News

Introduction

In the field of industrial logistics, forklifts, as key material handling equipment, the stability and durability of their power supply are of vital importance. Lead-acid batteries have become widely adopted as the power source for forklifts due to their advantages such as mature technology, low cost and large capacity. As a core component of lead-acid batteries, the electrolyte plays a decisive role in the battery's performance, lifespan and safety, just like the blood in the human body. The correct use and maintenance of electrolyte not only ensure the efficient and stable operation of forklifts, but also significantly reduce usage costs and minimize the risk of production disruptions caused by equipment failures. This article will delve into the key points for the correct use and maintenance of lead-acid battery electrolyte in forklifts, providing comprehensive and practical guidance for relevant practitioners.

1. The Function and Composition of the Electrolyte

(1) Mechanism of Action

The electrolyte plays an indispensable role in the charging and discharging process of lead-acid batteries. During charging, the sulfuric acid in the electrolyte participates in electrochemical reactions, converting electrical energy into chemical energy for storage. Specifically, the sulfuric acid reacts with the active substances on the plates, gradually transforming the lead sulfate on the plates into lead dioxide and spongy lead, while the density of the electrolyte gradually increases. During discharge, the process is reversed. The active substances on the plates react with the sulfuric acid in the electrolyte again, converting chemical energy into electrical energy and releasing it to provide power for the forklift. At this time, the density of the electrolyte will gradually decrease. Through this repeated chemical reaction, the electrolyte achieves the storage and release of energy, ensuring the continuous operation of the forklift.

(2) Components

The electrolyte of forklift lead-acid batteries is usually a mixture of high-purity sulfuric acid and distilled water in a certain proportion. Sulfuric acid provides the necessary ions in the electrolyte and is a key participant in electrochemical reactions. Its concentration directly affects the density of the electrolyte and the performance of the battery. Distilled water plays a role in diluting sulfuric acid, regulating the density of the electrolyte and maintaining the stability of the electrochemical reaction environment. High-quality electrolyte requires extremely high purity of sulfuric acid and very low impurity content to prevent impurities from corroding the battery plates and affecting the battery life. At the same time, distilled water must also meet strict purity standards and must not contain excessive minerals, metal ions or other impurities; otherwise, it will interfere with electrochemical reactions and reduce the charging and discharging efficiency of batteries.

2. Inspection and Addition of electrolyte

(1) Inspection Frequency and Methods

Inspection frequency: It is recommended to carefully check the electrolyte level of lead-acid batteries before each day or each shift of forklift operation. If the forklift is frequently used, such as in high-intensity operation environments like logistics warehouses, or in harsh working conditions like high temperatures, high humidity or dusty places, the inspection frequency should be appropriately increased to ensure that the electrolyte level is always within the normal range.

Inspection method: Determine whether the electrolyte level is normal by the liquid level scale line marked on the battery casing. Under normal circumstances, the electrolyte level should be maintained between the upper and lower limit marks. Some batteries may not have obvious scale lines. At this time, tools such as glass tubes can be used for measurement. Insert the glass tube vertically into the battery's liquid filling hole until it touches the top of the plates. Then, block the upper end of the glass tube with your finger and take it out. The height of the electrolyte adsorbed inside the tube is the actual liquid level height. By comparing it with the standard liquid level, you can determine whether the liquid level meets the standard.

(2) Liquid Level Standards and Abnormal Handling

Liquid level standard: When the electrolyte liquid level is below the lower limit scale, part of the plates will be exposed above the liquid surface, which will lead to the occurrence of sulfation on the plates. After sulfation of the plates, a layer of white lead sulfate crystals will form on their surface. These crystals are hard in texture and can hinder the electrochemical reaction between the electrolyte and the active substances on the plates, increasing the internal resistance of the battery and reducing its capacity, which seriously affects the performance and service life of the battery. Therefore, once the liquid level is found to be lower than the lower limit, distilled water or special lead-acid battery replenishment solution must be added in time.

