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In the field of modern logistics and warehousing, forklifts, as important handling equipment, rely on reliable power systems for their efficient operation. Lead-acid batteries have become one of the most commonly used power sources for forklifts due to their advantages such as mature technology and relatively low cost. However, during long-term use, various faults are inevitable in the lead-acid batteries of forklifts, which affect the normal operation of forklifts and increase maintenance costs. A thorough understanding of these common faults and the mastery of effective response strategies are crucial for ensuring the stable operation of forklifts.

1. Capacity decline failure

(1) Fault phenomenon

During the operation of the forklift, if there is a significant reduction in the driving range, insufficient power when lifting or moving heavy objects, and the battery drains quickly after charging, it indicates that the capacity of the lead-acid battery has decreased.

(2) Cause of the Fault

1. ** Plate sulfation ** : When a storage battery is in a state of discharge or semi-discharge for a long time, lead sulfate crystallizes on the plates to form coarse particles, resulting in a reduction of the active material on the plates and a decrease in battery capacity. This situation is prone to occur when forklifts are idle for a long time or not fully charged.

2. ** Abnormal electrolyte density ** : Both excessively high and low electrolyte density can affect the chemical reactions of the battery. Excessively high density will accelerate the corrosion of the plates, while too low density will lead to insufficient battery capacity. In addition, excessive impurities in the electrolyte can also interfere with normal electrochemical reactions, resulting in a decrease in capacity.

3. ** Battery aging ** : As the usage time increases, the active material on the plates gradually falls off, the separators age, and the internal resistance of the battery increases, thereby causing the capacity to continuously decline.

(3) Testing Methods

1. ** Measure the density of the electrolyte ** : Use a hydrometer to measure the density of each cell of the electrolyte and compare it with the standard value. If the deviation of the density value is large, the reasons need to be further analyzed.

2. ** Check the condition of the plates ** : Open the upper cover of the battery and observe whether there are large white particles on the surface of the plates. If there are, it may be sulfation of the plates. Meanwhile, check whether there is any shedding of active substances on the plates.

3. ** Conduct charge and discharge tests ** : Use professional charge and discharge equipment to charge and discharge the battery, record the charging and discharging time, voltage changes and other data of the battery, calculate the actual capacity, and compare it with the rated capacity to determine the degree of capacity decline.

(4) Maintenance and Preventive Measures

1. ** Repair Method ** : For plates with mild vulcanization, the method of long-term charging with a small current can be adopted for repair. For severely sulfurized plates, it is usually necessary to replace the plates or the entire battery pack. If the density of the electrolyte is abnormal, the density of the electrolyte can be adjusted according to the actual situation, and the electrolyte should be replaced if necessary.

2. ** Preventive Measures ** : Avoid excessive discharge of forklift lead-acid batteries and charge them promptly after each discharge. Regularly check the density and liquid level of the electrolyte and keep them within the normal range. For forklifts that have been idle for a long time, regular supplementary charging should be carried out to prevent sulfation of the plates.

2. Charging failure

(1) Fault phenomenon

During the charging process, situations such as excessively high or low charging voltage, abnormal charging current, severe battery heating, overly long charging time and inability to fully charge the battery may occur.

(2) Cause of the Fault

1. ** Charging equipment failure ** : Internal components of the charger are damaged, such as rectifier diodes, filter capacitors, charging control chips, etc., resulting in unstable charging voltage and current.

2. ** Internal short circuit of the battery ** : Short circuit between the plates, damage to the separator causing the positive and negative electrodes to come into contact, or excessive active material deposited at the bottom of the battery causing the positive and negative electrodes to conduct can all lead to an internal short circuit of the battery, affecting charging.

3. ** Connection line failure ** : Aging, damage or poor contact of the charging connection line can lead to poor transmission of charging current, resulting in charging failure.

(3) Testing Methods

1. ** Check the charging equipment ** : Use a multimeter to measure the output voltage and current of the charger, compare them with the nominal values of the charger, and determine whether the charger is working properly. Observe whether there are obvious signs of damage such as charring or deformation on the internal components of the charger.

2. ** Detection of Internal Short Circuits in batteries ** : Use a voltmeter to measure the voltage of each cell of the battery. If the voltage of a certain cell is significantly lower than that of the others, there may be an internal short circuit. It can also be judged by measuring the internal resistance of the battery. If the internal resistance is too large, there may be a short circuit.

3. ** Check the connection wires ** : Carefully inspect the charging connection wires for any damage or aging, and check if the connection terminals are loose or oxidized to ensure a good connection.

