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In the industrial field, forklifts, as important material handling equipment, the performance of their power source - lead-acid batteries - directly affects the working efficiency and operating costs of forklifts. Especially in low-temperature environments, the endurance of lead-acid batteries is often greatly reduced, causing many inconveniences to the production and operation of enterprises. How to enhance the endurance of lead-acid batteries for forklifts in low-temperature environments has become an urgent problem for many forklift users to solve.

Analysis of the Reasons for the Decline in Low-temperature Performance of Lead-acid Batteries

The rate of chemical reactions slows down

The working principle of lead-acid batteries is based on internal chemical reactions, and the charging and discharging process is achieved through ion exchange between the positive and negative plates and the electrolyte. When the temperature drops, the viscosity of the electrolyte increases, and the diffusion rate of ions in it slows down significantly. This is just like a vehicle moving slowly on a congested road. Ions cannot be exchanged quickly between the plates and the electrolyte, resulting in an increase in the internal resistance of the battery. An increase in internal resistance not only reduces the output voltage of the battery during discharge but also decreases the available capacity of the battery, directly resulting in a shortening of the driving range. For instance, in some extremely cold regions, the temperature can drop to tens of degrees below zero. At this point, the capacity of lead-acid batteries may decrease to 50% or even less of that at normal temperature, and the driving range of forklifts will also be significantly reduced.

The corrosion of the plate grid is intensifying

In low-temperature environments, the plate grids of lead-acid batteries are facing more severe corrosion tests. Low temperatures cause changes in the chemical balance inside the battery, making the plate grids more prone to chemical reactions with the components in the electrolyte, thereby intensifying the corrosion phenomenon. Once the plate grid is corroded, its structure will gradually become fragile and the plates will deform accordingly. The gap between the plates increases during the deformation process, which makes the electrolyte more prone to loss. The reduction of electrolyte not only lowers the charging and discharging performance of the battery, but also shortens its service life, thereby having a negative impact on its endurance. Forklift lead-acid batteries that operate in low-temperature environments for a long time have more prominent problems of plate grid corrosion, with a significant decline in overall battery performance and difficulty in ensuring the driving range.

The charging acceptance capacity has decreased

As the temperature drops, the charging acceptance capacity of lead-acid batteries will decline sharply. Under low-temperature conditions, the chemical reaction activity inside the battery decreases, and the reaction kinetics process on the electrode surface is inhibited. This leads to a significant reduction in the battery's acceptance efficiency of external input electrical energy during charging. During the same charging period, batteries in low-temperature environments cannot absorb sufficient electricity as they do at normal temperatures, resulting in the battery not being fully charged to the expected capacity. For instance, under normal circumstances, a battery can be fully charged in a few hours at room temperature. However, in a low-temperature environment, it may take several times longer to reach a similar charging amount, and the final charging capacity may not even meet the standard value, thereby seriously affecting the driving range of the forklift.

The risk of electrolyte freezing increases

At extremely low temperatures, there is a risk that the electrolyte of lead-acid batteries will freeze. Although the electrolyte of lead-acid batteries is usually a sulfuric acid water solution, whose freezing point is lower than that of pure water, when the temperature drops to a certain extent, the electrolyte may still freeze. Once the electrolyte freezes, its volume will expand, which will cause serious damage to the internal structure of the battery. The plates of the battery may deform or break due to the compression of the expansion force, and the battery casing may also be burst. This kind of structural damage not only causes the battery to fail to work properly, but also may trigger safety hazards, leading to the complete scrapping of the battery and making it impossible to talk about its endurance. In some cold outdoor operation scenarios, such as cold storage logistics and winter outdoor construction sites, the risk of electrolyte freezing constantly threatens the performance and safety of forklift lead-acid batteries.

Practical tips for improving low-temperature battery life

Preheat and charge

In low-temperature environments, preheating lead-acid batteries before charging is one of the effective methods to enhance their charging acceptance capacity and endurance. Preheating can be carried out in various ways, such as using hot water bags, hot air guns and other tools to heat the battery. By heating, the temperature of the battery is raised to a relatively suitable range. It is generally recommended to increase the battery temperature to around 10℃ - 20℃. This can significantly enhance the activity of chemical reactions inside the battery, reduce the viscosity of the electrolyte, accelerate the diffusion rate of ions, and thereby increase the battery's charging acceptance capacity. When preheating with a hot water bag, you can wrap the hot water bag around the battery surface. Be careful not to let the hot water bag directly touch the electrode part of the battery to avoid short circuit. When using a hot air gun for heating, it is necessary to maintain an appropriate distance and heating time to avoid local overheating causing damage to the battery. After preheating before charging, the battery can be charged with more power within the same period of time, thereby effectively enhancing the forklift's endurance in low-temperature environments.

