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In the modern logistics and warehousing field, forklifts, as indispensable handling equipment, the performance and lifespan of their power core lead-acid batteries directly affect the operational efficiency and cost control of enterprises. The procurement cost of a set of lead-acid batteries is relatively high. Frequent replacement not only increases capital investment but also affects the normal use of forklifts and reduces work efficiency. Therefore, mastering scientific and effective methods to extend the lifespan of lead-acid batteries in forklifts has become an important issue in enterprise equipment management. This article will start from the working principle of lead-acid batteries and the factors affecting their lifespan, and elaborate in detail on practical strategies for extending their service life.

1. Key Factors Affecting the Lifespan of Lead-Acid Batteries in Forklifts

(1) Improper management of charging and discharging

Overdischarge and overcharging are the main killers affecting the lifespan of lead-acid batteries. When the forklift is in operation and the battery power is excessively consumed, and the voltage drops below the specified minimum limit but it is still used, it will cause a large amount of lead sulfate on the plates to crystallize, resulting in irreversible sulfation, which leads to a reduction in the active material on the plates and a decrease in battery capacity. Overcharging, however, will cause the battery to heat up, accelerate the evaporation of water in the electrolyte, intensify the corrosion and aging of the plates, and shorten the battery's lifespan.

(2) Poor condition of the electrolyte

The density and level of the electrolyte are crucial to the performance of the battery. Both excessively high and low densities of the electrolyte will affect the chemical reaction efficiency of the battery. If the electrolyte level is too low and the plates are exposed to the air, it will cause the plates to oxidize and the active substances to lose their effectiveness. In addition, impurities mixed in the electrolyte can also cause self-discharge, reducing the battery's energy storage capacity.

(3) Use environmental factors

The working environment of forklifts is complex and diverse. Factors such as temperature, humidity and vibration can all affect the lifespan of lead-acid batteries. Under high-temperature conditions, the rate of chemical reactions inside the battery accelerates, the evaporation of the electrolyte intensifies, and the corrosion of the plates speeds up. Low-temperature environments will slow down the chemical reaction rate of batteries, reduce their output power, and long-term exposure to low-temperature conditions may even cause batteries to crack due to freezing. A working environment with frequent vibrations can cause the internal connection components of the battery to loosen, affecting its normal operation.

(4) Lack of daily maintenance

Lack of regular inspection and maintenance makes it impossible to detect problems with the battery in a timely manner. For instance, failure to replenish distilled water in a timely manner, clean the dust and electrolyte residue on the battery surface will lead to increased self-discharge of the battery, corrosion of the casing, and thereby affect the battery's performance and lifespan.

2. Practical Strategies for Extending the Lifespan of Lead-Acid Batteries in Forklifts

(1) Scientific and reasonable charging and discharging management

1.  Avoid over-discharge

During the operation of forklifts, a power monitoring device should be installed to monitor the battery power in real time. When the battery level drops to 20% to 30%, the forklift should be stopped from use and recharged in a timely manner. Avoid continuing to work when the battery power is too low to prevent sulfation. In addition, for forklift batteries of different models and specifications, it is necessary to strictly follow the manufacturer's regulations and set a reasonable discharge termination voltage.

2. Standardize charging operations

Choose a charger that matches the battery specifications and operate strictly in accordance with the charging process. The charging process is generally divided into three stages: constant current charging, constant voltage charging and float charging. During the constant current charging stage, the battery is charged with a constant current to quickly replenish its power. When the battery voltage reaches a certain value, it enters the constant voltage charging stage, maintaining a constant voltage and gradually reducing the current to fully charge the battery. Finally, float charging is carried out to maintain the battery's power with a smaller current and prevent self-discharge from causing power loss. Each charging time should not be too long to avoid overcharging. However, it is also necessary to ensure that the battery is fully charged. Generally, the charging time should be controlled at around 8 to 10 hours. At the same time, avoid frequent short-time charging, as this will cause the active material on the battery plates to fall off prematurely, affecting the battery's lifespan.

