Upgrade Your Forklift Power: Discover the Advantages of Lithium Batteries

Here are the key specifications that require attention:

Battery voltage (V) and capacity (Ah): Several standard voltage options (12V, 24V, 36V, 48V, 72V, 80V) and different capacity options (ranging from 100Ah to 1000Ah and higher) are available for various lift truck models. For instance, a 24V 210Ah battery is commonly used for a 4000 lb pallet jack, while an 80V 1050Ah battery is suitable for a counterbalance sit-down forklift handling loads up to 20K lbs.

The cycle life of lithium batteries for electric forklifts generally ranges from approximately 800 to 1500 cycles. Regardless of brand, the actual service life of a battery pack can vary from 1 to 5 years depending on the usage environment. So, how is this timeframe of 1 to 5 years determined? Why is there such a significant disparity, where some companies' electric forklift batteries last up to 5 years, while others fail in less than a year? 

The following factors contribute to the shortened lifespan of lithium batteries in electric forklifts:

1. Demanding Operational Conditions:  

   During actual use, such as in scenarios with short transport intervals and frequent starts and stops, the energy consumption during operation is relatively high. Meanwhile, the onboard charging system delivers a higher charging current compared to other types of electric vehicles. Prolonged high-current charging can intensify the water decomposition reaction within the battery, leading to increased gas evolution and water loss. Excessive gassing can weaken the adhesion between the active material and the grid, causing the active material to shed and contaminating the electrolyte. Furthermore, excessive gas generation increases internal pressure. If venting is obstructed, this pressure may force electrolyte mist and acid vapor to spray out. In severe cases, if pressure cannot be released promptly, there is a risk of rupture.

2.Vibration and Physical Stress:  

   Due to the compact design of electric forklifts, they have a relatively small turning radius. However, this also results in significant vibration during operation, which can potentially damage the battery. Internal components, such as weld points or busbars, may fracture, leading to internal sparking, short circuits between positive and negative terminals, and a sudden increase in internal pressure—potentially causing battery rupture. Vibration can also accelerate the mechanical shedding of active material and further contaminate the electrolyte.

3. Growing Importance and Cost Considerations:  

   Electric forklifts are valued for their operational safety, energy efficiency, and environmental benefits, playing an increasingly vital role in industrial production and storage/transportation. Demand for them is growing rapidly across various sectors. A significant portion of their operating cost comes from the power battery. The same battery, depending on maintenance and usage practices, can have vastly different service lives, leading to considerable differences in overall operating costs.

4. Battery-Specific Factors:  

A. Quality and Balancing Issues:  

   Substandard quality of the power battery itself, particularly poor balance among individual cells within the battery pack, can cause rapid degradation of the entire pack's lifespan. Imbalance leads to uneven stress during charging and discharging, accelerating overall capacity fade and failure.

B. Incompatible Chargers Causing Overcharging and Over-discharging:  

The use of mismatched chargers can lead to overcharging and over-discharging, which are primary causes of battery plate sulfation. Plate sulfation is a fundamental factor contributing to the shortened lifespan of batteries.

C. Improper Usage and Maintenance - "Dual Overload":  

Incorrect operational practices, such as the "Dual Overload" phenomenon during the discharge phase—where discharge currents persistently exceed allowable limits—also serve as a major cause of battery plate sulfation. This practice is highly detrimental to battery longevity.

Battery performance must align with the actual operational requirements of the forklift or lifting equipment. In some cases, even identical forklifts within the same facility may be used differently (e.g., handling varying types of cargo). Under such circumstances, it may be necessary to equip them with different batteries.

Lithium batteries represent the safest choice for industrial forklifts. They avoid all the issues associated with lead-acid technology, such as corrosion and sulfation, while emitting no pollutants. They eliminate the risk of accidents associated with daily replacement of heavy batteries—a critical advantage in industries like food and beverage. Additionally, lithium-ion batteries for electric forklifts do not require dedicated ventilation rooms for charging.For battery inquiries or forklift battery needs, please feel free to contact us！