How to improve the battery endurance of electric forklifts?

I. Battery-side Management: Maximize Actual Usable Capacity

The actual output capacity of the battery is the core of endurance. Scientific control is required to reduce capacity degradation and loss.

1. Strictly Control Depth of Discharge (DOD)
• Lead-acid batteries: The single discharge depth shall not exceed 80%. Deep discharge will cause plate sulfation and permanently reduce capacity. It is recommended to charge immediately when the remaining power is ≥20%.
• Lithium-ion batteries: The single discharge depth shall not exceed 90%. Avoid over-discharge triggering the protection mechanism, which may affect cycle life and endurance stability.
• Implementation Standard: Equip with a battery power monitor to display remaining power in real time, and set low-power alarm thresholds (20% for lead-acid batteries, 10% for lithium-ion batteries).
2. Optimize Charging Strategies
• Lead-acid batteries: Adopt the constant voltage and constant current charging method, avoid fast charging; perform floating charging for 1–2 hours after full charge to supplement power; it is prohibited to put into use without full charge.
• Lithium-ion batteries: Support fast charging for power supplement. Use lunch breaks and shift handover periods to fast charge to 80% (completed within 1 hour), which not only does not damage the battery but also quickly restores endurance; avoid long-term storage at full charge (storage at full charge for more than 7 days will accelerate capacity degradation).
• Responsible Person: Charging operator, who shall record the start and end time of each charging and power change.
3. Conduct Regular Capacity Calibration
• Cycle: Perform a full charge-discharge capacity test every 3 months (for lead-acid batteries) / 6 months (for lithium-ion batteries).
• Operation Steps: ① After full charge, operate continuously under rated load until the low-power alarm is triggered; ② Record the actual discharge duration and power consumption; ③ Compare with the nominal capacity, if the degradation exceeds 20%, evaluate whether the battery needs to be replaced.
• Acceptance Standard: The tested capacity ≥ 80% of the nominal capacity is qualified.

II. Operation-side Optimization: Reduce Invalid Energy Consumption

Reduce unnecessary power consumption by standardizing operation processes, and alleviate endurance pressure from the source.

1. Optimize Operation Routes and Working Condition Proportion
• Reduce no-load driving: Plan the shortest handling routes to avoid invalid transfer; merge similar tasks to reduce the proportion of no-load driving (target: no-load proportion ≤ 30%).
• Control lifting height: Adjust the fork lifting height according to needs, avoid redundant operations of "full-load lifting to the highest position" (energy consumption increases by about 5% for every 1 meter increase in lifting height).
• Prohibit frequent start-stop: Sudden acceleration and braking will increase the instantaneous current by 3–5 times, significantly increasing energy consumption; require drivers to operate smoothly, with an interval of ≥ 3 seconds between start and stop.
• Implementation Standard: Formulate the Forklift Operation Route Specification to clarify the optimal driving route for each area.
2. Reasonably Match Load and Operation Intensity
• Avoid overloading operation: Overloading will cause a sudden increase in motor current, increase energy consumption by 20%–30%, and damage the battery and motor at the same time; strictly implement the rated load of forklifts, and prohibit overloading.
• Balance operation rhythm: Avoid long-term high-intensity continuous operation (e.g., full-load lifting for 2 consecutive hours); arrange 10 minutes of standby rest every 1 hour to reduce battery heat loss.
• Responsible Person: Forklift operator, supervised by on-site supervisor.

III. Equipment-side Maintenance: Reduce Energy Loss

Reduce mechanical resistance and electrical loss, and improve energy utilization efficiency through regular maintenance of equipment components.

1. Chassis and Travel System Maintenance
• Tire inspection: Maintain normal tire pressure (in accordance with equipment manual standards); insufficient pressure will increase rolling resistance and energy consumption by 10%–15%; replace severely worn tires in a timely manner.
• Bearing and chain lubrication: Lubricate drive wheel bearings and lifting chains monthly to reduce mechanical friction loss; the type of lubricating grease shall meet equipment requirements.
• Brake system adjustment: Avoid overly tight brakes, which will increase driving resistance; check brake clearance weekly to ensure compliance with standards.
2. Electrical System Maintenance
• Motor and controller inspection: Clean motor dust quarterly, check whether the controller terminals are loose, to avoid power loss caused by poor contact.
• Battery connection maintenance: Check battery terminals monthly, remove oxides, tighten connecting bolts, to avoid power loss caused by excessive contact resistance; apply protective agent on terminals to prevent corrosion.
• Maintenance Standard: Formulate the Monthly Forklift Maintenance Checklist, specifying inspection items, standards, cycles and responsible persons.

IV. Environmental Control: Reduce the Impact of Environmental Factors

Ambient temperature and humidity are important factors affecting battery endurance, and targeted control is required.

1. Temperature Control

     Low-temperature environment (＜0℃):
• Lead-acid batteries: Endurance decreases by more than 50%. Store batteries in an insulated warehouse (temperature ≥5℃), preheat for 30 minutes before operation; avoid fast charging in low-temperature environments.
• Lithium-ion batteries: Endurance decreases by about 30%. The battery heating function can be activated (if equipped); maintain the ambient temperature ≥0℃ during charging to improve charging efficiency.
• High-temperature environment (＞35℃): Avoid battery exposure to direct sunlight; park forklifts in a cool place after operation; high temperature will accelerate battery aging, reduce endurance, and increase the risk of thermal runaway.

2. Humidity Control

   Keep the battery storage environment dry (humidity ≤60%) to avoid battery short circuit or corrosion caused by moisture; clean water stains on the battery surface in a timely manner after operation on rainy days.

V. Endurance Improvement Effect Verification

1. Data Monitoring: Record the daily operation duration, power consumption and endurance mileage of forklifts weekly, and compare the data before and after optimization.
2. Acceptance Standard: After optimization, under the same operating conditions, the endurance capacity improvement ≥15% is up to standard.
3. Continuous Improvement: Hold a monthly endurance optimization review meeting to analyze data and adjust optimization solutions.