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In the modern logistics and warehousing industry, forklifts, with their high efficiency and flexibility, have become indispensable handling equipment. As the "heart" of electric forklifts, the performance and stability of lead-acid batteries directly determine the working efficiency and operating costs of the forklifts. However, in the actual usage process, various problems with forklift lead-acid batteries are inevitable. These problems not only affect the operation progress but may also lead to high maintenance and replacement costs. This article will deeply analyze the common problems of lead-acid batteries in forklifts and provide practical solutions to help enterprises improve equipment management levels and reduce operating costs.
One. Battery capacity has declined
(1) Problem Manifestations
After being used for a period of time, the lead-acid battery of a forklift will show a significant reduction in working time after charging. Forklifts that were originally capable of working for 8 hours on a full charge can now only operate for 4 to 5 hours, or even less, failing to meet the demands of daily operations. This not only seriously affects work efficiency, but frequent charging also increases labor and time costs.
(2) Cause Analysis
1. ** Plate sulfation ** : Long-term undercharging, low electrolyte level or over-discharge of the battery will cause white and hard lead sulfate crystals to form on the surface of the plates, resulting in a reduction of active material on the plates and a decrease in battery capacity.
2. ** Excessive self-discharge ** : Impurities inside the battery or short circuits between the plates can cause the battery to continuously discharge even when not in use, resulting in rapid power loss and a reduction in actual available capacity.
3. ** Abnormal electrolyte density ** : An imbalance in the ratio of sulfuric acid to water in the electrolyte, as well as excessively high or low electrolyte density, will affect the chemical reactions of the battery and thereby reduce its capacity.
(3) Solutions
1. ** Prevent sulfation of the plates ** : Charge the battery strictly in accordance with the specified charging time and voltage to avoid undercharging and over-discharging. Regularly check the height of the electrolyte level, and promptly add distilled water or dedicated lead-acid battery replenishment liquid to keep the liquid level within the specified scale range.
2. ** Dealing with self-discharge issues ** : Conduct a comprehensive inspection of the battery, identify short-circuit points and repair them; If there are too many impurities inside the battery, it can be cleaned by charging and discharging it multiple times. Replace the battery if necessary.
3. ** Adjust the density of the electrolyte ** : Use a hydrometer to measure the density of the electrolyte. Based on the measurement results, add distilled water or sulfuric acid to adjust the density of the electrolyte to the specified value.
Two. Abnormal battery charging
(1) Problem Manifestations
During the charging process, the battery gets extremely hot and even smokes. The charging voltage is abnormal and cannot reach the normal charging termination voltage. The charging time is too long, far exceeding the normal charging duration.
(2) Cause Analysis
1. ** Excessive charging current ** : The output current of the charger is set too high, exceeding the battery's capacity to handle it, causing overly intense chemical reactions inside the battery and generating a large amount of heat.
2. ** Plate Short circuit ** : The active material on the plates falls off and accumulates at the bottom of the battery, causing a short circuit between the plates. If the separator is damaged, the positive and negative plates will also come into direct contact, causing a short circuit and affecting the charging process.
3. ** Charger failure ** : Damage to internal components of the charger, such as rectifier diode breakdown or filter capacitor failure, can cause unstable output voltage or current, affecting the charging effect.
(3) Solutions
1. ** Adjust the charging current ** : According to the battery capacity and specifications, set the charging current of the charger reasonably. Generally, the charging current is about one-tenth of the battery capacity.
2. ** Repair plate short circuit ** : Open the battery casing, inspect the condition of the plates and separators, remove the accumulated active material at the bottom of the plates, and replace the damaged separators; If the short circuit of the plates is severe and cannot be repaired, the entire battery pack needs to be replaced.
3. ** Inspect and Repair the charger ** : Conduct professional testing on the charger and replace damaged components; Regularly maintain and service the charger to ensure its stable performance.
Three. Battery leakage
(1) Problem Manifestations
There is residual electrolyte on the surface of the battery casing, and there is a pungent sour smell in the battery compartment. The level of the battery electrolyte drops too rapidly, and it is necessary to frequently add supplementary liquid.
(2) Cause Analysis
1. ** Battery casing damage ** : During the operation of the forklift, the battery is subject to collision or compression, causing cracks or damage to the casing and leakage of the electrolyte.
2. Poor sealing of the terminal posts: The sealant at the connection between the terminal posts and the battery casing ages, cracks, or is not sealed tightly, causing the electrolyte to seep out from around the terminal posts.
3. ** Damaged filling port cover ** : The sealing gasket of the filling port cover is aged or lost, or the filling port cover is not tightened properly, causing the electrolyte to overflow when the battery is shaken.
