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Battery industry information analysis -GSGT Mall Causes and preventive measures for Bulging lead-acid batteries in forklifts

Causes and preventive measures for Bulging lead-acid batteries in forklifts

Time:2025-07-15 09:53:10

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The following will conduct a detailed analysis of the causes of its bulging and the preventive measures.

During the operation of forklifts, lead-acid batteries play a crucial role. They provide power for forklifts and ensure their normal operation. However, bulging of lead-acid batteries in forklifts is a common and thorny problem, which not only affects the battery's service life but also may bring safety hazards. The following will conduct a detailed analysis of the causes of its bulging and the preventive measures.
The reasons for the bulging of lead-acid batteries in forklifts
Improper charging operation
Improper operation during the charging process is one of the main reasons for the bulging of lead-acid batteries in forklifts. Overcharging is a common problem. When a battery is fully charged but continues to be charged, a large amount of hydrogen and oxygen will be produced inside the battery. If these gases cannot be discharged in time, it will cause the battery casing to expand and bulge. Excessively high charging voltage can also cause bulging. High voltage will intensify the chemical reactions inside the battery, causing the active substances on the plates to fall off and generating excessive gas, thereby increasing the risk of bulging. In addition, using an mismatched charger with charging parameters that do not match the battery can lead to unstable current and voltage during the charging process, which in turn may cause the battery to bulge.
Environmental impact of use
Forklift lead-acid batteries are quite sensitive to the ambient temperature during use. High-temperature environments are an important factor leading to bulging. Under high-temperature conditions, the rate of chemical reactions inside the battery accelerates, generating more gas. Moreover, high temperatures can reduce the strength of the battery casing, making it prone to bulging under the influence of gas pressure. If forklifts are used outdoors for a long time in the hot summer or in a closed and poorly ventilated high-temperature workshop, the probability of battery swelling will increase significantly.
Problems with the battery itself
As the usage time increases, the battery will gradually age, the active material on the plates will constantly fall off, and the separator inside the battery will also be damaged, causing an internal short circuit of the battery and thus leading to bulging. In addition, the corrosion of battery plates is also a significant cause. Impurities in the electrolyte or improper charging methods can lead to plate corrosion, resulting in uneven plate thickness. During the charging and discharging process, excessive local current is generated, which in turn causes bulging.
Improper maintenance
Improper daily maintenance can also cause battery swelling. If the electrolyte in the battery is insufficient, the plates will be exposed to the air, leading to oxidation and corrosion of the plates. At the same time, during charging, the reaction area will decrease, the current density will increase, and excessive gas will be produced, causing bulges. Long-term undercharging is also a problem. When a battery is in a state of insufficient power for a long time, sulfation will occur on the plates, reducing the battery's capacity and deteriorating its charging and discharging performance. It is prone to swelling during charging.
Preventive measures for bulging lead-acid batteries in forklifts
Standardize charging operations
Charge strictly in accordance with the requirements of the battery manual to avoid overcharging. When the battery is fully charged, the power supply should be cut off in time and it should not be charged for a long time. Select a charger that matches the battery model and ensure that parameters such as charging voltage and current meet the battery requirements. Regularly check the working condition of the charger. If there is any fault, repair or replace it in time.
Control the usage environment
Try to avoid forklifts operating for long periods in high-temperature environments. During the hot summer, shading measures can be taken or forklifts can be used in well-ventilated areas. For forklifts operating in closed workshops, it is necessary to enhance workshop ventilation and lower the ambient temperature. At the same time, it is necessary to avoid subjecting the battery to severe vibration and collision to prevent damage to the battery casing.
Strengthen battery maintenance
Regularly check the height of the battery electrolyte level. If the level is lower than the specified mark, add distilled water in time. Be careful not to add tap water or electrolyte to avoid affecting the battery performance. To prevent the battery from being discharged for a long time, when the forklift is not in use, it should be charged in time to keep the battery fully charged. Regularly perform equalization charging on the battery to prevent sulfation of the plates.
Regularly check the battery status
Regularly test the battery, including appearance inspection, voltage detection, capacity detection, etc. If any phenomena such as bulging, leakage or corrosion of the plates are found in the battery, they should be dealt with or the battery replaced in time. For severely aged batteries, they should be replaced in a timely manner to prevent safety accidents caused by battery problems.
Frequently Asked Questions and Answers
Question: Can a slightly swollen battery still be used?
Answer: Even if the battery is only slightly swollen, it is not recommended to continue using it. Because a bulge indicates that structural damage has occurred inside the battery, continuing to use it may cause the bulge to worsen, and even lead to safety hazards such as leakage and explosion. At the same time, it will also affect the normal operation of the forklift and shorten the battery's service life. So once a bulging battery is found, it should be replaced in time.
Question: How to determine if the charger is compatible with the battery?
Answer: You can check the label on the charger and the manual of the battery to confirm whether the output voltage and current of the charger are consistent with the rated voltage and rated charging current of the battery. If the output voltage of the charger is too high or too low, or the output current is too large or too small, it indicates that the charger is not compatible with the battery. In addition, when using an mismatched charger, phenomena such as charging time being too long or too short, and severe battery heating may occur. These can also serve as criteria for judgment.
In conclusion, understanding the causes of bulging of lead-acid batteries in forklifts and taking effective preventive measures are of great significance for extending the battery's service life and ensuring the safe operation of forklifts. In daily use, it is necessary to operate in a standardized manner, strengthen maintenance, conduct regular inspections, and promptly address any issues with the battery to reduce the occurrence of bulges.

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