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Introduction

In modern logistics and industrial production, forklifts, as key material handling equipment, are widely used. Among them, electric forklifts have seen their market share continuously rise due to their advantages such as environmental friendliness and low noise. As the core power source of electric forklifts, the safe use of lead-acid batteries not only affects the normal operation and service life of the forklifts, but is also closely related to the personal safety of the operators and the safe environment of the workplace. Due to the fact that lead-acid batteries involve the conversion of chemical energy to electrical energy, there are certain risks during their use. If not operated in a standardized manner, it may cause serious accidents such as leakage, explosion and electric shock. Therefore, it is of vital importance to formulate and follow strict safety usage norms.

Characteristics of lead-acid batteries

Characteristics

1. ** Voltage Characteristics ** : The nominal voltage of a single lead-acid battery cell is usually 2V. The battery packs used in forklifts are composed of multiple cells connected in series to meet the different voltage requirements of forklifts. Common ones include 24V, 36V, 48V, etc. During the discharge process, the battery voltage will gradually drop. When it drops to a certain extent (the discharge termination voltage), it is necessary to charge it in time; otherwise, it will cause irreversible damage to the battery.

2. ** Capacity Characteristics ** : Battery capacity indicates its ability to store electrical energy, with the unit being ampere-hours (Ah). The capacity of the lead-acid battery in a forklift determines the working duration and load capacity of the forklift after a single charge. Generally speaking, the larger the capacity, the longer the forklift can work continuously, and the greater the weight of the goods it can handle. However, in actual use, the battery capacity is affected by factors such as the size of the discharge current, temperature, and service life. When discharging at a large current, the actual capacity that the battery can discharge will be less than the nominal capacity. When the temperature is too low, the viscosity of the electrolyte increases, the diffusion rate of ions slows down, and the battery capacity will also significantly decrease.

3. ** Self-discharge Characteristic ** : Even when not in use, lead-acid batteries will slowly discharge due to internal chemical reactions. This phenomenon is called self-discharge. The self-discharge rate is related to the quality of the battery, the purity of the electrolyte, the storage temperature, etc. Generally, the higher the temperature, the faster the self-discharge. Batteries that have been stored for a long time without timely recharging may experience sulfation of the plates due to excessive self-discharge, thereby shortening their lifespan.

Safety Usage Specifications

Daily inspection

1. ** Visual Inspection ** : Before each use of the forklift, the operator must carefully inspect the appearance of the battery. Check whether the battery casing is damaged, deformed, or leaking acid, etc. If the casing is found to be damaged, the leakage of acid solution will not only corrode the surrounding equipment and the ground, but also may cause burns to the operators. At the same time, check whether the battery connection strips and terminals are loose or corroded. Loose connection parts can lead to an increase in contact resistance, causing overheating during charging and discharging, and even triggering a fire. Terminal post corrosion can affect current conduction and reduce battery performance. Once a problem is found, the corrosive substances should be cleaned up in time and the connection parts should be tightened. If the casing is severely damaged, the battery needs to be replaced.

2. ** Liquid Level Check ** : During the charging and discharging process of lead-acid batteries, the moisture in the electrolyte will gradually decrease due to electrolysis and evaporation. Therefore, it is necessary to regularly check the liquid level of the electrolyte. Under normal circumstances, the liquid level should be 10 to 15mm higher than the plates. It can be judged through the liquid level indicator line on the battery casing or a dedicated liquid level measuring tool. If the liquid level is too low, the plates will be exposed to the air, causing sulfation of the plates and shortening the battery life. At this point, distilled water or special lead-acid battery replenishment liquid should be added. It is strictly forbidden to add ordinary tap water or sulfuric acid solution, because impurities in tap water may accelerate the self-discharge reaction inside the battery, and adding sulfuric acid at will will change the density of the electrolyte and affect the battery performance.

3. ** Voltage Check ** : Use a professional battery voltmeter to regularly measure the total voltage of the battery pack and the voltage of each individual battery. When the forklift is stationary and the battery is fully charged, the voltage of a single battery should be close to about 2.1V - 2.2V. If the total voltage of the battery pack is lower than the normal range, or the voltage difference between individual cells exceeds 0.1V, it indicates that there may be problems with the batteries, such as aging of individual cells or increased internal resistance. For batteries with abnormal voltage, further inspection and analysis are required. If necessary, repair or replacement should be carried out.

