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In modern logistics and industrial production, forklifts, as important handling equipment, are widely used. As a key power source for forklifts, the correct use of lead-acid batteries directly affects the performance, service life and operational safety of forklifts. If not used properly, it will not only significantly shorten the service life of the battery and increase operating costs, but also may trigger a series of safety risks. Therefore, a thorough understanding of the correct usage methods of lead-acid batteries in forklifts and effective avoidance of potential risks are of vital significance for ensuring the efficient and safe operation of forklifts.

The risks of incorrect use of lead-acid batteries in forklifts

Safety risk

1. ** Explosion Risk ** : During the charging process, lead-acid batteries undergo an electrolytic water reaction, generating hydrogen and oxygen. When the charging environment is poorly ventilated, hydrogen accumulates to a certain concentration. Once exposed to open flames, sparks or static electricity, it is highly likely to cause an explosion, which can seriously harm personnel and equipment. For instance, a certain logistics warehouse failed to install good ventilation facilities in the forklift charging area, and workers smoked illegally nearby. As a result, the hydrogen released from the batteries during the charging process exploded upon encountering an open flame, causing a partial collapse of the warehouse and injuring several workers.

2. ** Risk of Chemical burns ** : The electrolyte of forklift lead-acid batteries is a highly corrosive sulfuric acid solution. During daily maintenance, water addition or battery replacement, if the operator does not wear appropriate protective equipment such as protective gloves or goggles, once the electrolyte splashes onto the skin or into the eyes, it will rapidly corrode the skin and eye tissues, causing severe chemical burns. There was once a forklift maintenance worker who, while checking the electrolyte level of a battery, accidentally splashed the electrolyte into his eyes without wearing goggles, causing permanent eye damage.

3. ** Electric Shock Risk ** : The voltage of lead-acid batteries in forklifts is usually high, with common ones being 24V, 48V or even higher. If the electrical connection parts of the battery are loose, the insulation layer is damaged, or the operator violates the electrical safety regulations during operation, an electric shock accident may occur. For instance, in a humid environment, the terminals of forklift batteries, due to long-term exposure without effective protection, suffer from surface corrosion, leading to a decline in insulation performance. When the operator comes into contact with the battery, an electric shock accident occurs.

Performance and life risk

1. ** Capacity decline ** : Incorrect usage methods such as frequent overdischarging, long-term undercharging or overcharging can lead to problems like sulfation of battery plates and shedding of active materials, significantly reducing the actual capacity of the battery. For instance, the forklifts of a certain enterprise continued to operate with low battery power for a long time without timely charging. After some time, the forklift, which could have worked for 8 hours on a full charge, had its working time shortened to less than 4 hours, seriously affecting work efficiency.

2. ** Shortened lifespan ** : Improper use and maintenance can significantly reduce the service life of lead-acid batteries in forklifts. Under normal circumstances, the charge and discharge cycles of lead-acid batteries can reach hundreds or even thousands of times. However, if they are frequently charged and used in high-temperature environments or frequently discharged with large currents during battery use, their lifespan may be shortened to half or even less of the original, increasing the equipment replacement costs for enterprises.

The correct way to use lead-acid batteries in forklifts

Charging link

1. ** Select the appropriate charger ** : The charging characteristics and parameter requirements of lead-acid batteries for forklifts of different brands and models may vary. Therefore, it is essential to use a dedicated charger that matches the battery. It is strictly forbidden to replace the charger at will. For instance, some forklift brands have high requirements for the accuracy of charging voltage and current in their batteries. If an unmatched charger is used, it may lead to undercharging or overcharging, thereby damaging the battery's performance.

2. ** Control the charging environment temperature ** : The optimal charging environment temperature for lead-acid batteries is around 25℃. When the temperature is too high, the chemical reaction rate inside the battery accelerates, which can lead to intensified evaporation of the electrolyte, battery water loss, and even may cause thermal runaway. When the temperature is too low, the battery's charging acceptance capacity decreases, the charging efficiency drops, and it may also cause sulfation of the battery plates. Therefore, during the hot summer days, the charging area should be set up in a well-ventilated and cool place as much as possible. If necessary, forced cooling measures can be taken, such as installing fans or air conditioners. When the temperature is low in winter, you can consider using a charger with temperature compensation function, or move the battery to a warm room for charging.

3. ** Follow the correct charging steps ** : Before charging, first check the battery's appearance for any abnormal conditions such as damage or leakage, and at the same time confirm whether the charger is connected correctly and firmly. For new batteries or those that have not been used for a long time, initial charging should be carried out. The initial charging current is usually small and the charging time is long. Generally, the operation should be carried out in accordance with the requirements of the battery manual. During normal use, after the forklift is used, it should be charged as soon as possible to avoid excessive battery discharge. During the charging process, pay close attention to parameters such as the battery's temperature, voltage and electrolyte density. When the charger shows that the battery is fully charged, the float charging time should be appropriately extended to ensure that the battery is completely charged, but overcharging should be avoided. Generally speaking, the charging time should not be too long to avoid continuous charging overnight or even for several days.