(3) Solutions
1. ** Repair or replace the battery casing ** : For minor casing damage, a dedicated plastic welding tool can be used for repair. If the casing is severely damaged and cannot be repaired, a new battery casing needs to be replaced.
2. ** Reseal the terminal posts ** : Clean the impurities and old sealant at the connection between the terminal posts and the casing, apply new sealant, and ensure a firm seal. If the terminal posts are damaged, they should be replaced with new ones in time.
3. ** Replace the liquid filling port cover ** : Check whether the sealing gasket of the liquid filling port cover is intact. If it is damaged or lost, it should be replaced in time. After each addition of the electrolyte, make sure the cap of the filling port is tightened.
Four. Battery bulging
(1) Problem Manifestations
The battery casing may partially or completely expand and deform. In severe cases, the casing may crack, affecting the normal use and safety of the battery.
(2) Cause Analysis
1. ** Excessive charging time ** : Overcharging can cause a large amount of gas to be generated inside the battery, which cannot be discharged in time, leading to an increase in internal pressure and causing the casing to bulge.
2. Poor heat dissipation: During the battery charging process, heat is generated. If the charging environment is poorly ventilated or the battery's heat dissipation holes are blocked, the heat cannot be dissipated in time, causing the battery temperature to rise and the internal pressure to increase, resulting in bulging.
3. ** Mismatch of charger parameters ** : Using a charger that does not match the battery specifications, such as having a charging voltage that is too high or a charging current that is too large, will cause abnormal chemical reactions inside the battery, generating excessive gas and heat, leading to swelling.
(3) Solutions
1. ** Control charging time ** : Charge strictly in accordance with the charging time specified in the battery user manual to avoid overcharging; A charger with a timing function can be used. When the charging time reaches the set value, the charging will automatically stop.
2. ** Improve heat dissipation conditions ** : Ensure that the battery charging environment is well-ventilated, and regularly clean the dust and debris on the battery surface and heat dissipation holes; When charging in a high-temperature environment, appropriate cooling measures can be taken, such as using fans to assist in heat dissipation.
3. ** Use a matching charger ** : Select a charger that exactly matches the battery specifications. Do not replace or use inferior chargers at will. Before using the new charger, you should read the product manual carefully to understand its performance parameters and usage methods.
Five. Shortened battery life
(1) Problem Manifestations
Before the battery reaches its expected service life, problems such as severe capacity decline and abnormal charging occur, requiring early battery replacement, which increases the operating costs of the enterprise.
(2) Cause Analysis
1. Improper use and maintenance: Failing to follow the operating procedures when using the battery, such as frequent over-discharge, untimely charging, and lack of regular maintenance and care, will accelerate the aging and damage of the battery.
2. ** Harsh working environment ** : If batteries are exposed to high temperatures, high humidity, dust and other harsh conditions for a long time, it will affect their performance and lifespan. High temperatures can accelerate the chemical reactions inside the battery, causing the plates to age. A high-humidity environment can cause the battery casing and plates to rust and corrode. Dust can enter the battery interior, causing short circuits and other faults.
3. ** Quality issues ** : If the purchased battery itself has quality defects, such as poor plate material or substandard production processes, it will also lead to a shortened battery life.
(3) Solutions
1. ** Standardized Use and Maintenance ** : Establish strict battery use and maintenance management systems, and operators must operate in accordance with the procedures; Regularly inspect and maintain the battery, including measuring the density of the electrolyte, checking the condition of the plates, and cleaning the battery surface, etc.
2. ** Improve working environment ** : Create a good working environment for the battery and avoid using it in harsh conditions such as high temperature, high humidity, and dust; In high-temperature environments, cooling measures can be taken. In a high-humidity environment, dehumidification equipment can be used. For environments with a lot of dust, appropriate protection should be provided for the battery, such as installing a protective cover.
3. ** Select high-quality batteries ** : When purchasing batteries, choose brands and suppliers with good reputation and reliable quality; Carefully review the product manual and quality inspection report of the battery to understand its performance parameters and quality status.
To sum up, most of the various problems that occur during the use of forklift lead-acid batteries are related to improper use, maintenance and management. By thoroughly understanding the manifestations and causes of common battery problems and adopting corresponding solutions, as well as strengthening the daily maintenance and management of batteries, the service life of batteries can be effectively prolonged, the working efficiency of forklifts can be improved, and the operating costs of enterprises can be reduced. Meanwhile, enterprises should also enhance the training of operators, raise their awareness of the correct use and maintenance of batteries, and ensure that the lead-acid batteries of forklifts are always in good working condition.