Charging operation

1. ** Charging environment ** : The charging area should have good ventilation conditions, as lead-acid batteries produce gases such as hydrogen and oxygen during the charging process. Hydrogen is flammable and explosive. When the hydrogen content in the air reaches 4% to 75%, it is very likely to cause an explosion when exposed to open flames or sparks. Therefore, the charging area should be kept away from fire sources and heat sources. Smoking and open flame operations are strictly prohibited. Meanwhile, the charging area should be kept dry to prevent water from splashing onto the battery or charger, which could lead to short circuits and electric shock accidents. The ground is best laid with anti-slip and corrosion-resistant materials to ensure the safety of the operators.

2. ** Charger Selection ** : A charger that matches the model and specification of the forklift's lead-acid battery must be used. The charging requirements of batteries of different brands and models vary. Using an unmatched charger may cause the battery to be overcharged or undercharged. Overcharging can cause the battery to heat up, the electrolyte to boil, accelerate the aging of the plates, and even lead to battery bulging and explosion. Undercharging will cause the battery to be undercharged, resulting in a decrease in capacity and a shortened service life. Before connecting the charger, carefully check whether the parameters of the charger are consistent with the battery requirements.

3. ** Charging Steps ** : Before charging, park the forklift at the designated charging position, turn off the power of the forklift, pull up the handbrake, and ensure that the vehicle is in a safe stationary state. Then, open the battery box cover to ensure good ventilation of the battery. Connect the plug of the charger correctly to the charging socket of the battery pack. Be careful not to reverse the positive and negative terminals, as doing so may damage the charger and the battery. After the connection is completed, turn on the charger power. At this point, the charger will automatically adjust the charging parameters according to the battery's status and start charging. During the charging process, closely monitor the indicator light status of the charger and the charging condition of the battery, such as whether there are any abnormal heating, smoking, electrolyte overflow or other phenomena. After the charging is completed, first turn off the power of the charger, then unplug the charger plug, and finally close the battery box cover.

4. ** Charging Time ** : The charging time of lead-acid batteries should be reasonably controlled based on the remaining power, capacity of the battery and the charging current of the charger. Generally speaking, the charging time of forklift batteries is about 8 to 10 hours, but this is not a fixed value. If the battery discharge depth is relatively shallow, the charging time can be appropriately shortened. If the depth of discharge is relatively large, the charging time needs to be extended. Avoid overcharging and overdischarging. Overdischarging can cause sulfation of the plates, while overcharging can lead to water loss and overheating of the battery. To better control the charging time, the battery management system can be used or the charging and discharging data of the battery can be recorded regularly to summarize the charging rules suitable for the battery of this forklift.

Maintenance and upkeep

1. ** Electrolyte Maintenance ** : Regularly check the density of the electrolyte. Under normal circumstances, the density of the electrolyte in lead-acid batteries is 1.28g/cm³ (at 25℃). Both excessively high and low electrolyte density can affect battery performance. Excessively high density will accelerate the corrosion of the plates. If the density is too low, the battery capacity will decline. The density of the electrolyte can be measured with a dedicated hydrometer. If the density does not meet the requirements, it can be adjusted by adding distilled water or sulfuric acid solution. However, when making adjustments, one must operate with caution. First, measure the temperature of the electrolyte, make corrections based on the influence of temperature on density, and then proceed with the adjustment. At the same time, it is necessary to ensure that the added sulfuric acid solution has a high purity and no impurities.

2. ** Cleaning and Maintenance ** : Keep the battery surface clean and dry to prevent dust and impurities from accumulating on the battery surface, which may cause leakage and short circuit. Regularly wipe the battery casing, connecting strips and terminals with a clean damp cloth to remove acid, dirt and other impurities on the surface. Avoid using organic solvents or hard-bristled brushes to clean the battery to prevent damage to the battery casing and terminals. The interior of the battery box should also be cleaned regularly to prevent the accumulation of acid from corroding the box. During the cleaning process, if any traces of acid leakage are found on the battery surface, they should be cleaned up promptly and the cause of the leakage identified for repair.