Abnormal handling: When adding liquid, be sure to pour it in slowly to avoid splashing. Because the electrolyte is highly corrosive, if it accidentally splashes onto the skin or eyes, it can cause severe burns. In case of fluid splashing, immediately rinse the injured area with plenty of clean water and seek medical attention promptly. At the same time, it is strictly prohibited to add ordinary tap water. The calcium, magnesium ions and other minerals and other impurities contained in tap water will contaminate the electrolyte, undergo chemical reactions with the active substances in the electrodes, accelerate the corrosion of the plates, and further reduce the performance of the battery.

3. Monitoring and Adjustment of Electrolyte Density

(1) Monitoring tools and Frequencies

Monitoring tool: Using a hydrometer to regularly measure the density of the electrolyte is an important means to determine the charging and discharging status and performance of the battery. Common densitometers include float densitometers and digital densitometers. Float densitometers read density values by observing the suspension position of the float in the electrolyte. They are simple to operate but have relatively low accuracy. Digital densitometers use electronic sensors for measurement, providing more accurate and intuitive readings.

Monitoring frequency: It is generally recommended to measure the density of the electrolyte once every 1-2 weeks. If the forklift's operating environment is complex and changeable, such as large temperature fluctuations or frequent high-current charging and discharging, the measurement frequency should be appropriately increased to promptly detect density abnormalities and make adjustments.

(2) Density Standards and Adjustment Methods

Density standard: At 20℃, the density of the electrolyte in forklift lead-acid batteries should typically be controlled between 1.2 and 1.28kg/L. This density range can ensure that the battery has good charging and discharging performance and a long service life under normal working conditions. There may be slight differences among batteries of different brands and models. The specific technical parameters provided by the battery manufacturer should be taken as the standard.

Adjustment method: When the measurement reveals that the density of the electrolyte is too high, it indicates that the battery may be in an overcharged state or that too much water has evaporated from the electrolyte. At this point, it can be diluted by adding an appropriate amount of distilled water to reduce the density. After adding distilled water, the electrolyte should be gently stirred with a clean glass rod or other tools to ensure thorough and uniform mixing. Then, measure the density again until it reaches the standard range. If the density of the electrolyte is too low, it might be due to over-discharging of the battery or mistakenly adding too much water when adding the liquid. At this point, a special sulfuric acid solution needs to be added for adjustment. When adding sulfuric acid solution, it should be added slowly drop by drop while constantly stirring the electrolyte to prevent local excessive density. After each addition, the density should be measured in time to avoid excessive adjustment. During the process of adjusting the density of the electrolyte, it is necessary to closely monitor the temperature changes of the battery, as electrochemical reactions generate heat. If the temperature is too high, it may cause damage to the battery. If an abnormal increase in battery temperature is detected, the operation should be suspended until the temperature returns to normal before continuing to make adjustments.

4. Cleaning and Maintenance of the electrolyte

(1) External cleaning

The importance of cleaning: It is crucial to regularly clean the electrolyte residue, dust and dirt on the surface of the battery casing. These substances accumulate on the surface of the battery and may form conductive paths, leading to the occurrence of battery self-discharge. Self-discharge will gradually depleting the battery's power when it is not in use, reducing the actual efficiency and endurance of the battery, and also accelerating its aging.

Cleaning method: When cleaning, you can gently wipe the surface of the battery casing with a damp cloth. Avoid using chemical cleaners as they may have a chemical reaction with the material of the battery casing, causing corrosion and damage to the battery. For stubborn stains, you can first soak them in a damp cloth for a while and then wipe them. During the wiping process, be careful to avoid water entering the battery's liquid filling holes or other internal structures to prevent the electrolyte from being diluted or short-circuited.

(2) Internal cleaning

Internal cleaning timing: Although the interior of a battery generally does not require frequent cleaning, when the electrolyte is found to be turbid and there is a large amount of sediment, it is necessary to consider cleaning the battery's interior. The turbidity of the electrolyte may be caused by reasons such as plate corrosion and the mixture of impurities, which will seriously affect the performance and lifespan of the battery. At this point, if the internal cleaning is not carried out in time, the battery may experience abnormal charging and discharging, a sharp decline in capacity and other problems.

