Analysis of the charge and discharge Cycles and lifespan of Lead-acid Batteries for Forklifts

Time：2025-07-24 09:53:50

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The number of charge and discharge cycles of lead-acid batteries in forklifts is directly related to their service life, which in turn has a significant impact on the operating costs and production efficiency of enterprises.

In fields such as logistics and warehousing, and industrial production, forklifts, as important handling equipment, the performance and lifespan of their power source - lead-acid batteries - have drawn much attention. The number of charge and discharge cycles of lead-acid batteries in forklifts is directly related to their service life, which in turn has a significant impact on the operating costs and production efficiency of enterprises. So, how exactly are the charge and discharge cycles of forklift lead-acid batteries defined? What factors influence its lifespan?
1. Concept and Calculation of Charge and Discharge Cycles
The so-called number of charge and discharge cycles refers to the complete process of a lead-acid battery from being fully charged to being completely discharged and then fully charged again, which is regarded as one cycle. For instance, a forklift operates with a battery until it runs out of power and then is recharged until fully charged. This is a charge-discharge cycle. However, in practical applications, it is not necessary to completely discharge the battery before recharging it every time. The charging process after partial discharge will also accumulate as part of one cycle. Then how to accurately calculate the number of charge and discharge cycles? Some advanced battery management systems for modern forklifts automatically record the number of charge and discharge cycles. If the forklift is not equipped with such a system, the remaining battery power ratio before each charge and the usage duration after charging can be manually recorded, and the number of cycles can be estimated based on a certain algorithm. For instance, if the battery power drops from 100% to 30% after one use and then is recharged to 100%, this can be regarded as 0.7 charge-discharge cycles.
2. General Lifespan of Lead-acid Batteries for Forklifts
Generally speaking, under normal usage and maintenance conditions, the charge and discharge cycle times of forklift lead-acid batteries are approximately 1,500 times. Based on an average of 1 to 2 charge and discharge cycles per day, its service life is approximately 2 to 5 years. However, this is only a rough range. The actual lifespan can vary due to many factors. Just like in large logistics warehouses, forklifts are frequently used, and the daily charge and discharge cycles may reach 3 to 4 times. Under such circumstances, the battery life may only be 2 to 3 years. In some small factories with a lower usage frequency, where the charge and discharge cycle is less than once a day, the battery may last for 4 to 5 years or even longer. So, why is there such a big difference?
3. Factors Affecting Charge and Discharge Cycles and Lifespan
(1) Usage Habits
Deep discharge problem: Excessive deep discharge causes great damage to lead-acid batteries. When the battery power of a forklift is too low but it is still used, causing the battery voltage to fall below the normal range, this is considered deep discharge. For instance, charging the battery only when its power is reduced to 10% or even lower. Deep discharge can lead to excessive consumption of active substances on the battery plates, accelerate plate sulfation, and thus shorten the battery life. Therefore, it is recommended to charge the battery when it has 20% to 30% of the remaining power.
Frequent charging and discharging: Some forklift operators, for convenience, charge the battery when it still has a lot of power left, or stop charging and put it into use before it is fully charged. Such frequent charging and discharging behavior will make the internal chemical reactions of the battery unstable, resulting in a decrease in battery capacity and a reduction in the number of charging and discharging cycles.
(2) Charging Method
The size of the charging current: If the charging current is too large, it will cause the battery to heat up severely, accelerate water loss and corrosion of the plates. Generally speaking, the appropriate charging current is 0.1 to 0.2 times the battery capacity. For instance, for a battery with a capacity of 100Ah, the charging current should be controlled between 10 and 20A. If too high a current is used for charging, although the charging time will be shortened, the battery life will also be greatly reduced.
Charging time: Charging for too long, that is, overcharging, will cause the battery to produce a large amount of gas, leading to the drying up of the electrolyte and the deformation of the plates. However, if the battery is charged for too short a time, it cannot be fully charged. If this continues for a long time, the battery capacity will gradually decrease. Therefore, it is necessary to operate strictly in accordance with the charging time specified in the battery manual.
(3) Environmental factors
Temperature influence: Temperature has a significant impact on the performance and lifespan of lead-acid batteries. In high-temperature environments, the chemical reactions inside the battery accelerate, which will speed up the battery's water loss and the aging of the plates. In a low-temperature environment, the viscosity of the battery electrolyte increases, the ion diffusion speed slows down, resulting in a decrease in battery capacity and a reduction in charging and discharging efficiency. For instance, during the hot summer, if forklifts operate outdoors for a long time, the battery temperature will be too high, and its lifespan will be affected. In cold winter regions, the difficulty in starting forklifts and the decline in battery life are also caused by the temperature.
Humidity and corrosive gases: A humid environment can easily cause rust on battery terminals, affecting conductivity. If there are corrosive gases in the working environment, such as in some chemical plants, these gases may corrode the battery casing and plates, shortening the battery life.
4. How to Extend the Lifespan of Lead-acid Batteries in Forklifts
(1) Standardize the operation and usage
Avoid deep discharge and charge in a timely manner according to the recommended remaining power ratio.
Try to minimize unnecessary frequent charging and discharging, and rationally plan the forklift's working tasks to ensure that the battery operates within an appropriate power range.
(2) Optimize charging management
Choose the appropriate charger and ensure that the charging current and voltage meet the battery requirements.
Strictly control the charging time to avoid overcharging and undercharging. An intelligent charging device can be installed, which can automatically adjust the charging parameters according to the battery status and stop charging automatically when fully charged.
(3) Improve the working environment
Try to park the forklift in a place with suitable temperature, dryness and good ventilation, and avoid direct sunlight and rain.
In an environment with corrosive gases, protective measures can be taken for forklift batteries, such as using battery boxes with good sealing performance and regularly cleaning and protecting the batteries.
In conclusion, the charge and discharge cycles and lifespan of forklift lead-acid batteries are influenced by multiple factors. By understanding these factors and taking corresponding measures, the battery life can be effectively extended, the operating costs of enterprises can be reduced, and production efficiency can be improved.

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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