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Electric forklift, lead-acid battery use maintenance manual for traction

Return Listsource:Gratene date: 2022-06-17

Electric forklift, lead-acid battery use maintenance manual for traction1. Lead-acid traction battery (hereinafter referred to as the battery) is developed according to GB / T 7403.1-1996 “lead-acid battery”, mainly used for industrial and mining companies, warehouses, terminals and stations used in hand transport vehicles, forklifts, etc. The power supply can also be used as a supporting power supply in other ways. The lead-acid battery belongs to the secondary battery. When charging, the electrical energy is converted into chemical energy stored in the battery, and the chemical energy stored in the battery is converted into electrical energy supply electrical equipment during discharge; for each use (discharge), charged The method can restore the active substance and then discharge, charging and discharging can be repeated multiple times, recycled.

2, the battery is mainly composed of a positive electrode plate, an anode plate, an electrolyte, a partition, a battery tank, a battery cover, a pole column, and a nipper. The positive electrode plate uses a tubular structure, the negative electrode plate is a plate structure, and the battery tank is hot-fused between the battery cover. When the battery is used, it is used by the battery of the same type to be used in a predetermined number and a certain manner. The connection of the unit cell is combined into a battery pack, there are two forms of bolt connection and welding, wherein the bolt connection can be divided into an internal thread connection and an outer thread connection, and the welding connection can be divided into a soft wire welding and lead circuit welding ( Hard connection).

3. About the balance of traction battery: battery in use The battery is used, and there is a difference in battery condition. Long-term use of the battery will increasingly incapacitly, reducing the performance of the entire set of batteries. Balanced charging can prevent the sulfate fault of the battery, reducing the unaalability of the battery pack. For the above case, the battery should be balanced according to the situation. If the balance charging is not in time, it will affect the battery life.

Equilibrium charging should be performed if there is one of the following conditions.

Constant current charging: First make the battery normal, stand up, stand for 1 h, then use the current of the second stage of normal charging to continue charging until it produces severe bubbles, stop 1h. So repeated several times, until the voltage, the density remains unchanged, and immediately produces severe bubbles immediately after the interval is restored. Intelligent charging: Start equalization charging based on the intelligent charger instructions.

4, charging measurement record requirements

Pre-charging measurement record Check the voltage, electrolyte density and temperature of the battery; measure the voltage of the battery after charging, the voltage is measured during the charging process to check the battery’s voltage interval in the battery; in a balanced charging, each battery voltage, The density and temperature are measured and recorded, and the interval is 2 h; the measurement record is measured at the end of the charging, the voltage, the electrolyte density and temperature of the battery are detected, and the density of the electrolyte and the liquid level is adjusted to meet the requirements.

5. The characteristics of the battery are often faulty, the causes of the occurrence and maintenance is as follows:

(1) short circuit inside the battery

A / main feature

The internal short circuit, the voltage is low, the discharge is low, the discharge is low; when the discharge is fast; when charging, the voltage, the density is slow, and the charging is very weak, even without bubbles; charge and discharge In the process, the electrolyte temperature is high, the rise is also very fast, and the self-discharge is serious.

B / fault cause

The cause of battery short circuit is mainly: the conductive object falls into the battery, makes the positive and negative electrode to form a short circuit; the separator is damaged, causing the positive and negative electrode plates; the polar plate produces lead velvet, deposited on both sides of the pole or On the upper plate, the positive and negative electrode plates are bridged, resulting in short circuit; the polar active material is excessively falling off, and the precipitate hits the bottom of the polar plate, which forms a short circuit between the positive and negative electrode plates.

C / treatment method

For short-circuited batteries, it should first be tested that there is no conductive object into the battery, if there is, remove a short circuit conductive material. The polar group is observed whether it is a short circuit formed by excessive lead villus or peat material. If so, the new electrolyte should be removed and replaced. If the partition is damaged, the polarium should be separated, carefully find the damaged separator, and take the new partition.

