From Structure to Performance: A Complete Guide to Forklift Lead-Acid Battery Classifications

The scientific method for calculating the service life of a forklift battery isn't based on time, but rather on the maximum number of discharges the battery can withstand. The design life of mainstream forklift batteries is generally 1,600 cycles. This means that after 1,600 charge and discharge cycles, the battery's charge capacity drops below 80% of its factory value, and the battery is considered unusable and needs to be discarded or replaced.

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With advancements in technology and a proliferation of options, choosing a forklift battery can feel overwhelming. From traditional lead-acid, lithium-ion, hydrogen fuel cells, and more, there are several different battery types suitable for equipment handling operations. Getting the power you need means understanding how each technology works and its potential limitations.

Different equipment may require different battery types, depending on the application, environmental conditions, and any sustainability considerations. To help you understand what technology might be right for your application, this article provides a primer on some power solutions, including their advantages and disadvantages. While it certainly doesn't replace the advice a power expert can provide for your specific facility and situation, it should help provide an overview of your options.

Lead-acid batteries are available in two types: flat plate and tubular flat plate

In flat-plate lead-acid batteries, conductive positive plates are arranged in a grid-like honeycomb structure, and energy is generated through a chemical reaction between lead and sulfuric acid. Flat-plate models are very resistant to high charging rates. Simply put, the faster a flat-plate model is charged, the shorter the battery life. In most cases, flat-plate batteries remain a good choice for small, single-plate operations, especially where heavy objects are being lifted.

Tubular batteries differ from flat-plate batteries in the way their positive plate structure is designed. Instead of a grid-like honeycomb structure, tubular batteries have ridges that extend vertically downward into the electrolyte. These are surrounded by cylindrical or square sleeves filled with active material, forming the tubular structure. This design provides more surface area for the lead in the positive plate to interact with the acidic electrolyte, resulting in a slightly higher battery capacity compared to a similar flat-plate battery. In addition to an approximately 15% increase in battery capacity, the tubular design is also slightly more efficient at accepting a charge than a flat-plate design.

Here are some common features shared by all lead-acid battery models:

01 Cost

At first glance, lead-acid batteries appear to be the most cost-effective battery option on the market. Tubular batteries are approximately 10% more expensive than flat-plate lead-acid batteries. However, the costs associated with the required battery charging room and other maintenance requirements must also be considered.

Generally speaking, the purchase cost of a lead-acid battery, whether flat-plate or tubular, only accounts for approximately 30% of its total cost of ownership. The lifespan of a lead-acid battery depends on many factors, including the quality of the battery, how and how often the battery is used, the user's charging procedures and the quality of the charger being used, battery maintenance, and the application environment (both hot and cold conditions have a significant impact on the lifespan of a lead-acid battery). Depending on all these variables, most lead-acid batteries will provide reliable forklift power for between 1,200 and 1,800 charge and discharge cycles, or three to seven years. Some very light-use applications may even have well-maintained batteries that can last 10 years or more.

02 Charging Requirements

Standard lead-acid batteries must be charged more slowly than alternatives, with charging efficiencies ranging from 75% to 75%, depending on the charger technology and battery health. This means the amount of charge you pay for is not the same as the amount that ultimately goes into the battery itself. This inefficiency in the charging process generates heat, requiring extended cooling periods between uses. While recent advances in charger technology have enabled faster charge times for lead-acid batteries, many limitations still exist, including the need for weekly equalization charges.

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