(2) Strict management of electrolyte

1. Regularly check the density and level of the electrolyte

Check the electrolyte density and liquid level at least once a week. The density of the electrolyte should be measured with a hydrometer. Under different seasons and usage environments, the density of the electrolyte should be maintained within an appropriate range. When checking the liquid level, make sure the electrolyte level is 10 to 15mm higher than the top of the plates. If the liquid level is too low, distilled water or special lead-acid battery replenishment liquid should be added. Tap water should be avoided as impurities in tap water can affect battery performance.

2. Keep the electrolyte clean

Regularly clean the sediment inside the battery to prevent excessive accumulation of sediment, which may cause short circuits in the plates. When adding electrolyte or distilled water, clean utensils should be used to prevent impurities from mixing into the electrolyte. If the electrolyte is found to be turbid or has an abnormal color, it should be replaced in time, and the battery should be cleaned and maintained.

(3) Optimize the usage environment

1. Control the working temperature

Try to keep the working environment temperature of the forklift between 20 and 25 degrees Celsius. In high-temperature environments, measures such as installing ventilation devices and sunshades can be taken to reduce the temperature of the battery. In low-temperature environments, you can use an insulating cover to keep the battery warm, or move the battery to a warm indoor area for storage and charging. If it is impossible to avoid working in extreme temperature environments, the charging and discharging strategies should be appropriately adjusted.

2. Reduce the impact of vibration

Regularly inspect the shock absorption device of the forklift to ensure its normal operation and reduce the impact of vibration during driving on the battery. When handling goods, avoid sudden braking, sharp turns and other violent operations, and drive the forklift smoothly. At the same time, inspect and reinforce the battery's fixing device to prevent it from loosening or shifting during the forklift's operation, which could cause damage to the internal connecting components.

(4) Improve daily maintenance and upkeep

1. Clean the battery surface

After work every day, wipe the battery surface with a damp cloth to remove dust, electrolyte residue and other dirt. Keeping the battery surface clean and dry can effectively prevent self-discharge and corrosion of the casing. For stubborn stains, a dedicated battery cleaner can be used for cleaning, but be careful to avoid the cleaner entering the battery interior.

2. Check the battery connection components

Check the connection cables, terminals and other components of the battery once a week to ensure that the connections are firm and there is no loosening or oxidation. If oxidation of the terminals is found, they can be gently sanded with sandpaper and then coated with special anti-oxidation paste to prevent re-oxidation. Regularly check whether the connecting cables are damaged or aged. If any problems are found, replace them in time to avoid a decline in battery performance or safety accidents due to poor connection.

3. Regular deep discharge and charge

It is recommended to perform a deep discharge and charge every 2 to 3 months. Deep discharge refers to reducing the battery's power to a relatively low level, but it is important to avoid over-discharging. After deep discharge, a complete charging process is carried out, including constant current charging, constant voltage charging and float charging stages. This can activate the active substances on the plates, enhancing the capacity and performance of the battery.

3. Fault Detection and Emergency Response

When the lead-acid battery of a forklift malfunctions, it is necessary to carry out timely investigation and handling. Common faults include rapid battery power drop, inability to charge, and severe heat generation during charging, etc. For the problem of a rapid decline in battery power, it may be due to battery aging, severe self-discharge or leakage. It can be investigated by checking the battery connection components, measuring the density of the electrolyte and inspecting whether there is a short circuit inside the battery. If the battery fails to charge, check whether the charger is working properly, whether the charging connection is correct, and whether the battery terminals are oxidized, etc. In cases of severe heating during charging, it may be caused by overcharging, insufficient electrolyte or aging of the plates, etc. Charging should be stopped immediately, and the relevant factors should be checked and dealt with.

4. Conclusion

To extend the lifespan of lead-acid batteries in forklifts, it is necessary to take scientific and reasonable measures from multiple aspects such as charge and discharge management, electrolyte management, optimization of the usage environment, and daily maintenance. Through standardized operation and meticulous maintenance, not only can the performance and service life of batteries be enhanced, reducing the operating costs of enterprises, but also the normal operation of forklifts can be guaranteed and the efficiency of logistics operations can be improved. Enterprises should enhance the training of forklift operators and equipment managers, enabling them to master the correct methods of battery usage and maintenance, and jointly do a good job in the management of lead-acid batteries, providing a strong guarantee for the efficient operation of the enterprise.