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In the field of industrial logistics, forklifts, as key handling equipment, have always been a focus of enterprises' attention in terms of operating costs. Lead-acid batteries, as the main power source for electric forklifts, have advantages such as relatively low cost and mature technology. However, they also have problems such as limited charge and discharge cycles, short service life, high maintenance costs, and long charging times. These issues undoubtedly increase the operating costs of forklifts. How to optimize the use of lead-acid batteries and reduce the operating costs of forklifts has become an urgent problem for enterprises to solve.

The current situation of lead-acid batteries in forklift operation

At present, electric forklifts are increasingly widely used in industrial logistics, and lead-acid batteries, with their price advantage, have taken a dominant position in the power source market of electric forklifts. However, with enterprises' strict control over operating costs and the continuous improvement of environmental protection requirements, many drawbacks of lead-acid batteries have gradually emerged.

From a cost perspective, although the purchase cost of lead-acid batteries is relatively low, the maintenance cost and replacement cost throughout their entire service life cycle cannot be underestimated. Moreover, due to the limited charge and discharge cycles of lead-acid batteries, typically around 1,500 times, as the usage time increases, the battery capacity gradually declines. When it can no longer meet the normal operation requirements of forklifts, replacement is necessary, which incurs a considerable expense.

In terms of performance, the charging time of lead-acid batteries is relatively long, usually taking 6 to 8 hours to fully charge, which to some extent affects the working efficiency of forklifts. Especially in scenarios of multi-shift operations, it is often necessary to be equipped with multiple sets of batteries to ensure the continuous operation of forklifts, which undoubtedly increases the equipment investment cost of enterprises. Meanwhile, the energy density of lead-acid batteries is relatively low, which leads to a relatively short driving range of forklifts. For some working conditions that require continuous operation for a long time, they may not meet the demands.

Problems existing in the use of lead-acid batteries

The charging method is unreasonable

Many enterprises have problems such as too long or too short charging time and irregular charging frequency when charging lead-acid batteries for forklifts. Overcharging will cause the battery to heat up, accelerate the aging of the plates and shorten the battery life. Insufficient charging, however, will prevent the battery capacity from being fully utilized. Over time, it will also cause sulfation of the battery, further reducing its performance. In addition, frequent charging can also cause damage to the battery, as each charging process undergoes a chemical reaction. Excessive chemical reactions will accelerate the loss of substances inside the battery.

2. Inadequate maintenance and upkeep

Lead-acid batteries require regular maintenance and care, such as checking the electrolyte level and specific gravity, cleaning the battery surface, and testing the internal resistance of the battery, etc. However, in actual operation, some enterprises fail to carry out maintenance in accordance with the prescribed maintenance cycle and requirements due to the lack of professional maintenance personnel or insufficient attention to maintenance work. For instance, if the electrolyte is not replenished in time, the plates will be exposed to the air, accelerating their corrosion. Dust and acid accumulated on the surface of the battery can cause a short circuit in the battery and affect its performance.

3. Impact of the working environment

Forklifts usually operate in various complex environments, such as places with high temperatures, high humidity and a lot of dust. These harsh working environments will have an adverse impact on the performance of lead-acid batteries. In a high-temperature environment, the chemical reaction rate inside the battery increases, and the evaporation of the electrolyte intensifies, which can easily lead to water loss and overheating of the battery, shortening its lifespan. In a humid environment, the positive and negative electrodes of the battery are prone to oxidation and corrosion, reducing the battery's conductivity. Excessive dust may clog the ventilation holes of the battery and affect its heat dissipation.

4. Mismatch in selection

The models and working loads of forklifts vary, and lead-acid batteries of corresponding specifications and capacities need to be matched. However, some enterprises, when purchasing batteries, do not fully consider the actual working requirements of forklifts and choose batteries with either too small or too large capacities. Batteries with too small capacity cannot meet the power demands of forklifts, resulting in excessive battery discharge and damage to the battery. Batteries with excessive capacity, on the other hand, will cause waste of resources, increase the purchase cost, and also take longer to charge, affecting work efficiency.

Optimize the strategies for the use of lead-acid batteries

1. Improve charging management

- ** Adopt smart charging devices ** : Invest in purchasing chargers with smart charging functions. These chargers can automatically adjust the charging current and voltage based on the real-time status of the battery, enabling the switching between multiple charging modes such as constant current, constant voltage, and float charging, thereby preventing overcharging and undercharging. For instance, some smart chargers can precisely control the charging process by detecting parameters such as the battery's temperature, voltage and charging time. Once the battery is fully charged, they will automatically stop charging to prevent overcharging from causing damage to the battery.