Key points of cleaning operation: The internal cleaning of batteries usually requires professional personnel to carry out. First, use a dedicated device to suck out the old electrolyte. Be sure to collect the electrolyte properly to avoid environmental pollution. Then, rinse the interior of the battery multiple times with distilled water to remove any remaining impurities and sediment. During the rinsing process, make sure that every corner can be rinsed to ensure the cleaning effect. After the rinsing is completed, it is necessary to wait for the battery interior to dry naturally or use low-temperature hot air to blow dry, and then add new electrolyte again. Before adding new electrolyte, the interior of the battery should be inspected to ensure there are no residual impurities or moisture, and at the same time, check if there are any abnormal conditions such as damage to the plates. If the plates are found to be damaged, they should be repaired or replaced in time; otherwise, it will affect the normal use of the battery.

5. Common Problems and Countermeasures

(1) Electrolyte overflow

Cause analysis: The electrolyte overflow might be due to excessive current during the charging process, which leads to excessive gas generation inside the battery and an increase in pressure, causing the electrolyte to overflow from the filling hole or the safety valve. It could also be that when adding electrolyte, too much was added, exceeding the battery's capacity limit. In addition, if the battery is not installed firmly and is subjected to severe vibration during the operation of the forklift, it may also cause the electrolyte to overflow.

Countermeasures: Firstly, check the charging equipment to ensure that the charging voltage and current Settings meet the battery's specification requirements and avoid overcharging. During the charging process, closely monitor the battery's condition. If any abnormality is detected, stop charging immediately and conduct an inspection. In cases where too much electrolyte has been added, tools such as pipettes can be used to suck out the excess electrolyte and restore the liquid level to the normal range. At the same time, make sure the battery is installed firmly to avoid unnecessary vibrations during operation. If the electrolyte spills onto the battery casing or surrounding equipment, it should be wiped clean immediately with a damp cloth and neutralized with an alkaline substance such as sodium bicarbonate solution to prevent the electrolyte from corroding the equipment.

(2) Abnormal density of the electrolyte

Cause analysis: Abnormal electrolyte density might be due to excessive battery discharge, which leads to an overreaction between sulfuric acid and the active material on the plates, reducing the sulfuric acid content in the electrolyte and lowering its density. It could also be that during the maintenance process, too much distilled water or other liquid was mistakenly added, diluting the electrolyte and resulting in an excessively low density. On the contrary, if the battery is in an overcharged state for a long time, excessive evaporation of water will cause the relative concentration of sulfuric acid in the electrolyte to increase and its density to become too high.

Countermeasures: According to the above-mentioned density monitoring and adjustment methods, corresponding measures should be taken for different causes. If the density is too low due to excessive discharge, the battery should be charged in time, and the changes in the density of the electrolyte should be closely monitored during the charging process to check the charging effect. If the density is abnormal due to improper addition of distilled water, the composition of the electrolyte needs to be readjusted. Sulfuric acid solution or distilled water should be added in the correct way to restore the density to the standard range. During the adjustment process, the density should be measured multiple times to ensure the accuracy of the adjustment.

(3) The electrolyte is turbid

Cause analysis: The turbidity of the electrolyte is mainly due to the mixture of metal ions and impurities produced by the corrosion of the plates into the electrolyte, or the long-term exposure of the battery to harsh environments such as high temperature and high humidity, which leads to chemical reactions in the electrolyte and the formation of precipitates. In addition, abnormal conditions such as internal short circuits and excessive charging and discharging within the battery may also accelerate the corrosion of the plates, causing the electrolyte to become turbid.

