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Introduction

In modern logistics and industrial production, forklifts, as an important handling equipment, are widely used in various fields. Among them, forklifts that use lead-acid batteries as power sources have occupied a considerable market share due to their advantages such as relatively low cost and mature technology. However, lead-acid batteries have many potential safety hazards during use. If they are not taken seriously and effectively inspected, they may cause serious safety accidents, threatening people's lives and causing property losses. Therefore, it is of vital importance to conduct a comprehensive and detailed safety hazard inspection of lead-acid batteries in forklifts.

The characteristics of lead-acid batteries

Characteristics

Lead-acid batteries have high voltage stability and can provide relatively smooth power output for forklifts. However, it also has some obvious drawbacks. For instance, its energy density is relatively low, which means that under the same amount of electricity, the battery volume and weight are larger. A long charging time will affect the continuous operation time of the forklift. Moreover, during the charging and discharging process, gases such as hydrogen and oxygen are produced, and the electrolyte is corrosive. These characteristics all bring certain safety risks.

Analysis of Common Safety Hazards

Potential hazards related to electrolyte

1. ** Electrolyte leakage ** : Damage or aging of the battery casing, or failure of the sealing components, may all lead to electrolyte leakage. The electrolyte contains sulfuric acid and is highly corrosive. Once it leaks, it may cause corrosion and damage to the ground and equipment. If personnel come into contact with the leaked electrolyte, it may also lead to skin burns, eye stinging and other injuries.

2. ** Abnormal electrolyte level ** : During long-term use, the electrolyte will decrease due to electrolysis and evaporation. When the liquid level is too low, the plates may be exposed to the air, causing sulfation of the plates, shortening the battery life. At the same time, it may also cause the battery to overheat or even catch fire. On the contrary, if too much electrolyte is added, it may overflow during the charging process, which also brings corrosion and safety risks.

Gas emission hazard

1. ** Hydrogen accumulation explosion ** : During the charging process, an electrolytic water reaction occurs inside lead-acid batteries, generating hydrogen and oxygen. Hydrogen is a flammable and explosive gas. When the ventilation in the charging area is poor, hydrogen is prone to accumulate. Once its concentration reaches the explosive limit and it encounters open flames, sparks or other ignition sources, it may cause an explosion, resulting in serious casualties and property losses.

2. ** Corrosion by acidic gases ** : Besides hydrogen, the charging process also generates some acidic gases, such as sulfur dioxide, etc. These acidic gases, when diffused in the air, can cause corrosion to surrounding metal equipment, electrical circuits, etc., reducing the service life of the equipment and increasing the probability of electrical faults.

Electrical safety hazard

1. ** Short-circuit risk ** : Loose battery terminals, damaged insulation layers of wires, and short circuits in the internal plates of the battery can all lead to short circuits. When a short circuit occurs, the current will increase sharply, generating a large amount of heat, which may cause the battery to catch fire and burn. At the same time, the short-circuit current may also cause electric shock injuries to people.

2. Overcharging and overdischarging: If the charging equipment malfunctions or the charging control strategy is inappropriate, it may lead to overcharging of the battery. Overcharging will increase the internal pressure of the battery, accelerate the loss of water in the electrolyte, and may also cause the active material on the plates to fall off, shortening the battery life. In severe cases, it may even lead to an explosion. Over-discharging the battery will cause sulfation of the plates, reduce the battery capacity, and also affect the normal use of the battery.

Potential mechanical damage

1. ** Battery casing damage ** : During the daily operation of forklifts, collisions, jolts and other situations may occur. If the battery is not firmly fixed, it is prone to external force impacts, resulting in damage to the battery casing. A damaged casing not only causes electrolyte leakage but also may damage the internal structure of the battery, affecting its performance and increasing safety risks.

2. ** Plate Deformation ** : Long-term high-current charging and discharging, battery overheating and other factors may cause the battery plates to deform. After the plates are deformed, the spacing between them will be uneven, which can easily cause short circuits and also reduce the capacity and service life of the battery.

Methods for identifying potential safety hazards

Visual inspection

1. ** Battery casing ** : Regularly check the battery casing for any cracks, damages, deformations or other conditions. Pay special attention to the corners and connection parts of the casing that are prone to force. If any problems are found, the battery should be replaced in time to prevent electrolyte leakage and further damage to the internal structure

2. ** Electrolyte level ** : Check whether the electrolyte level is within the specified range through the level observation window on the battery casing or by using a dedicated level measurement tool. Generally speaking, the liquid level should be maintained between the upper and lower limit marks. If the liquid level is too low, distilled water should be added in time. If the liquid level is too high, the excess electrolyte should be sucked out with a pipette.

3. ** Terminals and Wires ** : Check if the terminals are loose or corroded, and if the wires are damaged, aged or exposed. Loose terminals should be tightened in time. Corroded terminal posts need to be cleaned and an appropriate amount of protective agents such as vaseline should be applied. Damaged wires should be replaced in a timely manner to ensure the reliability and safety of electrical connections.

