If you have an electric fleet, your forklift batteries might be the cause of unplanned downtime. An electric forklift battery that needs frequent charging eats through your bottom line. That's why getting the longest life possible out of your batteries is so important. Read on to learn how to extend the life of your forklift batteries.
Two general types of forklift batteries currently dominate the market: lead acid and lithium ion. Knowing which type you have is crucial to understanding how to maximize its life.
Lead acid batteries are an older but inexpensive battery design. They power your forklift via two lead electrodes submerged in a sulfuric acid solution diluted with distilled water. These batteries are simple to manufacture but aren’t as efficient and less safe than lithium ion batteries.
Lithium ion batteries (also called Li-ion batteries) come in several configurations. Still, most are comprised of a lithium, iron, and phosphate combination. These are more efficient, safer, and better for the environment than lead acid batteries. However, they have a large initial investment. Still, their ROI tends to be faster. These improvements on the lead acid design explain why many manufacturers are moving toward lithium ion as a forklift battery replacement for their electric fleets.
Regardless of type, forklift batteries have a finite lifespan defined by a maximum number of charging cycles. Lead acid batteries, for example, have a lifespan of about 1,500 charges, while Li-ion batteries can last as long as 3,000 cycles.
Another critical difference is what counts as a charging cycle. For lead acid, a charging cycle occurs whenever the battery hooks up to the charger. The battery recognizes no difference between charging a mostly depleted cell or a mostly full one. Each counts as a complete cycle in terms of battery lifespan. On the other hand, lithium ion only depletes a charging cycle when the battery charges to 100%. This means a partial charge only counts as a partial cycle, further extending the battery life.
To maximize battery life, use the best charging cycle for your battery type. Only charge lead acid batteries after they have been sufficiently depleted. Lithium ion batteries, however, can take advantage of opportunity charging without damaging the battery's lifespan.
As soon as a lead acid battery reaches the end of its work day or reaches 20 to 30% capacity, it needs immediate recharging. Do not let your lead acid batteries sit on a partial charge for extended periods. The chemical reaction that stores power within your battery continues whenever the battery is off the charger. Consequently, the electrodes continue to erode while the battery sits unused at a partial charge. Prevent this by storing batteries on the charger when not in use.
Lithium-ion batteries don’t use the same chemical reaction to store power. As a result, they can be safely left in a state of partial discharge without impacting the battery.
As discussed below, battery temperature can affect performance and lifespan. Batteries get warm during use and can benefit from periodic breaks. In particular, breaks improve the performance of lead acid batteries. So, while operators shouldn’t leave lead acid batteries in a state of partial discharge for extended periods, the benefits of allowing the battery to rest off the charger during a lunch break outweigh the downsides.
Completely discharging your battery can be harmful to it and your forklift. Deep discharges increase the temperature of your forklift's electrical components. The result can be serious damage to your fork truck, including scorched components and motor failure. Moreover, the forklift's traction and hydraulics will slow. To prevent this, charge batteries once they reach about 30% capacity and don't operate the forklift below 20% if possible. If a full discharge occurs, the forklift battery needs a complete uninterrupted charge cycle.
When an electric forklift battery needs charging part way through a shift, it can be tempting to use fast charging. However, this can damage some batteries. The rapid heat generation during fast charging can dramatically reduce the life expectancy of lead acid batteries, shaving two or more years off the expected lifespan. Conversely, Lithium ion batteries tolerate fast charging much better and thus can be more easily paired with a rapid charger.
Lithium ion batteries are essentially maintenance-free. Yet, lead acid requires a more hands-on approach. Primarily, lead acid maintenance involves watering, cleaning, and inspecting the battery for sulphuric crystals on the electrodes. Distilled water must be added to the battery at regular intervals (typically every five charge cycles) to ensure longevity and performance. Use only distilled water, and do not overfill batteries. Failure to do either can lead to permanent battery damage. A forklift battery watering system can make forklift battery maintenance easier.
Inspect your lead acid batteries daily for white sulphuric crystals forming on the lead electrode plates. These impede the battery's ability to charge and provide power. If you spot crystals, contact a technician for corrective measures. In some severe cases, you may require a forklift battery replacement.
Most forklift batteries are not intended to withstand extreme temperature ranges. Your battery lifespan can diminish by as much as 50% if consistently operated in environments with ambient temperatures above 92 degrees. Similarly, cold weather (30 degrees or less) reduces performance by up to 30%. If your forklifts regularly operate in cold or hot environments, consider investing in a battery designed for those temperatures.
Just like forklifts, there's no universal solution when it comes to power. Both lithium ion and lead acid have their advantages and disadvantages. So, if you're stuck weighing the pros and cons or looking to get the most out of your current batteries, let us help.
Our solutions team has the expertise you need to evaluate your power usage and make a plan that best fits your business needs. Don't let low power hold you back. Chat with one of our experts and supercharge your business today. To learn more about forklift batteries or to request a quote, contact us online or visit one of our locations throughout Georgia and Florida.
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Further Reading
Get the Most Out of Your Forklift Battery Care 101
Forklift Battery Charging Methods: What’s Best for Productivity
Are Lithium Ion Forklift Batteries Right For Your Business