Countermeasures: If the electrolyte is slightly turbid, first perform a deep discharge on the battery and then fully charge it. In this way, by taking advantage of the electrochemical reaction process, try to remove some impurities or make them reparticipate in the reaction, and observe whether the electrolyte improves. If the turbidity is severe, the battery should be sent to a professional repair institution for internal cleaning and maintenance. Maintenance personnel will restore the battery's performance through operations such as suctioning out the old electrolyte, flushing the battery interior, and replacing some damaged plates. When necessary, a brand-new electrolyte should be replaced to ensure that the battery can work properly. In daily use, it is necessary to avoid exposing the battery to harsh environments, reasonably control the charging and discharging processes, reduce the occurrence of abnormal situations, and thereby lower the risk of electrolyte turbidity.

6. Key Points for Electrolyte Maintenance in Different Environments

(1) High-temperature environment

The influence of high temperature on electrolyte: In a high-temperature environment, the evaporation rate of water in the electrolyte increases, which leads to a rapid drop in the electrolyte level and an increase in density. At the same time, high temperatures will accelerate the electrochemical reaction rate inside the battery, intensify the self-discharge phenomenon of the battery, and also speed up the corrosion rate of the plates. All these will seriously affect the service life of the battery.

Maintenance measures: Increase the frequency of checking the electrolyte level and density. Check the liquid level at least once a day and measure the density every 1-2 days. When the liquid level drops, add distilled water in time to keep the liquid level within the normal range. However, it should be noted that distilled water should be added after the battery is charged to avoid uneven mixing of the electrolyte and distilled water at high temperatures. At the same time, the charging current can be appropriately reduced to prevent the battery from overcharging in high-temperature environments and generating excessive heat. In addition, try to park the forklift in a cool and well-ventilated place to avoid the battery being exposed to high temperatures for a long time. If conditions permit, install a battery cooling device to lower the battery temperature.

(2) Low-temperature environment

The influence of low temperature on electrolyte: Low temperature will increase the viscosity of the electrolyte, slow down the ion migration speed, resulting in an increase in the internal resistance of the battery and a decline in charging and discharging performance. When the battery is discharged by 50%, the electrolyte is at risk of freezing at low temperatures. Once the electrolyte freezes, the volume expansion can cause serious damage such as the cracking of the battery casing and the deformation of the plates.

Maintenance measures: In low-temperature environments, to increase the temperature of the electrolyte, the forklift can be parked in a warm indoor area or the battery can be moved into a room with a temperature above 0℃. Increase the charging frequency appropriately. When the battery is discharged by 25% to 30%, it should be charged in time to prevent the electrolyte from freezing. When adding distilled water, it should be done during the charging process. This enables the distilled water to mix with the electrolyte more quickly and reduces the risk of freezing. Meanwhile, the density of the electrolyte can be appropriately increased based on the actual situation, but generally should not exceed 1.285g/cm³ to enhance the anti-freezing performance of the electrolyte. Before using a forklift, the battery can be preheated, such as by using heating pads and other equipment, to increase the battery's temperature and improve its charging and discharging performance.

7. Conclusion

The correct use and maintenance of electrolyte in forklift lead-acid batteries is a key link to ensure the normal operation of forklifts and extend the service life of batteries. From the inspection and addition of electrolyte, density monitoring and adjustment, to cleaning and maintenance, as well as dealing with common problems, every step must be carried out strictly in accordance with the norms. At the same time, the characteristic changes of the electrolyte under different environments should be fully considered, and corresponding maintenance measures should be taken. By maintaining the electrolyte scientifically and reasonably, not only can the operational efficiency of forklifts be enhanced and the equipment failure rate be reduced, but also a significant amount of equipment replacement and maintenance costs can be saved for enterprises. For forklift operators and maintenance personnel, mastering the correct use and maintenance knowledge of electrolyte is an essential skill to ensure the safe and efficient operation of forklifts. In practical work, it is necessary to constantly summarize experiences and continuously optimize maintenance methods to meet the usage requirements of forklift lead-acid batteries under different working conditions, providing a solid power guarantee for the smooth operation of industrial logistics.