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Introduction

In the field of industrial logistics, forklifts, as key handling equipment, the reliability of their power sources is of vital importance. Lead-acid batteries have become the mainstream choice for forklift power due to their advantages such as mature technology, low cost, and good high-rate discharge performance. However, as the usage time increases, the performance of lead-acid batteries often gradually declines, which not only affects the working efficiency of forklifts but may also increase operating costs. Therefore, a thorough understanding of the performance optimization methods and maintenance skills of forklift lead-acid batteries is of great significance for ensuring the efficient and stable operation of forklifts, extending the service life of batteries, and reducing the operating costs of enterprises.

Performance optimization strategy

Reasonable charging management

1. ** Choose the appropriate charger ** : Different types of chargers have a significant impact on the charging effect and lifespan of the battery. A charger that matches the specifications of the battery should be selected, such as one that can automatically identify the type of battery, monitor parameters like battery voltage, capacity, load quantity, and temperature, and has an automatic temperature compensation function. In summer, the battery temperature is relatively high. Conventional chargers without temperature compensation may cause overcharging of the battery, affecting its performance and lifespan. However, chargers with automatic temperature compensation can adjust charging parameters according to the battery temperature, achieving more precise and gentle charging and effectively protecting the battery.

2. ** Control charging current and time ** : When charging a new battery for the first time, the current should be small, generally around 0.1C. The charging time should last for 20 to 30 hours. This can ensure that the plates are fully vulcanized, thereby enhancing the battery's capacity and service life. When charging normally, a two-stage charging method can be adopted. In the first stage, a large current is used for rapid charging. Once the battery voltage rises to a certain value, it switches to the second stage and a smaller current is used for supplementary charging until the battery is fully charged. Avoid overcharging. Overcharging will cause a large amount of gas to be produced inside the battery, leading to water loss in the electrolyte and accelerated corrosion of the plates, thus shortening the battery's lifespan.

3. ** Regular equalization charging ** : For batteries used in groups, due to the differences in the characteristics of each individual battery, imbalance may occur after long-term use. Equalization charging can prevent sulfation faults in batteries and reduce the imbalance of battery packs.

Optimize the usage environment

1. ** Temperature Control ** : The optimal operating temperature for lead-acid batteries is around 25℃. When the temperature is too high, the chemical reactions inside the battery intensify, which will accelerate the corrosion of the plates. At the same time, the evaporation of water speeds up, causing the electrolyte to dry up and shortening the battery's lifespan. When the temperature is too low, the viscosity of the electrolyte increases, the diffusion rate of ions slows down, the internal resistance of the battery increases, and the charging and discharging performance declines. In summer, forklifts should be parked in a cool and well-ventilated area as much as possible. They should not be charged immediately after being exposed to direct sunlight. Measures such as using sunshades can be adopted to lower the battery temperature. In winter, if the ambient temperature is too low, it is advisable to install a heating device for the battery or park the forklift in a warm indoor area to increase the battery's working temperature and ensure its stable performance.

2. ** Avoid vibration and shock ** : During operation, forklifts are bound to encounter bumpy roads. Strong vibration and shock may cause deformation of battery plates, shedding of active substances, damage the internal structure of the battery, and affect battery performance. Therefore, when driving a forklift, one should operate it as smoothly as possible and avoid violent actions such as sudden braking and sharp turns. At the same time, regularly check the installation and fixation of the battery to ensure that it is firmly installed on the forklift and reduce the impact of vibration on the battery.

Improve battery design and technology

1. ** Adoption of new plate materials ** : Some advanced lead-acid batteries have adopted improved plate materials, such as adding silver to the positive plate grid, which can enhance the electrical conductivity by 12%, reduce resistance, decrease energy loss, and improve the charging and discharging efficiency of the battery; Incorporating nano-carbon materials into the negative electrode active material can extend the cycle life by 30% and enhance the durability of the battery.

2. ** Optimize the electrolyte formula ** : By optimizing the electrolyte formula, the low-temperature discharge efficiency of the battery can be enhanced. At the same time, an appropriate electrolyte density is also crucial for battery performance. The electrolyte density should be reasonably adjusted according to different usage environments and working conditions.

Maintenance skills

Regular inspection and maintenance

1. ** Electrolyte Inspection ** : Regularly check the electrolyte level. For liquid-rich batteries, it is generally necessary to check once every ten charges or so. Especially during the hot summer period, the battery water consumption increases. It is necessary to appropriately shorten the inspection time and increase the frequency of water addition. When the liquid level is too low, the plates will suffer irreversible damage due to contact with air, resulting in reduced capacity, shortened service life, and may also cause the battery to overheat. When adding water, deionized water or distilled water should be used, and it should be added to the maximum liquid level mark. This should be done 20 minutes after charging or before the end of charging. It is strictly forbidden to add water before charging. At the same time, measure the density of the electrolyte regularly. Under normal circumstances, the density of the electrolyte should be between 1.28g/cm³ (at 25℃). Both excessively high and low densities may affect the battery performance. This can be adjusted by adding distilled water or sulfuric acid solution.

