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Abstract

This article discusses in detail the precautions for equalization charging of lead-acid batteries used in forklifts, analyzes the principle and necessity of equalization charging, and puts forward specific operation steps and precautions. Through reasonable balanced charging management, the service life of the battery can be significantly prolonged and the working efficiency of the forklift can be improved. The research results show that the correct equalization charging method can effectively prevent the inconsistency of individual batteries in the battery pack, avoid overcharging and undercharging phenomena, and thus ensure the stable operation of the forklift power system.

Introduction

Lead-acid batteries, as the main power source of forklifts, their performance directly affects the working efficiency and operating costs of forklifts. During actual use, due to the influence of factors such as manufacturing processes, usage environments, and charge and discharge cycles, the voltage and capacity of each individual battery in the battery pack often become inconsistent. If this inconsistency is not corrected in time, it will lead to overcharging or undercharging of some batteries, thereby accelerating battery aging and shortening the overall service life. Equalization charging technology is precisely the solution proposed for this problem. It enables each individual battery to reach a relatively consistent state by charging the battery pack in a differentiated way. This article will systematically introduce the precautions for equalizing the charging of lead-acid batteries used in forklifts, providing practical references for relevant technicians.

1. The Basic Principle of Equalization Charging for Lead-Acid Batteries

The basic principle of equalization charging for lead-acid batteries is to make the voltage and capacity of each individual battery in the battery pack tend to be consistent through a specific charging strategy. During the conventional charging process, due to the differences in parameters such as the internal resistance and self-discharge rate of each individual battery in the battery pack, the charging acceptance capacity will vary. Equalization charging enables undercharged batteries to obtain more energy by extending the charging time, increasing the charging voltage or using pulse charging, while preventing other batteries from overcharging.

From an electrochemical perspective, equalization charging essentially aims to balance the concentration of the electrolyte in each individual battery and the state of the active material on the plates. When there is a voltage difference in the battery pack, the high-voltage battery will release energy to the low-voltage battery through the balancing circuit, or allow the low-voltage battery to obtain more charging capacity by extending the charging time. This process requires precise control. It is necessary to ensure that low-charge batteries are fully charged while preventing high-charge batteries from being damaged due to overcharging.

2. The Necessity of Equalizing Charging Forklift Batteries

Equalization charging of lead-acid batteries used in forklifts has multiple necessities. Firstly, the inconsistency of each individual battery in the battery pack will significantly affect the overall performance. When some batteries are in an undercharged state for a long time, their capacity will gradually decline, resulting in a decrease in the effective capacity of the entire battery pack. On the contrary, batteries that have been overcharged for a long time will encounter problems such as the drying up of the electrolyte and the corrosion of the plates. Regular equalization charging can effectively alleviate these adverse phenomena.

Secondly, equalization charging can extend the service life of battery packs. Studies show that the cycle life of a battery pack that has been reasonably balanced can be increased by 20% to 30% compared with an unbalanced battery pack. This is of great significance for reducing the operating cost of forklifts. In addition, a well-balanced battery pack can provide a more stable voltage output, ensuring the smooth operation of the forklift's power system and avoiding equipment failures caused by voltage fluctuations.

Finally, from a safety perspective, equalization charging can prevent individual batteries from generating a large amount of gas due to overcharging and reduce the risk of explosion. At the same time, it can also prevent the sulfation of the plates caused by the over-discharge of individual batteries and maintain the healthy state of the batteries.

3. Specific operation steps for equalization Charging

The implementation of equalization charging for lead-acid batteries used in forklifts requires following scientific operation procedures. First of all, equalization charging should be carried out after the regular charging is completed. Increase the charging voltage to the equilibrium voltage and maintain this voltage until the charging current drops to the set value. This stage may take 6 to 8 hours, with the exact time depending on the degree of battery imbalance.

Secondly, during the equalization charging process, it is necessary to closely monitor the voltage and temperature of each individual battery. It is recommended to record the data every 30 minutes to ensure that there is no abnormal temperature rise or excessive voltage in the battery. If it is found that the voltage of a certain single battery is significantly higher than that of other batteries, it should be considered to suspend the equalization charging and check whether there is a fault with the battery.

Finally, after the equalization charging is completed, the battery should be left to stand for 1 to 2 hours until the voltage stabilizes before being put into use. It is also recommended to carry out equalization charging once a month. For forklifts with high usage frequency, the interval can be appropriately shortened.

4. Precautions during the Equalization Charging Process

When performing equalization charging, there are several key points that require special attention. First is the environmental temperature control. The optimal charging temperature range is 15-30℃. Excessively high temperatures will accelerate battery aging, while excessively low temperatures will affect charging efficiency. In extreme temperature environments, corresponding insulation or cooling measures should be taken.

The second is the selection of charging equipment. An intelligent charger with equalization charging function should be selected to ensure the stability of its output voltage and current. Poor-quality charging equipment may lead to poor balancing effects and even damage the battery. At the same time, the voltage and current measurement accuracy of the charging equipment should be calibrated regularly.

In addition, a comprehensive inspection of the battery pack should be carried out before equalization charging, including the electrolyte level, battery appearance and the condition of the connecting parts, etc. If any abnormality is found, it should be dealt with first before charging. For open-type lead-acid batteries, it is also necessary to check whether the vent holes are unobstructed to ensure that the gases produced during the charging process can be smoothly discharged.

Finally, the safety protection of the operators should not be ignored either. Protective glasses and gloves should be worn to avoid contact with the electrolyte. The charging area should be well-ventilated and kept away from open flames and spark sources.

5. Evaluation of Equalization Charging Effect and Maintenance Suggestions

The effect of equalization charging is mainly evaluated by measuring the voltage difference of each individual battery before and after charging. The ideal equilibrium result should keep the voltage difference within ±0.05V. If the voltage difference remains large after equalization, it may be necessary to check whether there are any individual cells with severely deteriorated performance in the battery pack and consider replacement.

To maintain a good balanced state, it is recommended to establish a complete battery maintenance file to record the data of each balanced charge. Through long-term tracking, the changing trend of battery performance can be discovered in a timely manner. At the same time, in daily use, deep discharge should be avoided. It is advisable to charge when the battery remains at 20% to 30%.

For battery packs that have been in use for more than two years, the frequency of equalization charging should be increased. When it is found that the capacity of the battery pack has declined to less than 80% of its initial capacity, it is necessary to consider replacing the entire battery pack to ensure the normal working performance of the forklift.

6. Conclusion

Equalization charging of lead-acid batteries used in forklifts is an important measure to extend battery life and ensure the normal operation of equipment. By understanding the principle of equalization charging, mastering the correct operation method, and paying attention to relevant matters, the overall performance and service life of the battery pack can be effectively improved. It is recommended that forklift users incorporate equalization charging into their regular maintenance plans, carry it out regularly, and keep relevant records. Meanwhile, with the development of battery technology, more advanced equalization charging technologies and equipment may emerge in the future, which are worth continuous attention and adoption. Only by managing the battery scientifically and reasonably can the working efficiency of the forklift be maximized and the operating cost be reduced.