The stability of forklift lead-acid batteries can be observed from the discharge curve

Time：2025-07-10 10:42:47

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The discharge curve, as a reflection of the performance of the battery, can visually present the voltage variation law at different discharge stages, providing a key basis for judging stability.

In forklift operations, the stability of lead-acid batteries directly affects work efficiency and operational safety. The discharge curve, as a reflection of the performance of the battery, can visually present the voltage variation law at different discharge stages, providing a key basis for judging stability.
The basic concept and significance of the discharge curve
The discharge curve refers to the relationship curve of the voltage of a battery varying with time during the constant current discharge process. It takes time as the horizontal axis and voltage as the vertical axis, completely recording the entire process from the start of discharge to the end of voltage. For forklift lead-acid batteries, this curve is like a "physical examination report", containing important information such as battery capacity, internal resistance, and plate condition.
Under normal circumstances, the discharge curve of high-quality lead-acid batteries for forklifts should present three major characteristics: a steady voltage drop in the initial stage, a relatively long plateau period in the middle stage, and a rapid voltage drop to the terminal voltage in the final stage. This regular change indicates that the chemical reaction inside the battery is stable, the energy output is uniform, and it can provide continuous and reliable power for forklifts.
The correlation between the characteristics of discharge curves and the stability of storage batteries
Voltage fluctuations during the initial discharge stage
At the initial stage of discharge, if the voltage fluctuates sharply, it may be caused by sulfation of the internal plates of the battery or uneven concentration of the electrolyte. Plate vulcanization can lead to an increase in internal resistance, causing a sudden drop in voltage. An imbalance in the concentration of the electrolyte will affect the rate of chemical reactions, causing the voltage to fluctuate. This type of battery is prone to insufficient power and even sudden engine shutdown when the forklift starts, greatly reducing its stability.
On the contrary, a battery with a stable voltage in the initial stage indicates that its plates are in good condition, the electrolyte is evenly distributed, and it can quickly adapt to the large current demand when the forklift starts, providing a stable start for the operation.
The duration of the mid-term plateau period
The plateau period in the middle of discharge is a core indicator for measuring the stability of a battery. The longer the plateau period, the more it indicates that the battery can maintain a stable voltage output for a longer time, meeting the demand for the forklift to operate continuously for a long time. If the plateau period shortens and the voltage drop rate accelerates, it may be caused by the shedding of active material on the plates or an internal short circuit of the battery.
The shedding of active substances on the plates will reduce the area for chemical reactions and lower the energy output efficiency. Internal short circuits will lead to unnecessary consumption of electrical energy, causing the battery to enter the attenuation stage prematurely. Forklifts equipped with this type of battery will frequently experience power attenuation during operation and require frequent charging, which seriously affects the work progress.
The rate of voltage drop at the end
At the end of discharge, the rate of voltage drop should remain relatively stable. If there is a sudden drop, it may be caused by a severe shortage of battery capacity or aging of the plates. Batteries with insufficient capacity cannot meet the full-load operation requirements of forklifts, and aged plates will cause the battery to lose its regulating ability when approaching the terminal voltage, increasing the risk of sudden power failure of forklifts.
Q&A on Discharge curves and the stability of lead-acid batteries for forklifts
Question: How to determine whether the lead-acid battery of a forklift needs to be replaced through the discharge curve?
Answer: When the discharge curve shows the following situations, it indicates that the battery stability can no longer meet the operational requirements and replacement should be considered: First, the voltage fluctuation range in the initial stage exceeds 0.2V; Second, the plateau period is shortened by more than 30% compared to new batteries. The third point is that the time for the final voltage to drop from 1.8V to 1.75V is less than 5 minutes. These phenomena indicate that there has been severe wear and tear inside the battery. Continuing to use it may cause safety hazards.
Question: In daily use, what operations can cause abnormal discharge curves?
Answer: Frequent deep discharges (discharging below the terminal voltage) will accelerate the sulfation of the plates, intensifying the fluctuations in the initial stage of the discharge curve. Insufficient charging can lead to a low density of the electrolyte and shorten the plateau period. If left idle for a long time without maintenance, the electrolyte will stratify, causing a sudden drop in the final voltage. Therefore, standardized operation and regular maintenance are the keys to keeping the discharge curve normal.
Battery maintenance suggestions based on discharge curves
Regular detection of the discharge curve is an effective means to ensure the stability of lead-acid batteries in forklifts. It is recommended to conduct a discharge test once a month and record the trend of curve changes. If any abnormality in the curve is detected, targeted measures should be taken promptly: For batteries with sulfated plates, the de-sulfation charging method can be adopted to restore performance. For batteries with uneven electrolyte concentrations, distilled water should be added and balanced charging should be carried out. For batteries with fallen active substances, they should be replaced in a timely manner to prevent the fault from expanding.
In addition, plan the operation time of forklifts reasonably and avoid continuous discharge for a long time. Keep the charging environment well-ventilated and dry to ensure full charging. Regularly cleaning the battery terminals to prevent poor contact from affecting the discharge efficiency can effectively maintain the stability of the discharge curve and extend the service life of the battery.
In conclusion, the discharge curve is an important basis for judging the stability of lead-acid batteries in forklifts. By interpreting the curve characteristics, potential battery problems can be detected in a timely manner and scientific maintenance measures can be taken, which can significantly enhance the reliability of forklift operations, reduce operating costs, and provide a strong guarantee for the efficient production of enterprises.

Statement: The articles on this site are written by the GSGT team or reprinted from other media or compiled by AI.No reproduction without permission.For copyright or other issues, please contact:gsgtpower@163.com.

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