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Abstract

This article conducts an in-depth study on the bulging problem of lead-acid batteries in forklifts, systematically analyzing various causes leading to bulging, covering abnormal charging processes, poor usage environments, and quality defects of the batteries themselves. At the same time, a scientific and effective emergency response plan should be proposed, including the initial inspection and assessment of bulges, professional handling in the middle stage, and follow-up measures in the later stage. In addition, specific strategies for preventing bulging are expounded, aiming to provide comprehensive and practical reference basis for the safe use and maintenance of lead-acid batteries in forklifts, and reduce equipment failures and safety risks caused by battery bulging.

1. Introduction

In the modern logistics and warehousing industry, forklifts, as indispensable handling equipment, the stable operation of their power source - lead-acid batteries - is of vital importance. However, in actual use, the phenomenon of lead-acid batteries bulging occurs from time to time. Bulging not only leads to a decrease in battery capacity and performance degradation, but in severe cases, it may also cause safety accidents such as battery leakage, fire and even explosion, causing huge losses to the production of enterprises. Therefore, a thorough analysis of the causes of lead-acid battery bulging in forklifts and the formulation of scientific and reasonable emergency plans are of great significance for ensuring the safe and efficient operation of forklifts.

2. Analysis of the Causes of Bulging Lead-Acid Batteries in Forklifts

(1) Abnormal charging process

1. Overcharging: During the charging process of lead-acid batteries, if the battery voltage reaches a certain value and the charging continues for a long time, the "overcharging" phenomenon will occur. At this point, the water inside the battery will be electrolyzed to produce a large amount of hydrogen and oxygen. If these gases cannot be discharged in time, they will accumulate inside the battery, causing the pressure to rise and eventually leading to battery swelling. For instance, in some enterprises, if the forklift charging operators fail to strictly follow the prescribed charging time and voltage, or if the voltage and current of the charging equipment are not accurately regulated, it is easy to cause overcharging problems.

2. ** Excessive charging current ** : Excessive charging current will accelerate the chemical reaction rate inside the battery, and the heat and gas generated will also increase accordingly. When the heat dissipation and exhaust speed inside the battery cannot keep up, it will cause the internal temperature of the battery to rise and the pressure to increase, which may lead to bulging. For instance, in some emergency operation scenarios, in order to get the forklift back into operation as soon as possible, high-current chargers are blindly used to charge the battery quickly. Although this practice saves time, it seriously damages the battery's lifespan and safety.

3. ** Charger failure ** : Quality issues or aging damage of the charger may also cause abnormal charging processes. For instance, if the voltage control module of the charger malfunctions and fails to accurately control the charging voltage, or if the heat dissipation system of the charger fails, the heat generated during the charging process cannot be dissipated in time, it will affect the charging effect and increase the risk of battery bulging.

(2) Poor usage environment

1. ** High-temperature environment ** : Lead-acid batteries are relatively sensitive to the temperature of the usage environment. When the ambient temperature is too high, the rate of chemical reactions inside the battery accelerates, the evaporation of the electrolyte intensifies, and at the same time, the generation rate of gas inside the battery also speeds up. Using a forklift for a long time in a high-temperature environment or placing a charging battery in a high-temperature area may cause the internal pressure of the battery to rise, leading to bulging.

2. ** Damp environment ** : A damp environment can reduce the insulation performance of the battery casing, leading to internal short circuits in the battery. Once a short circuit occurs, the internal current of the battery will increase sharply, generating a large amount of heat and gas, which in turn causes the battery to bulge. In addition, a humid environment may also cause rust and corrosion of the battery terminals, affecting the normal charging and discharging performance of the battery.

3. ** Vibration and Collision ** : During the operation of forklifts, it is inevitable that they will be subject to vibration and collision. Frequent vibration may cause the plates, separators and other components inside the battery to loosen or get damaged, leading to an internal short circuit of the battery. However, a strong collision may directly damage the battery casing, disrupt the battery's sealing performance, prevent the internal gas from being discharged normally, and eventually cause the battery to bulge.

3. Emergency Plan for Bulging Lead-Acid Batteries in Forklifts

(1) Initial inspection and assessment of bulges

When the lead-acid battery of a forklift is found to be bulging, the operator should immediately stop using the forklift and move it to a well-ventilated and safe area away from flammable materials. Then, conduct a preliminary inspection of the battery to observe whether the battery casing is damaged or leaking, check if the battery terminals are loose or oxidized, measure parameters such as battery voltage and electrolyte density, and assess the severity of battery bulging. If the degree of bulging is relatively mild and there is no obvious damage or leakage on the battery casing, professional battery testing equipment can be further used to test the internal resistance, charging and discharging performance, etc. of the battery to determine whether it can still be used.

(2) Mid-term professional treatment

1. ** Mild bulge treatment ** : For batteries with mild bulges, if the battery performance is found to be acceptable after testing, you can try to repair the battery. First, remove the battery from the forklift and place it in a well-ventilated area to let it cool down naturally for a period of time. Then, open the vent hole on the battery to expel the accumulated gas inside the battery. Next, a dedicated battery repair instrument is used to perform charge and discharge cycles on the battery to adjust the internal chemical reactions and restore its performance. During the repair process, it is necessary to closely monitor parameters such as the battery's temperature and voltage to avoid new problems arising during the repair process.

