News

Introduction

In the fields of modern logistics and industrial production, forklifts, as key material handling equipment, have their power sources directly related to operational efficiency and operating costs. Water-added lead-acid batteries occupy an important position in forklift power systems due to their advantages such as cost-effectiveness and technological maturity. However, the performance of various water-added lead-acid batteries for forklifts on the market varies greatly. A thorough analysis of these performance differences is of great significance for users to make reasonable selections and improve the efficiency of forklift usage.

The structural foundation of water-added lead-acid batteries

Basic structure

Its structure is mainly composed of positive and negative plates, electrolyte, separator, shell and other parts. The positive and negative plates are the core sites of electrochemical reactions. Generally, lead dioxide is used as the active material for the positive plate, while spongy lead is used for the negative plate. The material, thickness and manufacturing process of the plates significantly affect the performance of the battery.

The electrolyte is a mixture of sulfuric acid and distilled water in a specific proportion. It serves as a medium for ion transport and plays a crucial role in the electrochemical reactions of batteries. The concentration, purity of sulfuric acid and whether it contains impurities will all have a direct impact on the performance of the battery. An appropriate concentration of sulfuric acid can optimize the charging and discharging performance of batteries. If the concentration is too high or too low, it may lead to problems such as reduced battery capacity and accelerated corrosion of the plates.

The separator is placed between the positive and negative plates to prevent short circuits between them while allowing ions to pass through. The material, pore size and porosity of the separator and other characteristics affect the internal resistance and cycle life of the battery. High-quality separators have excellent chemical stability, high ionic conductivity and strong mechanical strength, which can effectively prevent the migration of active substances on the plates and extend the service life of the battery.

The casing is used to accommodate components such as plates, electrolyte and separators, and is required to have good insulation, corrosion resistance and mechanical strength to ensure the safe and stable operation of the battery under various working conditions. Common shell materials include engineering plastics, etc. Shells made of different materials vary in terms of protective performance, weight and cost.

Performance indicators of water-added lead-acid batteries for forklifts

Capacity

Capacity is a key indicator for measuring a battery's ability to store electrical energy, with the unit being ampere-hours (Ah). For water-added lead-acid batteries used in forklifts, the capacity directly determines the driving range and working time of the forklift. In actual operations, if forklifts need to frequently carry heavy objects, travel long distances or operate continuously, large-capacity batteries can reduce the frequency of charging and improve work efficiency.

Charge and discharge efficiency

Charging efficiency refers to the proportion of input electrical energy converted into chemical energy for storage during battery charging, while discharging efficiency is the proportion of chemical energy converted into electrical energy for output. High charge and discharge efficiency means that the energy loss of the battery during the charging and discharging process is small, which can reduce the usage cost and extend the battery life. Advanced plate manufacturing processes and electrolyte formulations can enhance the charging and discharging efficiency of batteries. If special alloys are used to manufacture the plates, the internal resistance of the plates can be reduced, energy loss during charging and discharging can be decreased, and the charging efficiency can reach over 90%, with the discharging efficiency approaching 85%. Compared with batteries made by ordinary processes, the charging and discharging efficiency can be increased by 10% to 15%.

Cycle life

Cycle life refers to the number of cycles a battery can undergo charge and discharge under certain conditions until its capacity drops to a specified value (usually 80% of its initial capacity). Forklifts operate frequently, and the battery cycle life is directly related to the replacement cycle and operating costs. Long-term and frequent deep discharges will accelerate battery aging and shorten the cycle life. If the battery power of a forklift is frequently depleted to below 20% during use, its cycle life may be reduced by 20% to 30%.

Low-temperature performance

Forklifts operating in low-temperature environments such as cold storage facilities have strict requirements for the low-temperature performance of batteries. At low temperatures, the viscosity of the electrolyte increases, and the diffusion rate of ions slows down, resulting in an increase in the internal resistance of the battery and a decline in its capacity and discharge performance. Some high-performance water-added lead-acid batteries can enhance their low-temperature performance by improving the electrolyte formula, adding special additives, and optimizing the material and structure of the plates.