2. ** Battery Appearance Inspection ** : Before each use of the forklift, check whether the battery casing has any cracks, leaks, etc. If the casing is found to be damaged, it should be replaced in time to prevent electrolyte leakage from causing environmental pollution and equipment corrosion. Check if there is any corrosion on the battery terminals. If the terminals are corroded, it will increase the contact resistance and affect the charging and discharging effect. You can gently sand the terminals with sandpaper to remove the corrosion, and then apply protective agents such as Vaseline. In addition, it is necessary to check whether the battery connection wires are loose or damaged to ensure a firm connection and good insulation of the wires.

3. ** Discharge Degree Monitoring ** : Use a professional battery tester to regularly check the discharge degree of the battery. It is strictly prohibited for the depth of battery discharge to exceed 80% of the rated capacity. Excessive discharge can cause sulfation of the battery plates, resulting in the formation of sulfate crystals on the plate surface, blocking the plate pores and making it difficult for the electrolyte to penetrate, leading to a reduction in capacity. Moreover, this kind of damage is often irreversible. When the battery power drops to around 20%, use should be stopped immediately and charging should be carried out to prevent damage to the battery caused by prolonged insufficient power.

Fault diagnosis and handling

1. ** Plate sulfation ** : Plate sulfation is one of the common faults of lead-acid batteries, characterized by a significant reduction in capacity during normal discharge, a rapid increase in voltage during charging, premature formation of bubbles, and a quick rise in electrolyte temperature, etc. The main causes of plate sulfation include excessive discharge, insufficient long-term charging, and too low electrolyte level, etc. For batteries with mild sulfation, overcharging can be adopted for restoration, that is, charging for a long time with a current slightly larger than the normal charging current. For batteries with heavy sulfation, the low-current charging method can be adopted, that is, charging at a low current of 0.05C - 0.1C for a long time, or water therapy can be used. First, discharge the battery to the terminal voltage, then pour out the electrolyte, rinse it repeatedly with distilled water several times, and then add distilled water to the specified liquid level and charge it with a low current. When the density of the electrolyte rises to approximately 1.15g/cm³, pour out the electrolyte, replace it with electrolyte of standard density, and continue charging until fully charged.

2. ** Active Substance shedding ** : The shedding of active substances can lead to low battery voltage, reduced capacity, and the presence of brown substances in the electrolyte during charging. Excessive charging current, overcharging, and excessive battery vibration can all cause the active substances to fall off. To prevent the shedding of active substances, the charging current should be well controlled to avoid overcharging and reduce the vibration during the forklift's operation. For batteries with severe shedding of active substances, the plates and electrolyte need to be replaced. The electrode group should be removed from the battery cell, the damaged plates should be replaced, the battery cell should be cleaned, and the electrolyte that meets the standards should be added again. Then, charging and debugging should be carried out.

3. ** Internal Short circuit ** : When there is an internal short circuit in the battery, the charging voltage is low, the discharging capacity is low, the voltage drops rapidly during discharging, the voltage and density increase slowly during charging, and the temperature of the electrolyte is high during the charging and discharging process. The causes of internal short circuits include conductive objects falling into the battery, damaged separators, and lead accumulation on the plates, etc. After discovering an internal short circuit in the battery, the first step is to check if there are any conductive objects falling into the battery. If so, remove them. If the short circuit is caused by excessive lead fluff or shed substances, the electrode group needs to be lifted out, the short-circuited substances removed and new electrolyte replaced. If the separator is damaged, the pole group should be separated and the damaged separator should be replaced.

Conclusion

The performance optimization and maintenance of lead-acid batteries in forklifts is a systematic project, involving multiple aspects such as reasonable charging management, optimizing the usage environment, improving battery design and technology, as well as regular inspection and maintenance and fault diagnosis and handling. By taking scientific and effective measures, the performance of lead-acid batteries can be significantly improved, their service life can be prolonged, and the operating costs of enterprises can be reduced. In practical applications, enterprises should formulate personalized performance optimization and maintenance plans based on the usage conditions and working conditions of their forklifts, and strengthen the training of relevant personnel to ensure that all measures are effectively implemented. Meanwhile, with the continuous advancement of technology, new battery technologies are constantly emerging. Enterprises can also pay attention to industry trends and introduce more advanced power solutions in a timely manner to meet the evolving demands of logistics operations.