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Abstract
This article conducts an in-depth discussion on the deep repair technology of forklift lead-acid batteries, analyzes in detail the main reasons for the failure of forklift lead-acid batteries, systematically expounds the key technologies and methods of deep repair, and verifies the repair effect through actual cases. The aim is to provide scientific and effective reference basis for the maintenance and repair of forklift lead-acid batteries, and help enterprises reduce operating costs and improve resource utilization.
1. Introduction
In modern logistics and warehousing industries, forklifts, as indispensable handling equipment, mainly rely on lead-acid batteries for their power sources. Lead-acid batteries have occupied an important position in the forklift field due to their advantages such as low cost and mature technology. However, as the usage time increases, lead-acid batteries will experience problems such as reduced capacity and weakened charging and discharging performance, eventually leading to battery failure. If new batteries are replaced directly, not only will the cost be high, but it will also cause waste of resources and environmental pollution. Therefore, the research on the deep repair technology of lead-acid batteries for forklifts has significant practical significance. It can extend the service life of batteries, reduce the operating costs of enterprises, and at the same time respond to the national call for energy conservation and emission reduction.
2. Analysis of the Failure Causes of Lead-Acid Batteries in Forklifts
(1) Plate vulcanization
Plate sulfation is one of the common reasons for the failure of lead-acid batteries in forklifts. When the battery experiences long-term undercharging, over-discharge, or low electrolyte level during use, lead sulfate on the battery plates will crystallize and adhere to the surface of the plates, forming large and hard-to-dissolve lead sulfate crystals. This process is called plate sulfation. After sulfidation, the active material of the plates decreases, the internal resistance of the battery increases, resulting in a decline in battery capacity and a deterioration in charging and discharging performance.
(2) Plate softening
Long-term high-current charging and discharging, frequent deep discharging, and use in high-temperature environments and other factors will cause the active material on the plates to gradually become loose and fall off, resulting in plate softening. After the plates soften, the charging and discharging capacity of the battery is significantly reduced, and it may even fail to work properly.
(3) Deterioration of the electrolyte
The electrolyte plays a role in conducting ions during the charging and discharging process of the battery. As the usage time increases, the concentration of sulfuric acid in the electrolyte will change, and the moisture content will also decrease due to evaporation and electrolysis, resulting in an imbalance in the density of the electrolyte. In addition, impurities may also be mixed into the electrolyte, further affecting the battery's performance and accelerating its failure.
(4) Self-discharge
During the storage of forklift lead-acid batteries, self-discharge may occur due to the reaction between the chemical substances inside the battery and the components in the air, or the existence of tiny short circuits between the battery plates. Long-term self-discharge will gradually deplete the battery's power, causing it to be undercharged and thereby affecting its service life.
3. Key Technologies for Deep Repair of Lead-Acid Batteries in Forklifts
(1) Pulse repair technology
Pulse repair technology is to repair vulcanized plates by using high-frequency pulse waves. When high-frequency pulse waves act on the battery plates, they can break the molecular structure of lead sulfate crystals, causing them to redissolve into the electrolyte and restore the active substances of the plates. This technology has the advantages of good repair effect and no damage to the plates. When performing the specific operation, connect the pulse repair instrument to the battery, set the appropriate pulse frequency, pulse width and repair time. Generally, the repair time is determined by the degree of battery sulfation, ranging from several hours to tens of hours.
(2) Chemical remediation technology
Chemical repair technology repairs batteries by adding specific repair liquids to them. The repair solution contains substances that can undergo a chemical reaction with lead sulfate, converting lead sulfate into soluble substances, thereby achieving the purpose of repairing the sulfidation of the plates. Common components of repair fluids include organic acids, complexing agents, etc. When using chemical repair technology, first, the old electrolyte in the battery needs to be drawn out, then an appropriate amount of repair solution is injected. After standing for a period of time, the repair solution is drawn out again and new electrolyte is injected. It should be noted that the formula and usage method of the chemical repair solution need to be strictly controlled; otherwise, it may cause secondary damage to the battery.