- ** Develop a reasonable charging plan ** : Based on the usage frequency and working hours of the forklift, develop a scientific and reasonable charging plan. Avoid charging the battery when it is still at a high level. Try to schedule the charging time during the forklift's rest period to reduce the impact of frequent charging on the battery. At the same time, make sure that each charge can fully charge the battery, but do not overcharge it. For forklifts operating in multiple shifts, a phased charging method can be adopted. Appropriate charging should be carried out during the intervals of each shift to keep the battery power within an appropriate range.

2. Strengthen maintenance and upkeep

- ** Regular Inspection and maintenance ** : Establish a complete battery maintenance and care system, and arrange for professional personnel to regularly inspect and maintain lead-acid batteries. The inspection items include the electrolyte level, specific gravity, whether the battery appearance is damaged or leaking, and whether the connection terminals are loose or corroded, etc. Under normal circumstances, an appearance inspection should be conducted at least once a week, and the electrolyte level and specific gravity should be tested once a month. When the electrolyte level is found to be too low, distilled water or special electrolyte replenishment solution should be added in time. If any damage or leakage is found on the battery's appearance, its use should be stopped immediately and it should be repaired or replaced.

- ** Cleaning and Maintenance ** : Keep the battery surface clean. Regularly wipe the battery casing and connection terminals with a clean damp cloth to remove dust, acid, oil stains and other impurities on the surface. Prevent these impurities from forming conductive paths on the battery surface, which may cause self-discharge or short circuit of the battery. At the same time, it is necessary to ensure that the ventilation holes of the battery are unobstructed to prevent them from being blocked and affecting the battery's heat dissipation. In addition, regular oiling maintenance can be carried out on the battery connection terminals to prevent oxidation and corrosion of the terminals and enhance the reliability of the connection.

- ** Regular deep discharge and activation ** : To maintain the battery's activity and extend its lifespan, lead-acid batteries can be subjected to regular deep discharge and activation treatments. It is generally recommended to perform a deep discharge every 2 to 3 months, that is, to discharge the battery power to a level close to the terminal voltage, but be careful not to over-discharge. After deep discharge, the battery is activated using a dedicated battery activation device. Through special pulse currents or other methods, the sulfides on the battery plates are removed to restore part of the battery's capacity.

3. Improve the working environment

- ** Temperature Control ** : Try to keep the working environment temperature of the forklift within an appropriate range. Generally, the optimal working temperature for lead-acid batteries is 20-30 ℃. When working in a high-temperature environment, some cooling measures can be taken, such as installing ventilation equipment and sunshades in the forklift's working area, or equipping the battery with cooling fans, etc., to lower the temperature around the battery. At the same time, avoid exposing the forklift to the scorching sun for a long time, especially the battery part. When working in a cold environment, it is necessary to keep the battery warm to enhance its performance.

- ** Humidity and Dust Protection ** : For work environments with high humidity, it is necessary to enhance ventilation and dehumidification to keep the workplace dry. Dehumidification equipment can be installed to reduce the humidity in the air and decrease the risk of oxidation and corrosion of the positive and negative electrodes of the battery. In places with a lot of dust, effective dust-proof devices should be equipped for forklifts to prevent dust from entering the battery and affecting its normal operation. Meanwhile, the dust-proof devices should be cleaned and replaced regularly to ensure their protective effect.

4. Reasonable selection

- ** Select based on forklift requirements ** : When purchasing lead-acid batteries, it is necessary to fully consider factors such as the forklift model, working load, usage frequency, and working environment, and choose batteries with appropriate capacity and specifications. Generally speaking, the greater the working load and the higher the usage frequency of a forklift, the greater the battery capacity it requires. The capacity and specifications of the battery can be determined by calculating parameters such as the working power, operating time and required starting current of the forklift.

Conclusion

Although lead-acid batteries have some problems in forklift operation, through reasonable optimization strategies, their usage costs can be effectively reduced and the operational efficiency of forklifts can be improved. Enterprises should attach great importance to the management and maintenance of lead-acid batteries, and formulate scientific usage plans from aspects such as charging management, maintenance and care, improvement of working environment and reasonable selection. Meanwhile, with the continuous advancement of technology, the application of new battery technologies such as lithium batteries in the forklift field is gradually increasing. Enterprises can also consider upgrading and replacing battery technology at an appropriate time based on their own actual situations to further reduce operating costs and enhance their competitiveness. In the future development, constantly exploring and innovating the usage and management methods of forklift power sources will be one of the important ways for enterprises to achieve sustainable development.