To improve the endurance of electric forklifts, systematic optimization is required across dimensions such as battery management, driving operations, vehicle maintenance, energy supply, and technological upgrading. The core goals are to reduce energy consumption, enhance battery efficiency, and boost energy replenishment efficiency. Below are specific actionable solutions:
I. Battery Management and Charging Optimization (Core Measure)
Battery Selection and Maintenance
- Prioritize high-energy-density lithium batteries to replace traditional lead-acid batteries. Lithium batteries reduce weight by over 20% at the same capacity, are compatible with Battery Management Systems (BMS) for precise State of Charge (SOC) and State of Health (SOH) monitoring, prevent overcharging and over-discharging, and cut energy loss by 15%–20%.
- Regularly inspect battery terminals for cleanliness and tightness, remove oxides to minimize connection resistance; perform equalization charging once a month, test cell voltage and internal resistance quarterly, and replace aging cells promptly.
- Temperature Control: The optimal battery operating temperature ranges from 20–25℃. In low temperatures, park and charge the battery indoors for insulation; in high temperatures, enhance ventilation or adopt liquid cooling to avoid capacity degradation.
Charging Strategy Upgrading
- Adopt intelligent fast-charging technology (e.g., 80% charge in 30 minutes), combined with opportunistic charging (topping up during operation intervals) and off-peak charging to reduce grid load and costs.
- Avoid deep discharge (SOC < 20%). For lead-acid batteries, it is recommended to charge when remaining capacity is 30%–40%; for lithium batteries, charge when remaining capacity is 20%–30% to extend cycle life and endurance stability.
- Introduce battery swapping mode: multiple forklifts share standardized battery packs, with swapping completed in 3–5 minutes, suitable for high-frequency continuous operation scenarios.
II. Driving Operations and Load Management (Immediate Effect)
Driving Habit Optimization
- Start smoothly, maintain a constant speed, avoid sudden acceleration/braking to reduce instantaneous high-current discharge; use coasting instead of braking, and coordinate with the energy recovery system to reclaim braking energy.
- Reduce frequent starts and stops, plan operation routes, concentrate on completing tasks in the same area to cut ineffective energy consumption; use appropriate lifting/lowering speeds and avoid no-load high-speed operation.
Load and Working Condition Control
- Strictly adhere to rated load capacity and avoid overloading; center the placement of goods to lower tipping risks and additional energy consumption.
- For outdoor operations, avoid continuous climbing on long slopes; for indoor operations, optimize shelf layout to reduce long-distance, high-lifting tasks.
III. Vehicle and Component Maintenance (Basic Guarantee)
Transmission and Travel System
- Regularly check tire pressure (maintain within ±5% of the rated value), replace worn tires in a timely manner to reduce rolling resistance; lubricate wheel hub bearings as needed to decrease friction loss.
- Optimize the transmission system with high-efficiency gearboxes (transmission efficiency ≥ 98%), and match motors with drive axles to reduce no-load loss.
Energy Recovery and Electronic Control Optimization
- Upgrade the electronic control system with energy recovery function, which converts kinetic energy into electrical energy to recharge the battery during braking, increasing endurance by 5%–10%.
- Activate the eco-mode to limit maximum speed and acceleration performance, suitable for light-load long-distance transportation.
IV. Technological Upgrading and Vehicle Optimization (Long-term Efficiency Improvement)
Lightweight Design and High-efficiency Components
- Use carbon fiber composite materials instead of metal components to reduce the overall vehicle weight by 5%–20% and lower energy consumption; optimize the hydraulic system with low-viscosity hydraulic oil and high-efficiency pumps/valves to reduce standby loss.
Intelligent Management System
- Deploy a fleet management system to monitor energy consumption, SOC, and faults in real time, optimize scheduling through data analysis, and reduce empty running and inefficient operations.
- Apply the Internet of Vehicles (IoV) and AI algorithms to dynamically adjust power output based on road conditions, load, and battery level to achieve optimal energy consumption.
V. Advanced Solutions (High-demand Scenarios)
- Battery Upgrading: Pilot solid-state batteries/lithium-sulfur batteries, which can increase energy density by over 50% and achieve a cycle life of 2,000+ times, suitable for long-endurance requirements.
- Photovoltaic-assisted Charging: Install photovoltaic panels on warehouse roofs or forklift charging areas to supplement battery power and reduce operating costs.
- Multi-power Configuration: Dual-battery switching, with automatic switching to the backup battery when the main battery is low on power, suitable for 24-hour continuous operation scenarios.
Effect Evaluation and Implementation Path
| Measure Category | Implementation Difficulty | Effectiveness Cycle | Endurance Improvement Range |
|---|---|---|---|
| Driving Operation Optimization | Low | Immediate | 10%–15% |
| Battery Maintenance and Charging | Medium | 1–2 weeks | 15%–20% |
| Vehicle Component Maintenance | Medium | 1 month | 5%–10% |
| Technological Upgrading (Battery Swapping/Lithium Batteries) | High | 3–6 months | 30%–50% |
Implementation Recommendations
- Short-term (1–3 months): Conduct driver training and formulate operation specifications; improve battery maintenance and charging SOPs, and introduce opportunistic charging.
- Medium-term (3–6 months): Upgrade BMS and energy recovery systems; replace high-efficiency tires and transmission components; pilot battery swapping or fast-charging equipment.
- Long-term (6–12 months): Replace lead-acid forklifts with lithium battery forklifts in batches; deploy fleet management systems; integrate renewable energy sources such as photovoltaics.
