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In the field of industrial production, forklifts, as important handling equipment, are widely used in warehousing and logistics, factory workshops and other places. As the core power source of electric forklifts, the performance and lifespan of lead-acid batteries play a crucial role in the normal operation of forklifts. When forklifts are out of use for a long time due to seasonal shutdowns, equipment upgrades and other reasons, the storage issue of lead-acid batteries is often overlooked. If the storage method is improper, it will lead to faults such as sulfation of the battery plates, drying up of the electrolyte, and severe self-discharge. This not only affects subsequent use but may even significantly shorten the service life of the battery and increase the operating costs of the enterprise. Therefore, mastering the correct storage method for lead-acid batteries of forklifts that have been out of use for a long time is of great significance for ensuring the performance of the batteries and extending their service life.

1. Preparations before long-term Disuse

Before the lead-acid battery of a forklift enters a long-term idle state, a series of meticulous preparatory work needs to be carried out, which lays a solid foundation for its subsequent proper storage.

(1) Comprehensive inspection

First of all, conduct a comprehensive inspection of the battery. In terms of appearance, carefully inspect the battery casing for any damage or cracks. Once found, even the tiniest crack may cause electrolyte leakage, affecting the battery's performance and usage safety. Timely repair or replacement of the casing is necessary. At the same time, check whether the terminal posts are corroded. If there are white or green corrosions on the surface of the terminal posts, they can be cleaned with a sodium bicarbonate solution and then coated with protective grease such as Vaseline to prevent further corrosion. In addition, it is necessary to check whether the connecting cables are loose or aged, and ensure that the cables are firmly connected and the insulation layer is intact.

(2) Deep discharge and charging

Next, proceed with deep discharge and charging operations. Adjust the load of the forklift to an appropriate state and allow the battery to continuously discharge under a certain load until the voltage drops to the specified terminal voltage. This process can release the active substances inside the battery and prevent adverse reactions caused by local charge accumulation during long-term storage. After the deep discharge is completed, immediately fully charge the battery. Use an appropriate charger, set the charging current and voltage according to the specification parameters of the battery, and perform constant current - constant voltage charging. During the charging process, closely monitor the changes in charging current, voltage and the temperature of the battery to prevent overcharging. When the charging current drops to a certain value and the voltage remains stable, and the density of the electrolyte reaches the specified value, it indicates that the charging is complete.

(3) Adjust the density of the electrolyte

After the charging is completed, the density of the electrolyte needs to be adjusted. The density of the electrolyte has a significant impact on the performance and lifespan of the storage battery. An appropriate density of the electrolyte can effectively prevent the electrolyte from freezing and the sulfation of the plates. The adjustment standards for the density of the electrolyte vary at different ambient temperatures.

2. Storage Environment Requirements

A suitable storage environment is a key factor in ensuring the stable performance of lead-acid batteries in forklifts that have been out of use for a long time. It is necessary to strictly control multiple aspects such as temperature, humidity and ventilation.

(1) Temperature control

Temperature has a significant impact on the self-discharge rate and chemical reactions of lead-acid batteries. The ideal storage temperature range should be between 5℃ and 25℃. When the temperature is too high, the chemical reaction rate inside the battery increases, self-discharge intensifies, and the evaporation rate of water in the electrolyte also speeds up, which can easily lead to the drying up of the electrolyte. However, if the temperature is too low, the electrolyte may freeze, thereby damaging the battery plates and casing. Therefore, the place where batteries are stored should be equipped with temperature regulation devices, such as air conditioners or heaters, to maintain a constant temperature environment. If the temperature cannot be precisely controlled, it is also necessary to choose an area with relatively stable temperature and small fluctuations for storage as much as possible.

(2) Humidity control

Humidity is also an important factor affecting the storage of storage batteries. A humid environment can easily cause the battery casing and terminals to rust and corrode, and also increase the self-discharge rate of the battery. The relative humidity of the storage environment should be controlled between 40% and 60%. To effectively control humidity, desiccants such as silica gel desiccants can be placed in the storage area and replaced regularly. In addition, maintaining good ventilation in the storage area helps to reduce humidity and minimize the condensation of moisture on the surface of the battery.

(3) Ventilation and dust prevention

Good ventilation conditions can promptly expel harmful gases such as hydrogen that may be produced during the storage of batteries, avoiding potential safety hazards caused by gas accumulation. Meanwhile, ventilation can also reduce the humidity of the storage environment and maintain suitable storage conditions. In addition, the storage place should be kept clean and dust-free. If dust and impurities enter the interior of the battery, it may cause faults such as short circuits of the plates. Therefore, it is necessary to clean the storage area regularly to prevent dust from accumulating on the surface and around the battery.

