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Introduction
In fields such as logistics and warehousing, and industrial production, forklifts, as important material handling equipment, are widely used. As one of the main power sources for forklifts, the usage cost of lead-acid batteries is directly related to the operating costs of enterprises. Lead-acid batteries have advantages such as relatively low cost and mature technology. However, during long-term use, they also have problems such as long charging time, limited lifespan, and frequent maintenance, which lead to high usage costs. How to reduce the usage cost of lead-acid batteries for forklifts has become a focus of attention for many enterprises. Reducing the usage cost of lead-acid batteries through effective methods can not only enhance the economic benefits of enterprises but also improve their competitiveness in the market.
The characteristics and current application status of lead-acid batteries for forklifts
Feature analysis
Lead-acid batteries play an important role in the field of forklift power due to their unique chemical properties. Its positive electrode is lead dioxide, the negative electrode is spongy lead, and the electrolyte is sulfuric acid solution. This chemical composition endows lead-acid batteries with a relatively high specific energy, enabling them to provide a large current in a short period of time and meet the power demands when forklifts start and move heavy objects. Moreover, the technology of lead-acid batteries has become quite mature after long-term development, and the production process is stable. This makes their manufacturing cost relatively low, saving enterprises a certain amount of capital investment in the initial purchase stage. In addition, lead-acid batteries have relatively low requirements for the usage environment and can work stably in general industrial environments, demonstrating good adaptability.
Overview of Current Usage
At present, lead-acid batteries are still widely used in forklifts worldwide. Especially in some small and medium-sized enterprises, due to limited funds, they are more sensitive to equipment costs. Lead-acid battery forklifts have become the first choice because of their relatively low initial purchase cost. In logistics warehouses, a large number of forklifts shuttle between shelves for goods transportation, and a significant portion of them use lead-acid batteries. However, as the usage time increases, some drawbacks of lead-acid batteries gradually emerge. Its charging time is relatively long, usually taking 6 to 8 hours to fully charge, which to some extent affects the operational efficiency of the forklift. Moreover, the lifespan of lead-acid batteries is limited, typically around 1,500 cycles. Frequent battery replacement not only increases costs but also leads to equipment downtime and affects production progress.
The composition of the usage cost of lead-acid batteries for forklifts
Initial purchase cost
The initial purchase cost of lead-acid batteries for forklifts has certain advantages over other types of batteries, such as lithium batteries. The specific price will be affected by factors such as battery capacity, brand and quality. Generally speaking, the larger the capacity of a lead-acid battery, the higher its price. Some well-known brands of lead-acid batteries, due to their better quality and performance guarantees, tend to be relatively more expensive. For enterprises, when purchasing lead-acid batteries, although the initial purchase cost is relatively low, they still need to comprehensively consider multiple factors and cannot solely rely on price as the sole selection criterion.
Charging cost
The charging cost of lead-acid batteries is also an important component of their usage cost. Due to its relatively low charging efficiency, which is generally only 70% to 80%, this means that a considerable amount of electrical energy is wasted during the charging process. Moreover, lead-acid batteries take a long time to charge and consume a large amount of electrical energy. In addition, the cost of charging is also affected by electricity price policies. In some regions, electricity prices vary at different times. If enterprises can reasonably arrange charging time and use off-peak electricity prices for charging, they can reduce charging costs to a certain extent.
Maintenance cost
The maintenance cost of lead-acid batteries is relatively high. In daily use, it is necessary to regularly inspect and maintain the battery. It is necessary to regularly check the liquid level of the electrolyte. As lead-acid batteries consume water in the electrolyte during charging and discharging, distilled water or dedicated electrolyte replenishment liquid should be added regularly to ensure the normal operation of the battery. Generally speaking, such an operation needs to be carried out once a month. At the same time, it is also necessary to regularly check whether the battery terminals have shown signs of corrosion. If there is corrosion, it should be cleaned and maintained in a timely manner to ensure the battery's conductivity. In addition, lead-acid batteries also need to be equalized charged regularly, usually once a month, to ensure voltage balance among each battery cell and extend the battery's service life. Equalization charging requires the use of dedicated equipment, which also increases maintenance costs.