4. ** Regular equalization charging ** : For forklift lead-acid batteries used in groups, due to possible differences in performance and usage conditions among each battery, after long-term use, there may be an imbalance in voltage and capacity among the batteries. Therefore, regular equalization charging is required to eliminate the differences between batteries and extend the overall service life of the battery pack. The frequency of equalization charging is generally once every 2 to 3 months. The specific frequency can be adjusted according to the battery usage and the manufacturer's suggestions. When performing equalization charging, Settings and operations should be carried out in accordance with the operation instructions of the charger. During the charging process, pay attention to observing the battery status to ensure charging safety.

Discharge stage

1. Avoid excessive discharge: During the discharge process of forklift lead-acid batteries, their voltage and capacity will gradually decrease. When the battery voltage drops to the specified terminal voltage, discharge should be stopped immediately and charging should be carried out. If over-discharge continues, a large amount of lead sulfate will be generated on the battery plates and it will be difficult to be completely converted during the subsequent charging process, resulting in sulfation of the plates and seriously affecting the battery's capacity and lifespan. Generally speaking, forklift controllers are equipped with under-voltage protection functions. When the power meter shows a low battery level, operations should be stopped promptly and the battery charged.

2. ** Control discharge current ** : High current discharge can cause significant damage to the lead-acid battery of forklifts. During the operation of forklifts, frequent sudden acceleration, sudden braking and multiple high-load actions simultaneously should be avoided as much as possible to reduce the instantaneous large current discharge of the battery. In addition, when moving heavy objects, it is necessary to plan the moving route reasonably, avoid driving on steep slopes for a long time or frequently starting and stopping, so as to reduce the discharge current of the battery and extend its service life.

Daily maintenance link

1. ** Check the electrolyte level ** : During the charging and discharging process of lead-acid batteries, the water in the electrolyte gradually decreases due to electrolysis and evaporation, causing the electrolyte level to drop. Therefore, it is necessary to check the electrolyte level regularly, usually at least once a week. When the liquid level is found to be lower than the minimum scale line, distilled water or special lead-acid battery replenishment fluid should be replenished in time. Note that drinking purified water must never be used as a substitute for distilled water, as purified water contains various trace elements and ions, which will accelerate the self-discharge inside the battery and shorten its lifespan. When replenishing the electrolyte, use a clean plastic container to avoid impurities from mixing into the electrolyte.

2. ** Inspect the battery appearance and connection parts ** : Regularly check the battery casing for any damage, deformation, leakage, etc. If any of these are found, timely repair or replacement should be carried out to prevent electrolyte leakage from causing damage to surrounding equipment and the environment. At the same time, it is necessary to check whether the battery terminals, connection strips and other parts are loose or corroded. If they are loose, they should be tightened in time. If they are corroded, they should be cleaned with a special cleaning agent and protective grease should be applied to ensure good connection, reduce contact resistance and prevent problems such as heating and sparking caused by poor contact.

3. ** Clean battery surface ** : Keeping the battery surface clean and dry helps prevent leakage and corrosion on the battery surface. Regularly wipe the battery surface with a damp cloth to remove dust, dirt and residual electrolyte. Note that during the cleaning process, avoid using dry cloths or brushes to prevent the generation of static electricity and potential dangers. At the same time, it is necessary to ensure that the ventilation holes of the battery are unobstructed to prevent the accumulation of gas inside the battery due to the blockage of the ventilation holes, which may cause safety accidents.

4. ** Regular deep discharge and activation ** : To maintain the battery's activity and extend its service life, it is advisable to conduct a deep discharge and activation treatment on the forklift lead-acid battery at regular intervals. It is generally recommended to do it once every 2 to 3 months. The specific frequency can be adjusted according to the battery usage and the manufacturer's suggestions. The method of deep discharge is to operate the forklift on a flat road under normal load conditions until the first undervoltage protection is achieved, and then fully charge the battery. During the charging process, some battery activation devices or methods, such as pulse charging, can be adopted to enhance the battery's activity and restore part of its capacity.

Conclusion

The correct use of lead-acid batteries for forklifts is the key to ensuring the safe and efficient operation of forklifts, extending the battery's service life and reducing operating costs. By understanding the working principle and structure of batteries, recognizing the safety risks and performance life risks brought about by incorrect use, and strictly following the correct charging, discharging and daily maintenance methods, various risks can be effectively avoided. Meanwhile, enterprises should enhance the training of forklift operators and maintenance personnel, improve their safety awareness and operational skills, regularly inspect and maintain the lead-acid batteries of forklifts, and promptly identify and solve potential problems. Only in this way can the performance advantages of forklift lead-acid batteries be fully exerted, providing reliable power support for the production and operation of enterprises.