(4) Maintenance and Preventive Measures

1. ** Maintenance Method ** : For damaged charging devices, replace them according to the specific faulty components; If there is a short circuit inside the battery, the battery needs to be opened to check the cause of the short circuit, and the damaged plates and separators should be repaired or replaced. Replace the aged and damaged charging connection cables to ensure a secure connection.

2. ** Preventive Measures ** : Regularly maintain and service the charging equipment, and replace aged components in a timely manner; Avoid excessive discharging and charging of the battery to prevent short circuits caused by bending of the plates and shedding of active materials. Regularly check the charging connection cable to ensure a good connection.

3. Leakage Fault

(1) Fault phenomenon

Electrolyte leakage occurs at the battery casing, upper cover, terminals and other parts. There are white crystalline substances around the battery, which may be accompanied by a pungent smell of sulfuric acid.

(2) Cause of the Fault

1. ** Shell or upper cover damage ** : During the battery's use, it is subjected to collision or compression, causing cracks in the shell or upper cover, and the electrolyte seeps through the cracks.

2. ** Poor terminal sealing ** : The sealant between the terminal and the battery housing ages or cracks, or is not properly sealed during installation, causing the electrolyte to seep out from the terminal.

3. ** Poor sealing of the liquid filling port ** : The cap of the liquid filling port is not tightened properly, or the sealing ring of the liquid filling port is damaged. When the battery vibrates or gas is produced during charging, the electrolyte overflows.

(3) Testing Methods

1. ** Visual Inspection ** : Carefully observe whether there are cracks, damages, and traces of electrolyte on the battery casing, upper cover, terminals, and other parts.

2. ** Air Tightness Test ** : Conduct an air tightness test on the battery. By filling the battery with gas at a certain pressure, observe whether there is any leakage and determine the location of the leakage.

(4) Maintenance and Preventive Measures

1. ** Repair Method ** : For minor cracks in the casing, special battery repair glue can be used for repair; If the crack is large or the casing is severely damaged, the battery casing needs to be replaced. When the terminal seal is poor, reapply the sealant or replace the seal. The liquid filling port is not sealed tightly. Replace the sealing ring and tighten the cover.

2. ** Preventive Measures ** : During the operation of the forklift, avoid severe collision and compression of the battery; Regularly inspect the sealing parts of the battery and replace the aged sealing parts in time. Operate the liquid filling port correctly and ensure that the cover is tightened.

4. Battery overheating fault

(1) Fault phenomenon

During the charging or discharging process, the surface temperature of the battery rises significantly, and it feels hot to the touch. In severe cases, it may even be too hot to handle.

(2) Cause of the Fault

1. Excessive charging current: The charging current set by the charger exceeds the rated charging current of the battery, causing intense chemical reactions inside the battery and generating excessive heat.

2. ** Internal Battery faults ** : Issues such as sulfation of the plates, shedding of active materials, and internal short circuits can increase the internal resistance of the battery and generate a large amount of heat during charging and discharging.

3. Poor heat dissipation: Poor ventilation around the battery or the battery surface being covered with debris affects heat dissipation, causing the battery temperature to rise.

(3) Testing Methods

1. ** Measure charging current ** : Use an ammeter to measure the current during the charging process and check if it exceeds the battery's rated charging current.

2. ** Check the internal condition of the battery ** : By measuring the battery voltage and internal resistance, and observing the condition of the plates, determine whether there are any internal faults in the battery.

3. ** Check heat dissipation ** : Observe the surrounding environment of the battery to check if there are any obstructions blocking heat dissipation and if the ventilation is good.

(4) Maintenance and Preventive Measures

1. ** Maintenance method ** : Adjust the charging current of the charger to an appropriate range; For batteries that heat up due to internal faults, repair or replace them according to the specific faults. Clear the debris around the battery and improve the ventilation conditions.

2. ** Preventive Measures ** : Select an appropriate charger and set the charging parameters strictly in accordance with the charging requirements of the battery; Regularly inspect the internal condition of the battery to promptly identify and handle potential faults. Keep the environment around the battery clean and well-ventilated.

Common faults of lead-acid batteries in forklifts involve multiple aspects such as capacity decline, charging failure, leakage failure and overheating failure. By conducting in-depth analysis of the phenomena and causes of these faults and mastering the corresponding detection, maintenance and preventive measures, the service life and reliability of lead-acid batteries in forklifts can be effectively prolonged, the equipment maintenance costs of logistics and warehousing enterprises can be reduced, and the efficient and stable operation of forklifts can be ensured. During actual use, users should enhance the daily maintenance and inspection of the battery, promptly identify and resolve potential issues, and ensure the smooth operation of the forklift.