Gas detection

1. ** Hydrogen Concentration detection ** : Install hydrogen leakage detectors in the charging area to monitor the concentration of hydrogen in the air in real time. The detector should be equipped with an alarm function. When the hydrogen concentration reaches the set safety threshold, it can promptly issue an alarm to remind the staff to take measures such as ventilation to reduce the hydrogen concentration and prevent explosion accidents.

2. ** Acidic Gas Detection ** : Professional gas detection instruments can be used to regularly test the concentration of acidic gases in the charging area. If the concentration of acidic gases exceeds the standard, it is necessary to check whether the ventilation system is operating normally, clean the ventilation ducts in time to ensure good ventilation and reduce the corrosion of acidic gases on equipment and the environment.

Electrical performance testing

1. ** Voltage and Current Detection ** : Use a multimeter or other detection tools to regularly measure the battery's voltage and charging current. During the charging process, observe whether the changes in voltage and current are normal. If the voltage abnormally rises or drops, or the current is too large or too small, it may indicate that the battery has a fault, such as overcharging, overdischarging, short circuit of the plates, etc. Further investigation of the cause and repair are needed.

2. ** Insulation Resistance Testing ** : An insulation resistance tester is used to measure the insulation resistance between the positive and negative terminals of the battery and the casing, as well as between each battery cell. The insulation resistance should comply with the relevant standard requirements. If the insulation resistance is too low, it indicates a risk of leakage, which may cause electric shock to personnel and electrical fires. At this time, the leakage point should be located in time and repaired.

Mechanical property testing

1. ** Battery Fixation Inspection ** : Check whether the battery's fixation device on the forklift is firm and whether the bolts are loose. Ensure that the battery does not shift or shake during the forklift's operation and movement to prevent battery damage caused by mechanical collisions.

2. ** Plate Condition Inspection ** : For detachable batteries, regularly open the battery cover to check if the plates are deformed, sulfated, or if active material has fallen off, etc. Plate vulcanization is characterized by the adhesion of white hard substances on the surface of the plates. The shedding of active substances will cause the surface of the plates to be uneven. If serious problems are found with the plates, the battery should be replaced in time to ensure its performance and safety.

Preventive measures and suggestions

Daily maintenance and care

1. ** Keep the battery clean ** : Regularly wipe the battery casing with a damp cloth to remove dust, dirt and residual electrolyte on the surface, preventing the electrolyte from corroding the battery casing and terminals, and avoiding leakage caused by surface dirt.

2. ** Regularly replenish distilled water ** : According to the electrolyte level, add distilled water regularly to keep the electrolyte level within the normal range. Note to use distilled water of higher purity. Avoid using tap water or other water sources containing impurities to prevent impurities from adversely affecting battery performance.

3. ** Reasonable charging and discharging ** : Operate strictly in accordance with the battery's charging and discharging requirements to avoid overcharging and overdischarging. Choose reliable charging equipment and regularly maintain and calibrate it to ensure the accuracy of charging parameters. During the charging process, closely monitor the changes in battery temperature, voltage and current. If any abnormality is detected, stop charging immediately and conduct an inspection.

Safety facility configuration

1. ** Ventilation System ** : In the forklift charging area, install a good ventilation system to ensure smooth air circulation. The ventilation volume should be reasonably designed based on factors such as the size of the charging area and the number of batteries being charged simultaneously, in order to effectively discharge hydrogen and acidic gases generated during the charging process and reduce the risk of gas accumulation.

2. ** Fire and explosion prevention facilities ** : Sufficient fire extinguishing equipment, such as dry powder fire extinguishers and carbon dioxide fire extinguishers, should be provided in the charging area, and regular inspections and maintenance should be carried out to ensure their good performance. At the same time, clear fire and explosion prevention signs should be set up in the charging area. Smoking and open flames are strictly prohibited. Welding, cutting and other open flame operations are forbidden in the charging area.

3. ** Protective Equipment Provision ** : Provide necessary personal protective equipment for operators, such as protective glasses, rubber gloves, aprons, protective shoes, etc., to prevent operators from being injured when in contact with batteries and electrolytes. At the same time, eyewash stations and shower facilities should be set up in the charging area to ensure that personnel can be rinsed in time if they accidentally come into contact with the electrolyte.

Conclusion

The safety hazard investigation of lead-acid batteries for forklifts is an important link to ensure the safe operation of forklifts and prevent accidents. Through in-depth analysis of common safety hazards in aspects such as electrolyte, gas emissions, electrical safety and mechanical damage, and by adopting effective inspection methods such as visual inspection, gas detection, electrical performance testing and mechanical performance testing, as well as preventive measures such as strengthening daily maintenance and care, equising complete safety facilities, and intensifying personnel training and management, It can promptly identify and eliminate potential safety hazards, reduce the risk of accidents, ensure the safe and reliable operation of forklift lead-acid batteries, and provide a strong guarantee for the smooth progress of logistics and industrial production. In actual work, all enterprises and units should attach great importance to the safety management of lead-acid batteries for forklifts, take the investigation of potential safety hazards as a regular task, continuously improve the safety management system, enhance the level of safety management, and effectively ensure the safety of personnel's lives and property as well as the normal operation of production and business activities.