Understand the structural composition of forklift lead-acid batteries in One article

Time：2025-07-14 10:06:31

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Understanding the structural composition of forklift lead-acid batteries is of vital importance for their maintenance, troubleshooting and extending their service life.

In the operation of forklifts, lead-acid batteries play a crucial role in providing power support. Understanding the structural composition of forklift lead-acid batteries is of vital importance for their maintenance, troubleshooting and extending their service life. So, what exactly are the components of a forklift lead-acid battery?
Plate: The core component of a storage battery
The plates can be regarded as the core part of forklift lead-acid batteries. They are composed of grid frames and active materials. The grid frame is generally cast from lead-antimony alloy. The addition of antimony is mainly to enhance the mechanical strength of the grid frame, making it easier to cast and form during the production process. The active substance is made by mixing lead powder, additives and dilute sulfuric acid of a certain density. The plates are further divided into positive plates and negative plates. The active material on the positive plate is lead dioxide, which appears brownish red. The active material on the negative plate is spongy pure lead, with a bluish-gray color. During the charging and discharging process of a storage battery, it is the active substances on the plates that undergo chemical reactions with sulfuric acid in the electrolyte, achieving the mutual conversion of electrical energy and chemical energy. To increase battery capacity, multiple positive and negative plates are usually connected in parallel to form a positive plate group and a negative plate group respectively. During installation, the positive and negative plate groups are embedded in each other, with separators inserted in the middle to form a single battery. Here's a question: Why is it that in each single cell, the number of negative plates is always one more than that of positive plates? The reason lies in the fact that the active material on the positive plate is loose and has low mechanical strength. Clamping the positive plate between the negative plates can ensure uniform discharge on both sides of the positive plate. During operation, it is less likely to warp due to the expansion of the active material and can also reduce the situation of active material shedding.
Partition: The key to preventing short circuits
To prevent short circuits caused by adjacent positive and negative plates coming into contact with each other, a separator needs to be used to separate the positive and negative plates. The materials for partitions are diverse, with common ones including wood, microporous rubber, microporous plastic, as well as glass fiber pulp and glass wool. These materials all have a porous structure, the purpose of which is to enable the electrolyte to permeate freely, thereby ensuring that the carriers (ions) can move between the positive and negative electrodes and achieve the flow of current. Meanwhile, the chemical properties of the separator must be stable, with good acid resistance and oxidation resistance to adapt to the chemical environment inside the battery. The separator is usually a rectangular thin plate with a thickness of less than 1 millimeter, and its length and width are slightly larger than those of the plate. Some irregular-shaped partitions have special grooves on one side. When installing, the slotted side needs to face the positive plate perpendicularly. Such a design helps to better utilize the function of the partition.
Electrolyte: The "Catalyst" for Chemical Reactions
The electrolyte is a solution prepared by mixing pure sulfuric acid and pure distilled water in a certain proportion. Its specific gravity is generally around 1.28, but the exact value may vary depending on the usage environment and battery type. In forklift lead-acid batteries, the electrolyte plays a crucial role. It participates in the chemical reactions of active substances on the plates and serves as an important medium for the conversion of electrical energy to chemical energy. So, what impact does the concentration of the electrolyte have on battery performance? Generally speaking, if the electrolyte concentration is too high, although it can increase the electromotive force of the battery, it will accelerate the corrosion of the plates and shorten the battery life. However, if the concentration is too low, it will lead to a decrease in battery capacity and a deterioration in charging and discharging performance. Therefore, accurately controlling the concentration of the electrolyte is crucial for ensuring the normal operation of the battery.
Shell: Protects the internal structure of the battery
The casing is mainly used to hold the electrolyte and the plate group, making the battery form a complete whole. At present, the main shell materials are hard rubber and plastic. The hard rubber casing has high strength and good corrosion resistance, but it is relatively heavy. Plastic casings have the advantages of light weight and easy molding. Moreover, with the development of material technology, their corrosion resistance has been continuously improving. No matter which material is used, the casing needs to have good sealing performance to prevent the leakage of electrolyte, and at the same time be able to withstand certain external force impacts to protect the internal structure of the battery from damage.
Strips and terminals: Achieve voltage boosting and circuit connection
The function of the connecting bar is to link the single-cell batteries in series, thereby increasing the terminal voltage of the entire battery. By connecting multiple single-cell batteries in series, the different voltage requirements of forklifts can be met. The horizontal plates of the head and tail plate groups of ordinary lead-acid batteries are welded with terminal posts. The types of terminal posts include conical, L-shaped and side-hole types. These terminals are used to connect external circuits, outputting the electrical energy of the battery to various electrical devices of the forklift. At the same time, during charging, they are also connected to the charging power supply through the terminals to achieve the storage of electrical energy.
The various structural components of the lead-acid battery for forklifts work together to achieve the storage and release of electrical energy. From the core reaction of the plates, to the short-circuit protection of the separators, to the chemical reaction support of the electrolyte, as well as the protection of the casing and the circuit connection function of the connecting strips and terminals, every part is indispensable. Only by having a thorough understanding of these structural components can we better maintain and use the lead-acid batteries of forklifts, ensuring their efficient and stable operation.

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