How can forklift lead-acid batteries cope with peak warehouse operations

Time：2025-07-10 10:50:34

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Therefore, it is crucial to take effective measures to enable forklift lead-acid batteries to cope with peak warehouse operations.

During peak warehouse operations such as e-commerce promotions and holiday stockpiling, forklifts, as core equipment for goods handling, the stable operation of their lead-acid batteries directly affects operational efficiency. Once the battery malfunctions, it may cause the forklift to stop working and affect the operation of the entire warehouse. Therefore, it is crucial to take effective measures to enable forklift lead-acid batteries to cope with peak warehouse operations.
Carry out battery maintenance and inspection before peak hours
Before peak operation, conducting a comprehensive maintenance and inspection of the lead-acid battery of the forklift is the foundation for ensuring its normal operation. First of all, check the appearance of the battery to see if there is any shell cracking, leakage or other conditions. If the shell is found to be cracked, the electrolyte inside the battery may leak, which not only affects the performance of the battery but may also corrode other components of the forklift. In this case, the battery needs to be replaced in a timely manner.
Secondly, check the battery terminals. If the terminals become loose or oxidized, it will increase resistance, causing poor battery charging and discharging and affecting the power output of the forklift. For loose terminals, they should be tightened in time. For oxidized terminals, they can be sanded clean with sandpaper and then coated with Vaseline to prevent further oxidation.
In addition, the electrolyte level of the battery should be checked. During the use of lead-acid batteries, the electrolyte gradually evaporates, causing the liquid level to drop. If the liquid level is lower than the plates, it will affect the capacity and lifespan of the battery. Therefore, distilled water needs to be replenished regularly to keep the electrolyte level within the specified range (generally 10-15mm above the plates). It should be noted that tap water or electrolyte should not be replenished. Tap water contains impurities that can affect battery performance, while replenishing electrolyte will change the concentration inside the battery, leading to battery damage.
At the same time, the battery should be charged evenly. In daily use, due to the performance differences among individual batteries, there may be an imbalance in charging. A balanced charge before the peak can ensure that each individual battery is fully charged, thereby increasing the overall capacity of the battery. The method of equalization charging is as follows: First, fully charge the battery normally, and then continue charging with a small current until the voltage and electrolyte density of each individual battery reach the specified values.
Plan the charging strategy reasonably
During peak hours in the warehouse, forklifts are frequently used and the number of battery charges will also increase accordingly. Reasonable planning of charging strategies can ensure that the battery has sufficient power supply while avoiding damage to the battery caused by overcharging or undercharging.
First of all, a reasonable charging schedule should be formulated based on the operation time of the forklift and the capacity of the battery. During peak operation periods, the "intermittent charging" method can be adopted, that is, the battery can be charged in a timely manner during the intervals of forklift operation. For instance, when the battery power is consumed to a certain extent, charging can be arranged to prevent excessive discharge of the battery. Excessive discharge can cause sulfation of the battery plates, shortening the battery's service life.
Secondly, it is necessary to ensure the normal operation of the charging equipment. The quality of the charging equipment directly affects the charging effect. Before the peak period, a comprehensive inspection of the charging equipment should be carried out to ensure that it can work normally. At the same time, the charging positions should be reasonably arranged to avoid the situation of line overload when multiple batteries are charged simultaneously.
Also, pay attention to the temperature of the charging environment. The optimal charging temperature for lead-acid batteries is around 25℃. Both excessively high and low temperatures will affect the charging effect. Charging in a high-temperature environment will intensify the chemical reactions inside the battery, which may lead to problems such as battery swelling and leakage. When charging in a low-temperature environment, the charging efficiency of the battery will decrease and it will not be fully charged. Therefore, it is necessary to keep the temperature of the charging environment within an appropriate range as much as possible.
Strengthen the daily management of batteries
During the peak operation period in the warehouse, strengthening the daily management of batteries can promptly identify and solve problems, ensuring the normal operation of batteries. First of all, a battery usage ledger should be established to record information such as the usage time, number of charges, and charging duration of each battery. The usage of the battery can be understood through the ledger, and any abnormal conditions of the battery can be detected in a timely manner.
Secondly, it is necessary to standardize the operation behavior of forklift drivers. When forklift drivers are operating forklifts, they should avoid sudden acceleration, sudden braking and other operations. These operations will increase the instantaneous discharge current of the battery and shorten its service life. At the same time, it is necessary to avoid leaving the forklift idle for a long time. Long-term idleness can cause the battery to self-discharge, resulting in a decrease in power. When it is used again, it needs to be recharged, which affects the operational efficiency.
In addition, it is necessary to clean the dust and dirt on the battery surface in a timely manner. Dust and dirt can affect the battery's heat dissipation. During charging and use, the battery generates heat. If the heat dissipation is poor, it will cause the battery temperature to rise, affecting the battery's performance and lifespan.
Frequently Asked Questions and Answers
Question: What should I do if the battery suddenly runs out of power during peak work hours?
Answer: First, check if it is caused by excessive battery discharge. If so, the battery can be connected to a charging device for charging. However, it should be noted that high-current charging should not be carried out immediately. Instead, low-current slow charging should be performed first. After the battery voltage recovers to a certain extent, normal charging can be resumed. If the battery still cannot be used after charging, it may be faulty and a spare battery needs to be replaced in time. At the same time, faulty batteries should be inspected and repaired to identify the problem and prevent similar situations from happening again.
Question: How to determine if the battery needs to be replaced?
Answer: It can be judged from the following aspects: First, the service life of the battery. Generally speaking, the service life of lead-acid batteries for forklifts is 3 to 5 years. If the service life exceeds this range, the performance of the battery will decline significantly and replacement needs to be considered. The second is the battery capacity. By using professional testing equipment to measure the battery capacity, if the actual capacity of the battery is less than 70% of the rated capacity, it indicates that the battery has aged and cannot meet the demands of peak operations, and it needs to be replaced. The third is the battery's malfunction situation. If the battery experiences serious faults such as shell cracking or short circuit of the plates, the repair cost will be relatively high, and the battery also needs to be replaced at this time.
In conclusion, during the peak operation period of the warehouse, it is necessary to do a good job in the maintenance and inspection of the lead-acid batteries of forklifts, rationally plan the charging strategy, strengthen daily management, and at the same time understand the solutions to common problems. Only in this way can the stable operation of the batteries be guaranteed and the operation efficiency of the warehouse be improved.

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