3. ** Balanced Charging ** : As the lead-acid battery pack of forklifts is composed of multiple individual cells connected in series, during long-term use, the charging and discharging conditions of each individual cell may become inconsistent, resulting in overcharging or undercharging of some cells. In order to ensure that all individual batteries can maintain a good performance state, regular equalization charging is required. Equalization charging is generally carried out once a month. The specific method is to continue charging with a small current for a period of time after the normal charging is completed, so that the voltage and capacity of each individual battery reach equilibrium. Through equalization charging, the overall service life of the battery pack can be effectively prolonged and the working performance of the forklift can be improved.

4. ** Storage and Maintenance ** : If the lead-acid battery of the forklift needs to be stored for a long time, it should be fully charged first, and then a supplementary charge should be carried out every two weeks to prevent the battery from being overly discharged due to self-discharge. The storage environment temperature should be maintained between 5℃ and 40℃. If the temperature is too high, it will accelerate the self-discharge of the battery; if it is too low, it may cause the electrolyte to freeze and damage the battery. Batteries should be stored in a dry, well-ventilated and clean place, avoiding direct sunlight and contact with corrosive substances. When reusing batteries that have been stored for a long time, it is necessary to first check the battery's appearance, liquid level, voltage, etc., carry out necessary maintenance and care, and then conduct charge and discharge tests. Only after confirming that the battery performance is normal can it be put into use.

Safety protection

1. ** Personnel Protective Equipment ** : When operators perform operations related to lead-acid batteries, they must wear complete personal protective equipment. Including acid-resistant gloves to prevent hands from coming into contact with acid and causing burns; Protective glasses to protect the eyes from acid splashes. Acid-resistant work clothes to prevent the body from being corroded by acid. Acid-resistant rubber shoes ensure the safety of your feet. At the same time, operators should be familiar with the correct usage methods and precautions of protective equipment, and regularly check the integrity of the protective equipment. If there is any damage or aging, it should be replaced in time.

2. ** Anti-electric shock Measures ** : Although lead-acid batteries have relatively low voltage, there is still a risk of electric shock during charging and maintenance. Therefore, before operation, make sure your hands are dry and avoid touching batteries and electrical equipment with wet hands. When connecting or disconnecting the charger plug, checking the battery terminals and other operations, use insulated tools to prevent direct contact with live parts. At the same time, regular inspections and maintenance of the electrical system of the forklift should be carried out to ensure that the wires, plugs, sockets, etc. are free from damage, aging, short circuits and other problems, so as to prevent electric leakage accidents. Clear warning signs should be set up in the charging area to remind people to pay attention to the safety of electric shock.

3. ** Emergency Response Measures ** : The workplace should be equipped with necessary emergency rescue equipment and supplies, such as alkaline solutions for neutralizing acids, a large amount of clean water for rinsing the eyes and body, first aid kits, etc. At the same time, a complete emergency response plan should be formulated and the operators should be trained to be familiar with the emergency handling procedures in case of emergency situations such as acid leakage, electric shock and fire. In the event of an accident, the operator should immediately stop the operation and handle the situation in accordance with the emergency plan, such as quickly evacuating irrelevant personnel from the scene, providing emergency treatment to the injured, and promptly reporting to the relevant departments to take effective measures to control the expansion of the accident.

Conclusion

The safe use of lead-acid batteries in forklifts is the key to ensuring the efficient operation of forklifts, extending the battery's service life and guaranteeing workplace safety. By having a thorough understanding of the working principle and characteristics of lead-acid batteries and strictly following the safety usage norms in each link such as daily inspection, charging operation, maintenance and care, as well as safety protection, the risks during the usage process can be effectively reduced and the possibility of accidents can be decreased. Meanwhile, operators should constantly enhance their safety awareness and operational skills, regularly inspect and maintain batteries and related equipment, and promptly identify and resolve potential issues. Only in this way can the advantages of lead-acid batteries in forklift applications be fully exerted, providing reliable and safe power support for logistics and industrial production.