Influencing factors of performance differences

Plate materials and manufacturing processes

The purity of the plate material and the alloy composition have a significant impact on the battery performance. High-purity lead raw materials can reduce the self-discharge phenomenon caused by impurities and improve the storage performance of batteries. The positive grid adopts a multi-element low-antimony corrosion-resistant alloy, which can enhance the electrical conductivity and corrosion resistance of the plates, and improve the charging and discharging performance and cycle life of the battery. In terms of manufacturing processes, the uniformity of the coating of the active material on the plates and the curing process affect the adhesion between the active material and the plates. Evenly coated and firmly bonded plates have less likely active substances to fall off during charging and discharging, which can effectively extend the battery life.

Electrolyte composition and quality

The concentration and purity of sulfuric acid in the electrolyte are key factors. An appropriate concentration of sulfuric acid can optimize electrochemical reactions. Generally, the concentration of sulfuric acid in water-added lead-acid batteries used in forklifts is between 30% and 38%. Excessively high concentration will accelerate the corrosion of the plates, while too low concentration will lead to a reduction in battery capacity. The purity of the electrolyte directly affects the self-discharge rate and service life of the battery. High-purity electrolyte has fewer impurities, which can reduce the side reactions inside the battery, lower self-discharge, and extend the battery's service life.

Battery structure design

A reasonable battery structure design can enhance battery performance. The plate spacing affects the internal resistance and heat dissipation performance of the battery. A smaller plate spacing can reduce the internal resistance, but it is unfavorable for heat dissipation. A balance needs to be struck between the two. If thin plates are adopted and the plate spacing design is optimized, the internal resistance of the battery can be reduced while ensuring heat dissipation, and the charging and discharging performance can be improved. The sealing structure of the battery is crucial for preventing electrolyte leakage, reducing water evaporation and gas escape. A good sealing structure can maintain the stability of the electrolyte composition, reduce the entry of external impurities, and extend the battery's service life. Batteries with a fully sealed and maintenance-free design can effectively prevent electrolyte leakage, reduce maintenance workload, and simultaneously enhance the safety and reliability of the battery.

Usage and maintenance conditions

The ambient temperature of use has a significant impact on battery performance. Under high-temperature conditions, the chemical reactions inside the battery accelerate, and the evaporation of water intensifies, which can easily lead to the drying up of the electrolyte and the sulfation of the plates, thereby shortening the battery's lifespan. Low-temperature environments reduce battery capacity and charging and discharging performance. Reasonable charging and discharging methods are the key to extending battery life. Avoiding overdischarge and overcharging, and following the charging and discharging system recommended by the battery manufacturer can effectively reduce sulfation of the plates and the shedding of active materials. If intelligent charging devices are adopted, adjusting the charging current and voltage according to the battery status can improve the charging efficiency and extend the battery's cycle life. Regular maintenance and care of the battery, such as checking the electrolyte level and specific gravity, cleaning the battery surface, and promptly replenishing distilled water, can ensure that the battery is in good working condition. Batteries that are neglected in maintenance and care will gradually decline in performance and enter the scrapping period prematurely.

Conclusion

The performance differences of water-added lead-acid batteries for forklifts are comprehensively influenced by multiple factors, including the material and manufacturing process of the plates, the composition and quality of the electrolyte, the battery structure design, as well as the usage and maintenance conditions. When choosing batteries, users need to comprehensively consider factors such as the forklift's working environment, usage frequency, and budget, weigh the differences among various batteries in terms of capacity, charge and discharge efficiency, cycle life, and low-temperature performance, and select products with suitable performance and high cost performance. At the same time, pay attention to the correct use and maintenance of batteries to fully exert their performance, extend their service life and reduce the operating costs of forklifts. With the continuous advancement of technology, water-added lead-acid batteries will continue to innovate in performance optimization, environmental protection and energy conservation, providing more reliable and efficient solutions for the forklift power field.