The circuit design idea of checking and repairing the abnormal working current of lead-acid battery in forklift

Troubleshooting and repair of abnormal working current of forklift lead-acid battery

Time：2025-03-07 16:01:18

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In the operation system of the forklift, the lead-acid battery is like the "heart" and continuously provides power for the forklift.

In the operation system of the forklift, the lead-acid battery is like the "heart" and continuously provides power for the forklift. Abnormal working current is a common and difficult problem of lead-acid batteries, which not only affects the operation efficiency of forklifts, but also may cause damage to batteries and other electrical components. A thorough analysis of circuit design can provide clear and effective ideas for troubleshooting and repairing such faults.

First, forklift lead-acid battery circuit design basis

The lead-acid battery circuit of forklift truck is composed of several key parts. As the core power supply, the battery pack is usually composed of multiple lead-acid batteries in series or parallel to meet the demand for voltage and current under different working conditions of the forklift. The controller plays the role of "commander", which receives signals from the operating handle and precisely regulates the size and direction of the battery output current according to the operating state of the forklift (such as forward, backward, lifting cargo, etc.), and then controls the speed and torque of the motor. As a power output device, the motor converts electrical energy into mechanical energy to drive the forklift and carry out the task. In addition, the circuit also includes a variety of protective components, such as fuses, relays, etc., which quickly cut off the circuit when the circuit is abnormal, protecting the battery and other equipment from damage.

Under normal circumstances, the current starts from the positive electrode of the battery, flows to the motor after adjustment by the controller, completes the conversion of electrical energy to mechanical energy, and then returns to the negative electrode of the battery to form a complete closed loop. In this process, the various parts work together to ensure stable and efficient current transmission.

Second, the common manifestations and effects of abnormal working current

(1) The current is too large

When the working current of the lead-acid battery of forklift truck is too large, many abnormal phenomena will occur. The motor may emit an abnormal roar, and the speed is significantly accelerated, even beyond the normal range, which not only increases energy consumption, but also causes the motor to overheat and shorten the service life of the motor. At the same time, the battery will quickly heat up, which may cause the battery shell to deform and the electrolyte to boil over in serious cases, accelerating the aging of the battery and reducing the battery capacity. Too much current may also blow the fuse in the circuit, causing the forklift to suddenly stop working and affecting the progress of the operation.

(2) The current is too small

On the contrary, too little current will cause the forklift to be underpowered. When moving heavy objects, the lift speed of the forklift is slow, and the acceleration is weak when driving, which cannot meet the normal operation requirements. This may lead to inefficient cargo handling, delay the work process, and affect the smooth progress of the entire logistics or production link. In the low current working state for a long time, the battery plate may also be vulcanized, further reducing the battery performance.

Third, based on circuit design of the investigation ideas

(1) Check the battery pack

First, check whether the battery pack is securely connected. If the battery is used for a long time, the screws between the pole and the connecting clamp may be loosened due to vibration, resulting in increased contact resistance and affecting current transmission. Check the screws at each connection point one by one with a wrench to ensure that they are tight. At the same time, observe the appearance of the battery to check whether the shell is cracked or the electrolyte leaks. If yes, the battery may be short-circuiting or disconnected, affecting the current output. Use a professional battery detector to measure the open circuit voltage and internal resistance of the battery pack. Under normal circumstances, the open circuit voltage of a fully charged lead-acid battery should be close to its nominal voltage, and the internal resistance is in a reasonable range. If the open circuit voltage is obviously low and the internal resistance is too large, it may mean that there is a fault in the battery, such as plate vulcanization, active substances falling off, etc., and further testing or replacement of the battery is required.

(2) Check the controller

Controller failure is one of the common causes of abnormal current. Check whether the heat sink of the controller is overheated. If the heat dissipation is poor, the performance of the internal components of the controller may deteriorate and the current regulation may be affected. Check whether the controller enclosure is damaged or flooded. If yes, the internal circuit may be short circuit. Use the oscilloscope to detect the output signal of the controller. Under normal circumstances, the output signal should show regular changes according to the operation instruction. If the signal is abnormal, the power transistor, integrated circuit and other components in the controller may be damaged, and the controller needs to be repaired or replaced.

(3) Motor check

Motor as the main load of current, its failure will also cause current abnormal. Check the wear of the motor brush, brush and commutator close contact, transfer current. If the brush wear is serious, the contact resistance increases, which will cause the current to be unstable. It can be determined whether it needs to be replaced by observing the length of the brush and the degree of surface wear. At the same time, the insulation resistance tester is used to measure the insulation resistance of the motor winding. If the insulation resistance is too low, it indicates that the winding may have a short circuit, which will increase the current. In addition, check whether the motor bearing is stuck, too much mechanical resistance will make the motor difficult to operate, resulting in an increase in current.

(4) Circuit connection and protection components check

Carefully check the connected lines in the circuit to see if there is damage, short circuit, open circuit phenomenon. Especially in the environment of frequent movement and vibration of forklifts, the line is vulnerable to wear. Use a multimeter to measure the line resistance. If the value of the resistance is too large or infinite, the line is faulty and needs to be repaired or replaced. In addition, check fuses, relays and other protective components. The blown fuse may be caused by excessive current. Find out the cause of excessive current before replacing the fuse. If the relay has problems such as contact adhesion and poor contact, it will also affect the normal flow of current. It can be judged by measuring the resistance of the relay coil and the status of the contact, and replace the relay if necessary.

Repair and preventive measures

According to the troubleshooting points, the corresponding repair. If part of the battery pack is damaged, replace the damaged battery. The controller components are damaged, and professional maintenance personnel are required to replace the damaged components; Motor brush wear or winding short circuit, according to the code to replace the brush, maintenance winding; Circuit connection problems repair or reconnect the line. After the repair is complete, test the circuit again to ensure that the current is back to normal.

In order to prevent abnormal working current, it is necessary to strengthen the maintenance of lead-acid battery circuit of forklift truck. Periodically check the battery connection points to ensure tight; Keep the controller, motor clean, good heat dissipation; Avoid overload operation of the forklift for a long time to prevent excessive current from damaging the equipment. At the same time, professional testing equipment is regularly used to test the performance of batteries, controllers, and motors. Potential problems are found and dealt with in time to ensure the stable and efficient operation of the lead-acid battery circuit of the forklift truck and improve the reliability of the forklift truck operation.

Statement: The articles on this site are written by the GSGT team or reprinted from other media or compiled by AI.No reproduction without permission.For copyright or other issues, please contact:gsgtpower@163.com.

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