With advantages such as high energy density, no memory effect, and low self-discharge rate, lithium batteries have become a new favorite in the power systems of electric forklifts. However, the performance and lifespan of lithium batteries are closely related to maintenance methods. Only by mastering scientific maintenance methods can their advantages be fully utilized and usage costs be reduced. The following details the key maintenance points for lithium batteries of electric forklifts from aspects such as charging management, daily maintenance, and storage precautions.
Lithium batteries support charging at any time and do not need to be fully discharged before charging, unlike lead-acid batteries. However, overcharging and over-discharging should be avoided. When the remaining battery level is around 20% - 30%, charging should be carried out in a timely manner. It is recommended to stop charging once the battery reaches 100% to prevent irreversible damage caused by overcharging. Use original or compliant chargers. Chargers for lithium batteries of different brands and models have different parameters. Mixing chargers may lead to mismatches in charging current and voltage, affecting battery performance and even causing potential safety hazards.
During charging, lithium batteries should be placed in a dry and well-ventilated environment, away from heat sources and flammable and explosive materials. Lithium batteries are sensitive to temperature, and the optimal charging temperature range is generally between 0°C - 45°C. If the ambient temperature is too low, the internal chemical reaction rate of the battery slows down, reducing charging efficiency and potentially causing permanent damage to the battery. If the temperature is too high, it will accelerate battery aging and may even lead to thermal runaway. When the ambient temperature is outside the suitable range, temperature regulation equipment can be used to improve the charging environment.
Although lithium batteries have no memory effect, conducting a deep charge and discharge (i.e., fully discharging and then fully charging) every 2 - 3 months helps activate the Battery Management System (BMS), making the battery level display more accurate. At the same time, it balances the consistency of the internal cells of the battery and improves overall performance.
Before and after each use, check the appearance of the lithium battery for any damage, deformation, or bulging. If any abnormalities are found, stop using it immediately and contact professionals for inspection and repair. At the same time, check whether the connection terminals between the battery and the forklift are loose or oxidized to ensure a tight and good connection. If there is oxidation on the surface of the terminals, they can be wiped with a clean soft cloth dipped in an appropriate amount of alcohol to keep the terminals clean.
The built-in Battery Management System (BMS) of lithium batteries can monitor parameters such as battery voltage, current, temperature, and charge in real time. Regularly check the BMS data to understand the battery's operating status. If abnormal alarm information such as overvoltage, overcurrent, or high temperature appears, the cause should be investigated in a timely manner, and maintenance should be carried out if necessary. In addition, do not modify the parameter settings of the BMS casually to avoid affecting the normal operation of the battery.
During the operation of electric forklifts, try to avoid high-current discharge operations such as sudden acceleration, sudden braking, and long-term uphill driving. High-current discharge will increase the internal temperature of lithium batteries, accelerate battery aging, and may also lead to a decrease in battery capacity. Smooth driving and reasonable route planning can help extend the service life of lithium batteries. If lithium batteries need to be stored for a short period (1 - 3 months), keep the battery level at around 50% - 60%, then disconnect the connection with the forklift and store them in a dry, cool, and well-ventilated environment. Check the battery level every 1 - 2 weeks. When the battery level is lower than 40%, recharge it in a timely manner to prevent over-discharging.
For long-term storage (more than 3 months), also charge the battery to 50% - 60% first and disconnect the power connection. To prevent excessive power loss due to self-discharge, perform a supplementary charge every 1 - 2 months to maintain the battery level at an appropriate level. The storage environment temperature should be controlled between 5°C - 25°C, and the humidity should be kept between 45% - 75% RH. In addition, avoid storing lithium batteries together with metal objects to prevent metal objects from short-circuiting the positive and negative poles of the battery, causing safety accidents.
Avoiding Vibration and Impact: The internal structure of lithium batteries is delicate. Strong vibrations and impacts may damage the internal cells and circuits of the battery, affecting battery performance and safety. When handling and installing lithium batteries, handle them with care to prevent bumps. During the operation of the forklift, try to avoid driving on bumpy roads to reduce vibrations on the battery.
Regular Professional Inspections: Even if lithium batteries are used normally in daily life, it is recommended to have a comprehensive inspection by professionals once a year, including battery capacity testing, internal resistance detection, cell consistency evaluation, etc., to detect potential problems in a timely manner and take corresponding maintenance measures.
Proper maintenance of lithium batteries for electric forklifts can not only extend the battery's service life but also ensure the stable operation of the forklifts and improve work efficiency. During the maintenance process, strictly follow relevant specifications and requirements. If problems that cannot be solved are encountered, contact the manufacturer or professional maintenance personnel in a timely manner. Do not disassemble and repair lithium batteries by yourself to avoid potential dangers.