D / polar plate irreversible sulfate

(2) Main features

The battery discharge capacity is lowered, the electrolytic solution density is lower than the specified normal value; during the charging process, its initial and final voltage is higher than the normal battery; the air bubble occurs prematurely, the temperature of the electrolyte rises, easy to exceed 55 ¡ã C; the voltage drop in the time of discharge, and the termination voltage is lowered.

(3) Causes of failure

Since the battery is often charged, it is not possible to perform in time to charge, often over-discharge or small current depth discharge, long-term in semi-discharge or discharge state, the electrolyte liquid surface is too low, the upper portion of the plate is exposed, and the positive, negative electrode The partial sulfate charging process is difficult to convert into active substances during the charging of the plate.

(4) Treatment method

A battery that has produced a plate sulfate has a slight degree of degradation, and a small current charging method can be treated with a small current charging method. To prevent the formation of sulfate, it should be operated according to the requirements of the maintenance manual, and the sulfate can be eliminated on time.

(5) Battery repair, replacement electrolyte

a) Saw of the battery tank in the following 20 mm below, and take it out of the pole group;

b) Measure the electrolyte density, then pour it off, and rinse the precipitate of the battery tank with tap water;

c) Mount the pole group into the battery cell, and the servings are welded with the plastic strip of the battery tank with the material.

d) adding the electrolyte of the same density from the nipple port to the specified height;

e) perform charging, adjust the electrolyte density and liquid surface.

E / Replace the battery tank

Methods The electrolyte of the original battery tank is poured into the new battery tank, and other A, C, D, E of the replacement of the electrolyte are referred to. When removing the pole group, the time exposed during the air should not be too long to reduce the oxidation of the negative electrode board, or put it in water (the technical requirements of water should comply with JB / T 10053-1999). . In the electrolytic liquid sampling test, replace the electrolyte, replace the battery cell, take out the polar group to repair and remove the precipitate, should be discharged after 5 hours.

F / transportation, storage

1. Battery and spare parts, attachments, special tools should be packaged in the box, between the box and the box and the contact portion of the box and the transportation tool take a reinforcement measures to prevent mutual collision and damage the traction battery. Battery due to hoisting, long-term transportation, etc., the height of the electrolyte liquid is lower than the standard value, which is a normal phenomenon. As the liquid level height is too low due to the sputter or water evaporation of the electrolyte, the liquid surface height should be adjusted during the later or equalization of the cell during the pre-charging period or equalization charging process.

2. The storage of batteries should meet the following requirements:

1.1 Uncharged factory battery, should be stored in a temperature (5 ~ 45) ¡ã C, clean and dry indoors, the battery is 2 years from the date of the factory, and if more than two years, the battery initial charging time should be appropriately extended.

1.2 If the battery is shipped after the initial charging, its storage should match:

a) Storage in the room is (5 ~ 45) ¡ã C, clean and dry indoors, regular ventilation;

b) The electrolyte dropped in the battery on the dust and measurement process of the battery cover and the electrolyte (5 ~ 10)% of the soda solution and the tap water, keep the outer surface of the battery, dry dry;

c) Avoid direct sunlight, away from heat sources;

d) Replenishing the battery once a second phase of normal charging is used every 30 days.

3, product acceptance precautions

1 Clearing the specifications and quantities of the battery and accessories are consistent;

2 Check only whether the battery parts and the accessories are damaged;

3 After the battery, the battery, check and record the density of the battery electrolyte and the level of the liquid level meet the requirements;

4 The battery pack should carefully check whether the connection between the battery is good;

5 If you find an abnormal phenomenon, please feedback immediately.

Battery file should be established

1 Receive the date of the battery;

2 Start date and storage conditions for battery storage, such as ambient temperature, relative humidity, etc .;

3 Battery use start date;

4 The record of the battery is charged, especially the initial charging record;

5 Problems and processing methods that occur during use during use;

6 Conditions of the battery: discharge current, discharge time, temperature and density, ambient temperature and relative humidity of the electrolyte.

service items

1 Introduce product performance and how to use.

2 Training uses the operator.

3 Perform charging and repair services to solve the quality problems that appear in user u 


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