Choose cold-resistant batteries

There are some cold-resistant lead-acid batteries specifically designed for low-temperature environments on the market. These batteries have undergone special treatments on key components such as the electrolyte and the plate grid. Its electrolyte can still maintain good fluidity at low temperatures, effectively reducing the possibility of the electrolyte freezing. Meanwhile, the plate grids of cold-resistant batteries are made of special alloy materials and processed through special techniques, which can better resist low-temperature corrosion and significantly enhance the battery's lifespan and discharge performance. When choosing cold-resistant batteries, users should pay attention to the low-temperature performance parameters of the batteries, such as capacity retention rate and discharge platform in specific low-temperature environments. Generally speaking, the capacity retention rate of high-quality cold-resistant batteries in low-temperature environments can be 20% to 30% higher than that of ordinary lead-acid batteries. This means that under the same working conditions, forklifts using cold-resistant batteries can achieve a longer driving range. Although cold-resistant batteries are relatively expensive, from the perspective of long-term usage costs and improved work efficiency, they offer a high cost-performance ratio.

Use the charger reasonably

When using lead-acid batteries in winter, it is crucial to choose a charger suitable for low-temperature environments. This type of charger usually has an intelligent temperature control function, which can automatically adjust charging parameters such as charging voltage and current according to the ambient temperature and battery temperature to ensure that the battery can be charged safely and efficiently in a low-temperature environment. When using a charger, make sure the charging environment temperature of the charger is above 0℃. Try to place the charger in a warm, dry and well-ventilated area. If the charger operates in a low-temperature environment, the performance of its internal electronic components may be affected, leading to inaccurate charging parameters and even causing charger malfunctions. At the same time, it is necessary to regularly check whether the connection wires of the charger are damaged and whether the contact is good to ensure the smooth progress of the charging process. The rational use of chargers suitable for low-temperature environments can effectively prevent overcharging or undercharging of batteries, and improve the charging efficiency and battery life of batteries.

Regular maintenance and servicing

Regular comprehensive maintenance and care of lead-acid batteries is an important measure to ensure their normal operation in low-temperature environments and enhance their endurance. First of all, the concentration of the electrolyte and the liquid level height should be checked regularly. In a low-temperature environment, the concentration of the electrolyte can have a significant impact on the performance of the battery. The concentration of the electrolyte should be adjusted in a timely manner according to the actual situation to keep it within the optimal range. Generally speaking, the concentration of the electrolyte in winter can be appropriately increased, but it should not be too high; otherwise, it may accelerate the corrosion of the plate grid. At the same time, it is necessary to ensure that the liquid level of the electrolyte meets the standard. If the liquid level is too low, distilled water or special electrolyte replenishment liquid should be added in time. Secondly, it is necessary to regularly clean the dust and dirt on the battery surface to keep it clean and dry. Dust and dirt on the surface of the battery are prone to absorbing moisture. In low-temperature environments, this may cause corrosion of the battery casing, affecting the battery's sealing performance and safety. In addition, it is necessary to regularly check whether the connection cables of the battery are loose or oxidized. If there are any problems, they should be tightened and cleaned in time to ensure good connection of the battery, reduce resistance and improve the charging and discharging efficiency of the battery. Through regular maintenance and care, problems that occur during battery use can be detected and resolved in a timely manner, ensuring that the battery is in good working condition and thereby enhancing its endurance in low-temperature environments.

Optimize the usage habits of forklifts

In low-temperature environments, the usage habits of forklifts also have a significant impact on the endurance of lead-acid batteries. First of all, try to avoid violent operations such as sudden acceleration and braking. When accelerating sharply, the battery needs to provide a large current instantaneously, which will increase the internal resistance of the battery, resulting in a decrease in the battery's discharge efficiency and an accelerated consumption of power. Similarly, when braking suddenly, the kinetic energy of the forklift is converted into heat energy through the braking system and dissipated. This part of the energy could have been fed back to the battery for charging through the energy recovery system. Frequent sudden braking would waste this recoverable energy. Secondly, it is necessary to rationally plan the work tasks and driving routes of forklifts, and try to minimize unnecessary driving mileage and waiting time. Long waiting times will cause the battery to be in a state of natural discharge. Although the amount of discharge is relatively small, in a low-temperature environment, the self-discharge rate of the battery will increase, which will also have a certain impact on the battery life. In addition, when the forklift is not in use, it should be parked in a warm indoor environment as much as possible to avoid the battery being exposed to low-temperature conditions for a long time, so as to reduce the self-discharge of the battery and energy consumption during cold starts. By optimizing the usage habits of forklifts, the energy consumption of batteries can be effectively reduced and the driving range of batteries can be prolonged.

To enhance the endurance of forklift lead-acid batteries in low-temperature environments, it is necessary to take multiple approaches, including understanding the reasons for the decline in battery performance and taking targeted measures such as preheating and charging, choosing cold-resistant batteries, using chargers reasonably, regular maintenance and care, optimizing usage habits, and adopting battery insulation measures. Only by comprehensively applying these practical techniques can we ensure that forklifts can operate efficiently and stably in low-temperature environments, providing a strong guarantee for the production operations of enterprises.