2. ** Severe Bulging Treatment ** : If the battery is severely bulging, the casing is damaged, leakage occurs, or after inspection, it is found that there is a serious short circuit inside the battery and its performance has seriously deteriorated, the repair should be stopped immediately and the battery should be treated as hazardous waste. It is strictly prohibited to continue using or disassemble severely swollen batteries by oneself to avoid causing safety accidents. When dealing with severely swollen batteries, one should contact a professional hazardous waste treatment agency and follow the relevant regulations and procedures for recycling and disposal. During handling and transportation, effective protective measures should be taken to prevent situations such as battery leakage and fire.

(3) Post-event handling measures

1. ** Equipment Inspection and Maintenance ** : After dealing with the swollen battery, a comprehensive inspection of the forklift's charging equipment, circuit system, etc. should be carried out. Check whether the voltage and current output of the charging equipment are normal, and whether there is any damage or aging on the charging line to ensure the safe and reliable operation of the charging equipment. At the same time, the electrical system of the forklift should be inspected to prevent circuit failures caused by battery bulging. In addition, other components of the forklift, such as the motor and controller, should also be inspected to ensure that the overall performance of the forklift is normal.

2. ** Accident Cause Analysis and Summary ** : Organize relevant personnel to conduct a cause analysis of the battery bulging accident and identify the specific factors leading to the bulging. Based on the analysis results, formulate corresponding improvement measures and perfect the management system for the use and maintenance of forklift batteries. For instance, if the bulge is caused by improper charging operation, it is necessary to enhance the training of charging operators and standardize the charging operation procedures. If it is caused by equipment failure, the equipment should be repaired or replaced in a timely manner. Through the analysis and summary of the accident, similar problems can be prevented from happening again.

4. Preventive Measures for Bulging Lead-Acid Batteries in Forklifts

(1) Standardize charging operations

1. ** Operate strictly in accordance with charging standards ** : Operators should be familiar with the charging characteristics and requirements of lead-acid batteries and charge strictly in accordance with the charging parameters and operating procedures provided by the battery manufacturer. Control the charging time, voltage and current well to avoid overcharging and high-current charging. Generally speaking, the charging voltage of lead-acid batteries should be controlled at about 1.2 to 1.3 times the rated voltage, and the charging time should not exceed 8 to 10 hours.

2. ** Regularly inspect charging equipment ** : Regularly maintain and service the charging equipment, check whether the voltage and current regulation functions of the charging equipment are normal, and whether the heat dissipation system is in good condition to ensure the stable and reliable operation of the charging equipment. Replace aged or damaged charging equipment in a timely manner to prevent battery bulging due to equipment failure.

3. ** Adopt an intelligent charging management system ** : To enhance the accuracy and safety of charging, an intelligent charging management system can be adopted. This system can monitor the charging status of the battery in real time and automatically adjust the charging strategy based on parameters such as voltage, current and temperature of the battery, achieving intelligent charging. The intelligent charging management system can also record and analyze the charging process, facilitating managers to grasp the battery usage and charging effect.

(2) Optimize the usage environment

1. ** Control the operating environment temperature ** : Try to avoid forklifts operating for long periods in high-temperature environments, especially during the hot summer days. The operation and rest times of forklifts should be reasonably arranged to provide sufficient heat dissipation time for the battery. When charging, the battery should be placed in a well-ventilated area with a suitable temperature, avoiding direct sunlight and high-temperature baking. If the working environment temperature is too high, appropriate cooling measures can be taken, such as installing air conditioners, fans and other equipment, to lower the ambient temperature.

2. ** Keep the working environment dry ** : Ensure that the working and charging areas of the forklift are dry and well-ventilated to prevent the battery from coming into contact with moisture. For forklifts operating outdoors, rain-proof measures should be taken to prevent rainwater from entering the battery interior. Regularly check the sealing performance of the battery casing, promptly repair any damaged battery casing, and prevent external moisture from entering.

3. ** Reduce vibration and collision ** : During the operation of forklifts, operators should pay attention to operating norms, avoid sudden braking, sharp turns and other violent operations, and reduce the vibration and collision of forklifts. When handling goods, it is necessary to arrange the placement of the goods reasonably to ensure the stability of the center of gravity of the goods and prevent the shaking of the goods from causing impact on the forklift. In addition, shock-absorbing devices can be added to the battery installation area to reduce the impact of vibration on the battery.

5. Conclusion

The bulging of lead-acid batteries in forklifts is a complex issue involving multiple factors. The causes cover abnormal charging processes, poor usage environments, and quality defects of the batteries themselves, among others. For these reasons, it is of vital importance to formulate scientific and reasonable emergency plans and preventive measures. By standardizing charging operations, optimizing the usage environment, and strengthening battery quality control, the probability of battery bulging can be effectively reduced, ensuring the safe and stable operation of forklift lead-acid batteries, enhancing the production efficiency of enterprises, and minimizing economic losses and safety risks caused by battery failures. At the same time, enterprises should also continuously enhance the training of forklift operators and maintenance personnel, improve their safety awareness and professional skills, and ensure that all preventive and emergency measures can be effectively implemented.