3. Selection of Storage Methods

There are mainly two storage methods for lead-acid batteries of forklifts that have been out of use for a long time: dry storage and wet storage. Each method has its own characteristics and applicable scenarios, and a reasonable choice should be made based on the actual situation.

(1) Dry storage

Dry storage involves completely draining the electrolyte from a fully charged battery and repeatedly rinsing the plates with distilled water until the pH of the rinsing solution approaches neutral. Then, dry the battery surface, seal the liquid injection holes, and store it in a dry, well-ventilated, and cool environment. The advantage of this storage method is that it can effectively prevent problems such as sulfation of the plates and drying up of the electrolyte, making it suitable for long-term storage. However, the disadvantages of dry storage are also quite obvious. When it is reactivated, the electrolyte needs to be refilled and a long period of charging and activation treatment should be carried out, which is relatively complicated to operate.

When dry storage is carried out, it is necessary to ensure that the electrolyte is completely drained out. The rinsing process should be thorough to prevent the residual electrolyte from corroding the plates. When sealing the liquid injection holes, reliable sealing materials should be used to prevent air and moisture from entering the battery interior.

(2) Wet storage

Wet storage involves keeping the electrolyte at a normal level after the battery is fully charged, tightening the cap of the liquid injection hole, and storing it in a suitable environment. Wet storage operation is relatively simple. When reactivated, no complex processing is required. Just appropriate supplementary charging is needed for use. It is suitable for situations where the storage time is relatively short. However, during wet storage, it is necessary to regularly recharge the battery to make up for the power loss caused by self-discharge and prevent the battery from being damaged due to excessive discharge.

No matter which storage method is chosen, it is necessary to make a mark on the surface of the battery, indicating the storage date, storage method and relevant precautions, so as to facilitate subsequent management and maintenance.

4. Maintenance and Inspection during Storage

Even if the correct storage method is adopted, during the long-term storage period, the lead-acid battery of the forklift cannot be ignored. Regular maintenance and inspection are required to promptly identify and solve potential problems.

(1) Regular supplementary charging

For wet storage batteries, supplementary charging should be carried out once every 1 to 2 months. The charging method is the same as that before storage to ensure that the battery remains fully charged. For dry-stored batteries, although they do not need to be charged during storage, a relatively long period of initial charging is required before they are reactivated to activate the active substances on the plates.

(2) Check the electrolyte level

For batteries that are stored wet, the electrolyte level should be checked regularly. If the liquid level drops, distilled water should be added in time to keep the liquid level 10-15mm above the plate. When adding distilled water, do it slowly to avoid splashing the electrolyte. At the same time, check whether the density of the electrolyte has changed. If it does not meet the standard, adjustments should be made promptly.

(3) Visual inspection

Regularly inspect the appearance of the battery to check if the casing is damaged or deformed, if the terminals are corroded, and if the connecting cables are loose. If any problems are found, they should be repaired or replaced in a timely manner to prevent them from worsening further.

5. Methods for Reactivation

When the lead-acid battery of a forklift needs to be reactivated after a long period of inactivity, a series of processing work must be carried out to ensure the normal operation of the battery.

(1) Activation of dry-stored batteries

For dry-stored batteries, first open the cover of the liquid injection hole and add qualified electrolyte according to the specified density. After the charging is completed, let the battery stand for 2 to 3 hours to allow the electrolyte to fully penetrate the plates. Then, use an appropriate charger for the initial charge. The charging time is generally 12 to 24 hours, and the specific time depends on the capacity and condition of the battery. After the initial charging is completed, conduct a discharge test on the battery to check if its capacity and performance have returned to normal. If the capacity is insufficient, 2 to 3 charge and discharge cycles can be carried out to activate the plates and improve the performance of the battery.

(2) Activation of wet storage batteries

It is relatively simple to reactivate batteries that have been stored in a wet state. First, check whether the liquid level and density of the electrolyte are normal. If not, make corresponding adjustments. Then, perform supplementary charging on the battery. After the charging is completed, the battery can be installed on the forklift for use. During the initial stage of use, closely monitor the changes in voltage, current and temperature of the battery to ensure its normal operation.

The storage of lead-acid batteries in forklifts that have been out of use for a long time is a systematic and important task, involving multiple links such as preparations before disuse, control of storage environment, selection of storage methods, maintenance during storage, and reactivation handling. Only by strictly following the correct methods for operation and management can the performance of the battery be guaranteed to the greatest extent, its service life be prolonged, costs be saved for the enterprise and production efficiency be improved.