a humid environment to forklift lead-acid batteries mainly lies in two aspects: increased risk of corrosion and greater potential for short circuits. Since battery casings are usually made of materials such as plastic, in a humid environment, the battery surface is prone to absorbing moisture and forming a water film. When there are corrosive gases such as acidic or alkaline ones in the air, these gases dissolve in the water film and can cause corrosion to metal parts such as the battery casing and terminal posts. If exposed to such an environment for a long time, the battery casing may age and crack, and the terminals may be corroded and thinned, resulting in an increase in contact resistance and affecting the battery's charging and discharging performance.

Meanwhile, in a humid environment, the water film on the battery surface may cause a slight conductive path between the positive and negative electrodes, posing a risk of short circuit. If the battery has poor sealing, moisture may seep into the interior of the battery, diluting the electrolyte, altering its density and chemical composition, and thereby affecting the chemical reactions inside the battery, reducing its capacity and service life. Once a short circuit occurs inside the battery, it may cause serious safety accidents such as overheating, bulging and even explosion of the battery.

Protective measures

To reduce the impact of humid environments on forklift lead-acid batteries, it is crucial to enhance battery sealing. Regularly check whether the sealing rubber strip of the battery is in good condition. If it is aged, deformed or damaged, it should be replaced in time. Make sure the seal between the battery cover and the battery compartment is tight to prevent moisture from entering the battery interior. Some high-quality lead-acid batteries for forklifts adopt special sealing techniques and materials, such as hot-melt sealing technology, which ensures a firm seal between the battery cover and the battery compartment, effectively resisting the erosion of a humid environment.

At the same time, moisture-proof treatment for batteries is also indispensable. Apply moisture-proof insulating paint on the surface of the battery to form a protective film, which can prevent moisture from adsorbing and accumulating on the battery surface and reduce the risk of corrosion. Park the forklift in a dry and well-ventilated area to avoid prolonged exposure to a damp environment. For some unavoidable high-humidity working environments, desiccants such as silica gel desiccants can be placed in the forklift battery compartment to absorb the moisture inside the compartment, reduce the humidity, and create a relatively dry working environment for the battery, thereby effectively extending the battery's service life in a humid environment.

Key points for battery maintenance in dusty environments

The harm of dust to batteries

In dusty working environments such as cement plants, flour mills and coal mines, forklift lead-acid batteries are confronted with numerous problems. A large amount of dust is prone to adhere to the surface of the battery. Once accumulated, it will affect the battery's heat dissipation. During the charging and discharging process of batteries, heat is generated. Under normal circumstances, it needs to be dissipated in time to maintain an appropriate working temperature. However, after being covered with dust, it is like putting on an insulating layer for the battery, and the heat cannot be effectively dissipated, causing the battery temperature to rise. When exposed to high temperatures for a long time, the chemical reactions inside the battery will accelerate, the aging of the plates will intensify, the capacity will decline rapidly, and the cycle life will be shortened. For instance, in the workshop of a cement plant, the lead-acid batteries of forklifts, due to long-term exposure to a high-dust environment, have accumulated a thick layer of cement dust on their surface, and their service life is shortened by approximately one-third compared to that in a clean environment.

In addition, dust may also enter the battery interior through the vent holes of the battery. Once in, impurities in the dust may undergo chemical reactions with the electrolyte, contaminating it, altering its composition and properties, affecting the normal electrochemical reactions inside the battery, and reducing the battery's charging and discharging efficiency and capacity. Meanwhile, the accumulation of dust inside the battery may also cause short circuits between the plates, leading to battery failure and seriously affecting the normal operation of the forklift.

Maintenance measures

To reduce the harm of dust to the lead-acid batteries of forklifts, regular cleaning of the battery surface is the top priority. Use compressed air or a dedicated vacuum cleaner to regularly clean the dust on the battery surface to ensure it is clean and tidy with no dust accumulation, which is conducive to battery heat dissipation. During the cleaning process, be careful not to damage the battery casing and terminals. For instance, in a flour mill, conducting a comprehensive dust cleaning of forklift batteries once a week can effectively reduce the risk of overheating caused by dust coverage and extend the battery's service life.

Meanwhile, optimizing the battery ventilation system is also very crucial. Install highly efficient dust-proof filters at the battery vent holes to prevent dust from entering the battery interior. The dust-proof filter should have good air permeability, not affecting the normal discharge of the gas inside the battery, and at the same time effectively filtering out most of the dust. Regularly inspect and replace the dust-proof filter to ensure its filtering effect. Through these measures, the impact of dusty environments on the performance of forklift lead-acid batteries can be effectively reduced, ensuring the stable operation of forklifts in dusty conditions.

Conclusion

The performance of forklift lead-acid batteries varies significantly under different working environments. Normal temperature and dry environment is its ideal working environment, which can demonstrate good capacity retention and charge and discharge efficiency, but regular maintenance is required to maintain performance. High-temperature environments can accelerate battery capacity decline and shorten cycle life, which can be addressed by installing cooling systems and adjusting charging strategies.