Replacement cost
As the usage time increases and the number of charge and discharge cycles rises, the performance of lead-acid batteries will gradually decline. When the battery capacity drops to a certain extent and can no longer meet the normal usage requirements of forklifts, replacement is necessary. For frequently used forklifts, the battery may need to be replaced every 2 to 3 years. The cost of replacing batteries not only includes the purchase cost of new batteries, but also the labor cost during the replacement process and the production loss caused by equipment downtime. Moreover, the used batteries that have been replaced need to be properly disposed of. If not handled properly, they will cause pollution to the environment, and the standardized disposal of used batteries also requires certain costs.
The impact of common problems in the use of lead-acid batteries for forklifts on costs
The battery capacity has declined
During the use of lead-acid batteries in forklifts, the decline in battery capacity is a common problem. As the number of charge and discharge cycles increases, the active substances inside the battery will gradually decrease, and sulfation will occur on the plates. All these will lead to a decline in battery capacity. When the battery capacity decreases, the working time of the forklift will be significantly shortened. A forklift that was originally capable of continuous operation for 8 hours may only be able to work for 5 hours or even less after the battery capacity drops. This means that forklifts need to be charged more frequently, increasing the charging cost. At the same time, to ensure the continuity of work, enterprises may need to be equipped with additional spare batteries, which further increases the initial purchase cost. Moreover, frequent charging will accelerate the aging of the battery, further shorten its service life and increase the cost of replacement.
The charging speed slows down.
After a period of use, the charging speed of lead-acid batteries will gradually slow down. This is because the internal resistance of the battery increases, resulting in a decrease in the efficiency of converting electrical energy into chemical energy. A battery that originally takes 6 to 8 hours to fully charge may take 10 hours or even longer to do so after being used for a period of time. A slower charging speed not only affects the operational efficiency of forklifts, reducing their actual working time, but also increases charging costs. Because the charging time is prolonged, the consumed electrical energy will also increase accordingly. In addition, the slowdown in charging speed may also affect the production plans of enterprises. To avoid production halts caused by forklifts running out of power, enterprises may need to adjust their operation processes, which will also bring certain indirect costs.
Shortened battery life
Multiple factors can lead to a shortened lifespan of lead-acid batteries in forklifts. Over-discharge is a significant cause. When the battery power is too low, if the forklift is still used, it will cause irreversible damage to the battery and accelerate its aging. In addition, improper charging can also affect battery life. For instance, overcharging can cause the internal temperature of the battery to rise, leading to deformation of the plates and shedding of active materials, thereby shortening the battery's lifespan. At the same time, the usage environment also has an impact on battery life. In high or low temperature conditions, the performance of lead-acid batteries will be significantly affected, and their lifespan will be correspondingly shortened. A shortened battery life means that batteries need to be replaced more frequently, which undoubtedly significantly increases the usage costs for enterprises, including the purchase cost of new batteries, the labor cost for battery replacement, and production losses caused by equipment downtime.
Methods to reduce the usage cost of lead-acid batteries in forklifts
Reasonable maintenance and upkeep
Regularly check the electrolyte level: Regularly checking the electrolyte level is an important part of maintaining lead-acid batteries. Check the electrolyte level at least once a month to ensure it is within the upper and lower limits marked on the battery casing. When the liquid level is too low, distilled water should be added in time. Never add tap water or mineral water, as the impurities they contain may have adverse effects on the chemical reactions inside the battery and accelerate its damage. When adding distilled water, pour it in slowly to avoid overflow. By conducting regular inspections and adding distilled water reasonably, the normal chemical reactions inside the battery can be guaranteed, the battery life can be prolonged, and the replacement cost can be reduced.
Check the terminals and connection points: Regularly inspect the terminals and connection points of the battery for any signs of corrosion. Terminal post corrosion will increase the internal resistance of the battery and affect its charging and discharging performance. The corrosion on the surface of the terminal posts can be regularly cleaned with tools such as wire brushes, and then a layer of vaseline or special protective grease can be applied to prevent the terminal posts from being corroded again. At the same time, check whether the bolts at the connection points are loose to ensure a firm connection and good electrical conductivity. This can reduce the decline in battery performance caused by problems with the terminal posts and connection points, and lower the charging cost and maintenance cost.
