The Impact of Environmental Factors on the Endurance of Electric Forklift Batteries and Its Control Scheme

The endurance of electric forklift batteries (mainly lead-acid batteries and lithium batteries) depends on three core aspects: charge-discharge efficiency, reaction rate of active materials, and energy loss. Environmental factors are the key external variables affecting the above indicators. A systematic solution is constructed from four dimensions: core influencing factors, mechanism analysis, quantitative standards, and control measures.

I. Core Environmental Influencing Factors and Their Mechanisms

1. Temperature (The Most Critical Factor)

Temperature directly affects the internal chemical reaction rate of the battery and the characteristics of the electrolyte, with varying impacts on lead-acid batteries and lithium batteries, as detailed in the table below:

Temperature Range	Impact on Lead-Acid Batteries	Impact on Lithium Batteries	Reference Value of Endurance Attenuation
Low Temperature (＜5℃)	Increased electrolyte viscosity slows down ion migration; insufficient reaction of active materials on plates reduces charge acceptance and causes a sharp drop in discharge capacity	Reduced ionic conductivity of organic electrolyte triggers over-discharge protection in the Battery Management System (BMS), limiting discharge current	At 0℃: 40%-50% attenuation for lead-acid batteries; 20%-30% for lithium batteries
Optimal Temperature (15℃-25℃)	Stable chemical reaction rate and good electrolyte fluidity achieve maximum charge-discharge efficiency, with endurance reaching the rated value	Optimal cell activity allows BMS to operate without current limitation, achieving an energy conversion rate of over 90%	95%-100% of the rated endurance
High Temperature (＞35℃)	Accelerated electrolyte water evaporation intensifies plate sulfation and corrosion; increased self-discharge rate and heat accumulation during discharge may trigger thermal runaway	Increased side reactions inside cells accelerate lithium dendrite growth; BMS activates over-charge/over-discharge protection, while accelerating battery aging	At 40℃: 10%-20% short-term attenuation for lead-acid batteries; 5%-10% for lithium batteries (long-term high temperature causes irreversible attenuation)

2. Humidity (Relative Humidity, RH)

Humidity mainly affects battery safety and contact resistance, thereby indirectly influencing endurance:

• High Humidity Environment (RH＞85%): The battery casing and terminals are prone to moisture-induced corrosion, increasing terminal contact resistance and energy loss during charging and discharging. For lead-acid batteries, electrolyte is easily diluted by moisture, reducing reaction concentration; for lithium batteries, oxidation of positive and negative electrode tabs impairs current transmission.
• Low Humidity Environment (RH＜30%): Dry air is likely to generate static electricity, which may interfere with BMS signals; the battery casing is prone to cracking, resulting in reduced sealing performance.
• Critical Threshold: Controlling relative humidity within 45%-65% has no negative impact on battery endurance.

3. Dust and Corrosive Gases

Forklifts are commonly used in warehouses, workshops, ports and other scenarios, where dust and corrosive gases are typical pollutants:

• Dust Pollution: Dust adhering to the battery surface and vents blocks heat dissipation channels, causing an increase in battery operating temperature; dust entering the battery interior contaminates the electrolyte, damages the plate structure, and reduces reaction efficiency.
• Corrosive Gases (e.g., sulfur dioxide, chlorine gas): Under high humidity conditions, gases react chemically with metal components of the battery, causing terminal corrosion and plate damage, increasing internal resistance, leading to rapid voltage drop during discharge and shortened endurance.

4. Altitude

The impact of high-altitude environments on batteries is mainly reflected in air pressure and heat dissipation:

• At altitudes above 1000m, reduced air pressure and air density decrease battery heat dissipation efficiency, making overheating more likely to occur.
• High-altitude and low-pressure conditions accelerate electrolyte evaporation in lead-acid batteries, increasing water loss.
• Impact on Endurance: For every 1000m increase in altitude, battery endurance decreases by approximately 3%-5%.

II. Control Standards and Implementation Schemes for Environmental Factors

To reduce the impact of environmental factors on endurance, hierarchical control standards and a responsibility-assigned implementation process should be formulated, as follows:

1. Temperature Control SOP

Control Link	Operating Standards	Responsible Person	Cycle	Acceptance Indicator
Storage Environment	Install heating, ventilation and air conditioning (HVAC) or floor heating in battery storage areas to maintain temperature at 15-25℃; avoid direct sunlight	Warehouse Manager	24-hour Real-time Monitoring	Temperature fluctuation ≤ ±3℃
Charging Environment	Set up an independent charging room equipped with a temperature control system; suspend charging if battery temperature exceeds 35℃ during charging	Charging Operator	Each Charging Cycle	Battery temperature ≤ 30℃ during charging
Operating Environment	In low-temperature seasons (＜5℃), preheat the battery for 30 minutes before operation (via low-current charging); in high-temperature seasons (＞35℃), extend battery heat dissipation time during operation intervals	Forklift Operator	Daily Pre-shift / During Operation	Battery temperature ≥ 10℃ after preheating; temperature ≤ 30℃ after heat dissipation

2. Humidity and Dust Control Measures

• Humidity Control:
• In high-humidity seasons: Install dehumidifiers in battery storage areas and charging rooms, setting RH at 45%-65%.
• In low-humidity seasons: Place humidifiers to prevent static electricity generation.
• Dust and Corrosive Gas Control:
• Clean the battery surface daily, wiping terminals and casings with a dry cloth.
• Regularly sprinkle water in the operation area to reduce dust; in environments with corrosive gases (e.g., chemical workshops), install sealed protective covers for batteries.
• Keep charging rooms and battery storage areas away from acid and alkali storage zones.

3. Special Adjustments for High-Altitude Environments

• Adjust BMS parameters: Relax low-temperature discharge current limits (with technical support from battery manufacturers).
• Enhance heat dissipation: Install cooling fans for batteries and optimize ventilation structures.
• Shorten charging intervals: During high-altitude operations, appropriately increase charging frequency based on endurance attenuation (3%-5% per 1000m altitude gain).

III. Adaptation Suggestions for Environmental Factors and Battery Types

Different battery types have varying environmental tolerance levels, and enterprises can select battery types based on operating environments:

Environmental Characteristics	Recommended Battery Type	Core Advantages
Low-Temperature Environment (＜0℃)	Lithium Battery (Lithium Iron Phosphate)	Superior low-temperature discharge performance compared to lead-acid batteries, with smaller endurance attenuation
High-Temperature and High-Humidity Environment (＞35℃, RH＞85%)	Sealed Lead-Acid Battery / Lithium Battery	Sealed structure reduces risks of electrolyte evaporation and moisture damage
High-Dust / Corrosive Gas Environment	Lithium Battery	Compact structure and excellent sealing performance, resistant to dust pollution

IV. Monitoring and Evaluation of Endurance

• Data Collection: Equip each forklift with a battery management system to record real-time data such as ambient temperature, humidity, battery temperature and endurance mileage.
• Comparative Analysis: Collect and analyze endurance data under different environmental conditions monthly, establish an environment-endurance correlation model, and determine the impact coefficient of environmental factors.
• Abnormal Handling: When endurance attenuation exceeds the standard value (e.g., ＞20%), prioritize checking environmental factors (temperature, humidity, dust) before investigating battery malfunctions.