During the operation of electric forklifts, as the core power component, the performance of lead-acid batteries directly affects the work efficiency and endurance of the forklifts. In addition to daily basic maintenance, mastering in-depth maintenance techniques can effectively delay battery aging and improve its service life and work efficiency. The following details the in-depth maintenance methods for lead-acid batteries of electric forklifts from several key dimensions.
I. Fine-grained Management of Charging and Discharging
1. Optimizing the Charging Process
Avoid using mismatched chargers. Instead, choose dedicated chargers with a three-stage charging mode (constant current charging, constant voltage charging, and floating charging). In the initial stage of charging, constant current charging can quickly replenish the power. When the voltage reaches a certain value, switch to constant voltage charging to prevent overcharging. Finally, use floating charging to maintain the battery's activity. During the charging process, closely monitor the battery temperature. If the temperature exceeds 45°C, pause the charging and resume it after the temperature drops to prevent the sulfation of battery plates from accelerating due to high temperatures. Additionally, conduct a deep charge after a full discharge once a month, which helps activate the active substances on the battery plates and increase the battery capacity.
2. Scientific Discharge Control
Strictly adhere to the principle of preventing over-discharge of lead-acid batteries, and control the depth of discharge within 60% - 70%. When the battery level displayed on the forklift dashboard drops to around 30%, stop the operation and charge the battery in a timely manner. Avoid frequent deep discharges because deep discharges can cause the active substances on the surface of the plates to fall off, shortening the battery life. Moreover, during the operation of the forklift, try to avoid sudden accelerations and sudden brakes to reduce instantaneous high-current discharges and protect the battery performance.
II. In-depth Maintenance of Electrolyte
1. Precise Liquid Level Adjustment
Regularly checking the electrolyte level is crucial for in-depth maintenance. Use a transparent plastic pipette or a dedicated liquid level measuring tool to accurately measure the height of the electrolyte, ensuring that the liquid level is always kept 10 - 15 millimeters above the plates. When adding electrolyte, only use distilled water or special lead-acid battery replenishment liquid, and never use tap water. The calcium, magnesium, and other ions contained in tap water will react with the sulfuric acid in the electrolyte, generating impurity precipitates, which will affect the battery's chemical reactions and reduce its performance. At the same time, add the electrolyte after the charging is completed to avoid the danger of the electrolyte boiling and overflowing during the charging process.
2. Detection and Adjustment of Electrolyte Composition
Use a hydrometer to detect the specific gravity of the electrolyte every 3 - 6 months. Under normal circumstances, the specific gravity of the electrolyte should be between 1.28 - 1.30g/cm³ (25°C). If the specific gravity is lower than the standard value, it indicates that the sulfuric acid concentration in the electrolyte has decreased, and an appropriate amount of special sulfuric acid solution can be added for adjustment. If the specific gravity is too high, distilled water needs to be added for dilution. When adjusting the specific gravity of the electrolyte, add the solution slowly, stir while adding to ensure uniform mixing, and measure multiple times until the specific gravity reaches the standard range.
III. Maintenance and Repair of Plates
1. Regular Plate Inspection
Open the battery cover every six months to check the condition of the plates. Observe whether there are white lead sulfate crystals (sulfation phenomenon) on the surface of the plates, whether the plates are bent or deformed, or whether the active substances have fallen off. If mild sulfation is found, it can be repaired by charging with a small current for a long time. For severe sulfation, a professional pulse repair instrument is required to break up the lead sulfate crystals through high-frequency pulse current and restore the activity of the plates. In case of plate bending or deformation, replace the plates in a timely manner to prevent the plates from short-circuiting and damaging the battery.
2. Preventing Plate Oxidation
When the battery is not in use, fully charge it and disconnect the connection between the battery and the forklift to prevent self-discharge of the battery. At the same time, apply a layer of petroleum jelly or special battery protective agent on the surface of the battery terminals to form a protective film, isolate the air, prevent the terminals from oxidation and corrosion, ensure good battery connections, and reduce resistance losses.
IV. Environmental and Storage Maintenance
1. Optimizing the Working Environment
Lead-acid batteries of electric forklifts should be avoided from being used and stored in environments with high temperatures, humidity, or corrosive gases. High temperatures will accelerate the evaporation of the electrolyte and the aging of the plates. A humid environment is likely to cause corrosion of the battery case and terminals, and corrosive gases will damage the internal structure of the battery. When operating in a high-temperature environment, install a heat dissipation device for the battery or choose to operate during the cooler morning and evening hours. In a humid environment, keep the battery surface dry and promptly clean up the water around the battery.
2. Long-term Storage Maintenance
If the battery needs to be stored for a long time, fully charge it first, and then perform a supplementary charge every 15 - 20 days to prevent the battery from losing power. When storing, place the battery in a dry, ventilated, and shaded place, and avoid direct sunlight. At the same time, regularly check the battery surface and clean it in a timely manner if there is dust or dirt to prevent self-discharge of the battery. For batteries that have been idle for a long time, conduct a comprehensive charging and discharging cycle before reuse to activate the battery performance.
Mastering the in-depth maintenance techniques for lead-acid batteries of electric forklifts can effectively improve the battery performance and service life and reduce the equipment maintenance costs of enterprises. During the maintenance process, if complex problems are encountered, it is recommended to contact professional battery maintenance personnel or manufacturer technical support in a timely manner to ensure the safety and effectiveness of the maintenance operations.
