Lead-acid batteries and forklift operation time management are key

Time：2025-07-23 14:22:02

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As the power source for most forklifts, the performance and condition of lead-acid batteries are the key factors determining the operating time of forklifts.

In scenarios such as logistics warehousing and manufacturing workshops, forklifts, as core equipment for material handling, their operational efficiency directly affects the overall production rhythm. As the power source for most forklifts, the performance and condition of lead-acid batteries are the key factors determining the operating time of forklifts. Scientific management of lead-acid batteries can not only extend the effective operation time of forklifts but also reduce the downtime losses caused by battery problems.
The core impact of lead-acid battery characteristics on forklift operation time
The performance parameters and usage status of lead-acid batteries directly affect the operation duration and stability of forklifts.
In terms of endurance, the nominal capacity of lead-acid batteries determines the theoretical operating time of forklifts. However, the actual range can be affected by multiple factors. For instance, when forklifts frequently start and stop or climb slopes under load, the motor power consumption increases sharply, and the battery discharge speed speeds up, which may shorten the actual operation time by 20% to 30%.
Charging efficiency is another key factor. The charging process of lead-acid batteries is divided into three stages: constant current, constant voltage and float charging. The complete charging cycle usually takes 8 to 10 hours. If charging is interrupted halfway and the battery is put into use before it is fully charged, not only will the single operation time be shortened, but it will also accelerate the sulfation of the battery plates. In the long run, this will cause the battery capacity to decline by more than 30%, further compressing the effective operation time.
In addition, the degree of battery aging should not be ignored either. As the number of uses increases, the plates of lead-acid batteries will gradually wear out, and their capacity will decline year by year. Generally speaking, after 3 to 5 years of use, the battery capacity will drop to 60% to 70% of its initial state, and the single operation time of the forklift will also be significantly reduced, requiring more frequent charging, which seriously affects the continuity of operation.
Operation time management strategy based on the characteristics of lead-acid batteries
In view of the characteristics of lead-acid batteries, formulating scientific management strategies can effectively extend the effective operation time of forklifts.
Reasonable planning of the charging cycle is the foundation. Enterprises should formulate a fixed charging schedule based on the operational intensity of forklifts and battery capacity. Forklifts operating during the middle shift can be recharged during the lunch break, but it should be noted that the recharging time should not exceed 2 hours to avoid overcharging and damaging the battery. At the same time, it is necessary to ensure that the charging environment is well-ventilated and the temperature is controlled at around 25℃. At this temperature, the battery charging efficiency is the highest, which can shorten the charging time by 10% to 15%.
Strengthening the daily maintenance of batteries is also of vital importance. Regularly check the battery level to ensure that the electrolyte level is 10-15mm higher than the plates. If it is insufficient, add distilled water in time (do not add tap water to avoid impurities affecting battery performance). Perform a balanced charge once a month to activate the deep capacity of the battery. Check the battery terminals every quarter, remove the oxide and apply vaseline to prevent the decline in power supply efficiency caused by poor contact. Doing these maintenance tasks well can increase the battery capacity retention rate by 15% to 20% and extend the single operation time by 1 to 2 hours.
Optimizing operation processes can also reduce battery wear and tear. By rationally planning the operation routes of forklifts, unnecessary round trips can be reduced. According to the weight of the goods and the distance of handling, forklifts of different capacities should be reasonably allocated to avoid small-capacity batteries undertaking heavy-load operations. When waiting for loading and unloading goods, turn off the power of the forklift in time to reduce idle power consumption. These measures can reduce the power consumption per unit time of the battery, enabling batteries of the same capacity to support a longer operating time.
Frequently Asked Questions
Question: How long can a forklift operate continuously after a lead-acid battery is fully charged?
Answer: The continuous operation time of forklifts is affected by factors such as battery capacity, operating load, and working conditions. If frequent heavy-load climbing and start-stop operations are carried out, the operation time may be shortened to 3 to 4 hours. It is recommended to plan the charging time in advance based on the actual working intensity to avoid power outages in the middle.
Question: How can the impact of lead-acid battery charging on the operation time of forklifts be reduced?
Answer: The mode of "off-peak charging + backup battery" can be adopted. Arrange for the forklift to be fully charged during non-operating hours (such as at night and during lunch breaks) to ensure that the main battery is fully charged. At the same time, 1 to 2 spare batteries should be equipped. When the power of the main battery drops below 20%, replace it in time to avoid downtime caused by waiting for charging. In addition, by using an intelligent charger, the charging current and voltage can be automatically adjusted, which can shorten the charging time by 1 to 2 hours compared with traditional chargers.
Question: Does the maintenance of lead-acid batteries take up too much working time?
Answer: Scientific maintenance not only does not take up too much working time, but also reduces the downtime caused by battery failure. During daily maintenance, checking the liquid level and terminal posts only takes 5 to 10 minutes each time and can be completed during the forklift shift handover. Although equalization charging takes 12 to 14 hours, it can be scheduled on weekends or during periods when the device is idle. In fact, proper maintenance can reduce the battery failure rate by more than 40%, shorten the forklift downtime caused by battery repairs, and improve overall operational efficiency.
Conclusion
Lead-acid batteries are closely related to the operation time management of forklifts. From battery selection, charging planning to daily maintenance, every link affects the effective operation time of forklifts. Enterprises should formulate targeted management plans based on their own operation intensity and scenarios. By scientifically utilizing the characteristics of lead-acid batteries, they can minimize downtime, enhance the operational efficiency of forklifts, and provide a strong guarantee for the smooth operation of production logistics.

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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