Equalization charging: Equalization charging once a month is crucial for lead-acid batteries. Balanced charging can make the voltages of each battery cell in the battery pack tend to be consistent, avoiding the impact on the performance and lifespan of the entire battery pack due to the voltage of individual battery cells being too high or too low. Use a dedicated equalization charging device and charge it in accordance with the operation instructions of the device. Generally speaking, the time for equalization charging is longer than that for ordinary charging, and the charging current is also relatively smaller. Regular equalization charging can effectively extend the battery's service life, reduce the frequency of battery replacement, and thereby lower the usage cost.
Optimize the charging strategy
Select the appropriate charging time: Based on the enterprise's electricity policy and the usage of the forklift, choose the charging time reasonably. If the area where you are located implements a peak-valley electricity price policy, try to charge the lead-acid battery of the forklift during the off-peak electricity price period. Charging during off-peak hours can effectively reduce charging costs. At the same time, based on the actual working time of the forklift, a reasonable charging plan should be arranged to ensure that the forklift has sufficient power during operation and avoid affecting work efficiency due to untimely charging.
Avoid overcharging and undercharging: Overcharging can cause the battery to heat up, accelerate the chemical reactions inside the battery, lead to plate deformation, active material shedding, and shorten the battery's lifespan. Undercharging will prevent the battery capacity from being fully utilized. Long-term undercharging can also cause battery sulfation, which in turn affects the battery's lifespan. Therefore, it is necessary to use a reliable charger and set the appropriate charging parameters according to the battery's specifications and manual. During the charging process, closely monitor the battery's charging status. Once the battery is fully charged, stop charging promptly. By avoiding overcharging and undercharging, the service life of the battery can be prolonged, and the cost of replacement and maintenance can be reduced.
Avoid frequent sudden acceleration and braking: When driving a forklift, frequent sudden acceleration and braking can cause the battery to output a large current instantaneously, which has a significant impact on the battery's lifespan. When accelerating rapidly, the battery needs to provide a large amount of electrical energy in a short period of time, which will cause the chemical reactions inside the battery to intensify, generating excessive heat and accelerating the aging of the battery. Sudden braking will cause the kinetic energy of the forklift to be converted into heat energy and wasted, and it will also have an adverse effect on the battery discharge process. Therefore, drivers should maintain smooth driving operations and try to avoid frequent sudden acceleration and braking. This can reduce battery wear and tear, extend battery life and lower usage costs.
Reasonable control of forklift load: When forklifts are moving goods, the load should be reasonably controlled according to the rated load capacity of the forklift. Overloading will increase the working current of the forklift motor, thereby increasing the output current of the battery and accelerating its aging. Long-term overloading may also lead to a rapid decline in battery capacity and shorten battery life. Before moving goods, the weight of the goods should be estimated to ensure that it does not exceed the rated load capacity of the forklift. If heavy goods need to be moved, they can be moved in several installments to avoid overloading causing damage to the battery and reduce the cost of battery replacement.
Consider battery repair technology: When the lead-acid battery of a forklift experiences problems such as capacity decline, battery repair technology can be considered. Some advanced battery repair technologies, such as pulse repair technology, can break the sulfide crystals on the surface of the plates by applying pulse currents of specific frequencies to the battery, reactivate the active substances inside the battery, and enhance the battery's capacity and performance. After repair, the service life of the battery can be extended to a certain extent, thereby reducing the frequency of battery replacement and lowering the usage cost.
Conclusion
In conclusion, reducing the usage cost of lead-acid batteries in forklifts has significant practical significance. Through understanding the characteristics and current usage status of lead-acid batteries for forklifts, the composition of their usage costs has been clarified, including initial purchase cost, charging cost, maintenance cost and replacement cost. Meanwhile, the impact of common problems such as reduced battery capacity, slowed charging speed, and shortened battery life on costs was analyzed. In response to these issues, a series of practical and feasible methods to reduce costs were proposed.