(3) Heating repair technology
Heating repair technology is mainly aimed at batteries whose performance declines or is slightly sulfated due to low-temperature environments. By appropriately heating the battery, the temperature of the electrolyte can be raised, the viscosity of the electrolyte can be reduced, and the dissolution of lead sulfate crystals can be promoted. Water bath heating or dedicated heating equipment can be used to heat the battery, but the heating temperature should not be too high, generally controlled at around 40-50 ℃. Excessively high temperatures can damage the internal structure of the battery. During the heating process, it is necessary to ensure uniform heating and monitor the temperature and voltage changes of the battery in real time.
(4) Balanced charging repair technology
Balanced charging repair technology is applicable to forklift battery packs where multiple battery groups are used in series. During the use of battery packs, due to the performance differences of each individual battery, the voltage of each individual battery in the battery pack may become unbalanced. Some batteries may experience overcharging or overdischarging, accelerating the aging of the battery. Balanced charging repair technology uses special charging equipment to charge and monitor each individual battery in the battery pack separately, making the voltage of each individual battery consistent, thereby extending the service life of the battery pack. When performing equalization charging, it is necessary to select the appropriate charging current and charging time to avoid causing damage to the battery.
4. Steps for Deep Repair of Lead-Acid Batteries in Forklifts
(1) Battery testing and Evaluation
Before conducting a deep repair, a comprehensive inspection and assessment of the battery must be carried out first. Use professional battery testing equipment to measure parameters such as battery voltage, internal resistance, and capacity, and determine the cause of battery failure and the extent of damage. For instance, by measuring the internal resistance of a battery, the degree of sulfation of the plates can be determined. The greater the internal resistance, the more severe the sulfation. The actual performance of a battery can be understood by measuring its capacity.
(2) Formulate a repair plan
Based on the test results of the battery, formulate a targeted repair plan. If the main problem with the battery is sulfation of the plates, pulse repair technology or chemical repair technology can be selected. If it is a problem of plate softening, the repair is rather difficult. You can try to combine multiple repair techniques for the repair. For the problem of electrolyte deterioration, it is necessary to replace the electrolyte and carry out appropriate charging and discharging treatment. For self-discharge issues, it is necessary to identify the causes of self-discharge, such as checking whether the battery casing is damaged or if there is a short circuit in the plates, and then carry out corresponding repairs.
(3) Restoration and Implementation
Carry out the repair operation in accordance with the established repair plan. When using a pulse repair instrument, it is necessary to connect the device correctly, set the parameters properly, and closely observe the changes in battery voltage, current, etc. When using chemical remediation technology, it is essential to strictly follow the instructions for the use of the remediation solution to ensure the accuracy of the injection volume and the standing time of the remediation solution. During the heating repair process, it is necessary to control the heating temperature and time well to prevent the battery from overheating. When performing balanced charging repair, it is necessary to follow the operation procedures of the charging equipment to ensure that each individual battery is charged evenly.
(4) Post-repair inspection and maintenance
After the repair is completed, the battery should be inspected again, and various parameters of the battery should be measured and compared with those before the repair to evaluate the repair effect. If the repair effect is not satisfactory, you can consider repairing it again or replacing the battery. At the same time, it is necessary to strengthen the maintenance of the repaired battery, regularly check the liquid level height and density of the electrolyte, keep the battery clean and dry, avoid over-discharge and long-term undercharge of the battery, and extend the service life of the battery.
5. Conclusion
Deep repair technology for forklift lead-acid batteries is a technology of significant practical value. By accurately analyzing the causes of battery failure, rationally applying key technologies such as pulse repair technology, chemical repair technology, heating repair technology and balanced charging repair technology, and operating in accordance with scientific repair methods and steps, it can effectively extend the service life of forklift lead-acid batteries. Reduce the operating costs of enterprises. However, at present, the deep repair technology for lead-acid batteries in forklifts still has some shortcomings, such as limited repair effect on severely damaged batteries. In the future, further in-depth research and exploration are still needed to continuously improve the repair technology and enhance the repair effect, providing more powerful support for the maintenance and sustainable development of forklift lead-acid batteries.