Performance parameters of lead-acid batteries for forklifts: capacity and voltage

Time：2025-06-28 16:00:48

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A thorough understanding of these parameters is of great guiding significance for the selection, use and maintenance of forklifts.

Introduction

As an indispensable handling equipment in modern logistics and industrial production, the power source of forklifts is of vital importance. Lead-acid batteries occupy an important position in the field of forklift power due to their advantages such as mature technology, relatively low cost and stable performance. There are numerous performance parameters for lead-acid batteries in forklifts, among which capacity, voltage and cold start current are the most crucial ones. They directly affect the working efficiency, endurance and starting performance of forklifts under different working conditions. A thorough understanding of these parameters is of great guiding significance for the selection, use and maintenance of forklifts.

Capacity parameter

Definition and Unit

Capacity refers to the amount of electricity a battery can release under certain discharge conditions, and its unit is usually ampere-hours.

Influencing factors

1. ** Discharge current ** : The greater the discharge current, the lower the actual available capacity of the battery. This is because when a large current is discharged, the chemical reaction rate inside the battery increases, which intensifies the electrode polarization phenomenon, increases the internal resistance of the battery, and thus reduces the amount of electricity the battery can output. For instance, for the same battery, its capacity might be 400Ah when discharged at a 5-hour rate, but it could drop to around 300Ah when discharged at a 1-hour rate.

2. ** Electrolyte temperature ** : Temperature has a significant impact on battery capacity. Within a certain range, as the temperature rises, the battery capacity increases. When the temperature drops, the battery capacity decreases. This is because temperature affects the conductivity of the electrolyte and the activity of the electrode material. Generally speaking, the optimal operating temperature for lead-acid batteries is around 25℃. When the temperature drops below 0℃, the battery capacity may decrease by 20% to 30%. When the temperature exceeds 40℃, although the capacity will increase, it will accelerate the aging and water loss of the battery, affecting its lifespan.

3. ** Electrolyte density ** : There is also a certain relationship between the electrolyte density and the battery capacity. An appropriate electrolyte density can ensure the smooth progress of chemical reactions inside the battery, thereby increasing the battery capacity. Under normal circumstances, when a lead-acid battery is fully charged, the density of the electrolyte is around 1.28 (at 25℃). As the discharge proceeds, the density of the electrolyte gradually decreases. When it drops to around 1.15g/cm³, the battery is basically discharged completely.

The impact on forklift operation

1. ** Endurance capacity ** : Capacity is the key factor determining the endurance capacity of a forklift. The larger the capacity, the longer the forklift can work continuously after a single charge, and the farther the distance it can handle goods. In large logistics warehouses or factories, forklifts need to operate continuously for long periods of time. At such times, high-capacity batteries can reduce the number of charging cycles and enhance work efficiency.

2. ** Load capacity ** : To a certain extent, battery capacity also affects the load capacity of forklifts. When forklifts handle heavy goods, greater power output is required, which demands that the battery be able to provide sufficient current. High-capacity batteries usually can provide a larger discharge current in a short time to meet the power demand of forklifts when lifting heavy objects, thus ensuring that forklifts can successfully complete heavy-load handling tasks.

Voltage parameter

Common voltage specifications

The voltage specifications of lead-acid batteries for forklifts are diverse, with common ones including 24V, 36V, 48V, 72V and 80V, etc. These different voltage specifications are designed based on the type of forklift, load capacity and usage scenarios. Generally speaking, small electric forklifts or light handling equipment mostly use 24V or 36V batteries, such as electric pallet trucks, etc. Medium and large forklifts, especially counterbalanced forklifts used for handling heavy goods, often employ 48V, 72V or 80V batteries.

The relationship between voltage and forklift performance

1. Power Output: Voltage directly affects the power output of forklifts. According to Ohm's Law, when the current is constant, the higher the voltage, the greater the power that the battery can output, and the stronger the power of the forklift will be. This enables high-voltage forklifts to handle heavier goods and perform better in conditions such as acceleration and climbing.

2. ** Motor Efficiency ** : An appropriate voltage can enhance the operational efficiency of the motor. Different motors have their suitable voltage ranges. When the battery voltage matches the rated voltage of the motor, the motor can operate in the best condition, with high energy conversion efficiency and less heat generation, thereby extending the service life of the motor. If the voltage is too low, the motor needs to increase the current to output sufficient power, which will cause the motor to overheat, reduce efficiency, and may even damage the motor. However, if the voltage is too high, it may damage the insulation of the motor and also affect its normal operation.

Charging and voltage changes

1. ** Voltage Changes during Charging ** : When charging the lead-acid battery of a forklift, the battery voltage will gradually increase as the charging proceeds. In the initial stage, the voltage rises rapidly. As the battery is gradually fully charged, the rate of voltage rise gradually slows down. When the battery is fully charged, the voltage reaches its maximum value. The voltage at this time is called the float voltage.

2. ** Voltage Variation during Discharge ** : During the discharge process, the battery voltage will gradually decrease. As the depth of discharge increases, the rate of voltage drop will gradually accelerate. When the voltage drops to a certain extent, it indicates that the battery power is about to run out and needs to be charged. Generally speaking, when the voltage of a 48V battery pack drops to around 42-44V, it is necessary to charge it in time. Otherwise, excessive discharge will cause irreversible damage to the battery and shorten its lifespan.

The interrelationship between capacity and voltage

The relationship between capacity and voltage

In the same type of lead-acid batteries, there is a certain correlation between capacity and voltage. Generally speaking, the higher the voltage of a battery pack, the more individual cells are connected in series inside, and the capacity of each individual cell is basically the same. Therefore, under the condition of meeting the same power demand, high-voltage battery packs can transmit electrical energy with less current, thereby reducing line losses and improving energy utilization efficiency. Meanwhile, high-voltage battery packs usually also support larger-capacity battery configurations to meet the demands of forklifts for long-term and high-load operation.

Conclusion

The capacity and voltage parameters of lead-acid batteries in forklifts are the key factors affecting the performance of forklifts. Capacity determines the endurance and load capacity of a forklift, while voltage affects the power output and motor efficiency of the forklift. These two parameters are interrelated and jointly affect the actual working performance of the forklift. In the process of selecting, using and maintaining forklifts, fully considering these parameters, rationally configuring batteries and taking effective maintenance measures can improve the working efficiency of forklifts, extend the service life of batteries and reduce operating costs. With the continuous advancement of technology, the technology of lead-acid batteries for forklifts is also constantly developing. In the future, it is expected that battery products with larger capacity, higher and better voltage, as well as greater environmental friendliness and efficiency will emerge, injecting new vitality into the development of the forklift industry.

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