Translation of 2-Ton Electric Forklift Battery Heating Issues

The heating of 2-ton electric forklift batteries can be divided into "normal slight heating" and "abnormal overheating". The core causes mainly focus on four aspects: charging, usage, battery status, and environment.

1. Charging-Related Causes (Most Common)

• Mismatch between the charger and battery model: Excessively high output voltage/current leads to low charging efficiency and severe heating.
• Overlong charging time (more than 12 hours): Under overcharging conditions, the battery undergoes continuous chemical reactions, generating a large amount of heat.
• Oxidation or looseness of battery terminals: Increased contact resistance hinders the passage of current during charging, causing local heating.
• Charger malfunction (e.g., damaged rectifier module): Unstable output current results in abnormal heating of the battery during charging.

2. Improper Usage and Operation

• Deep discharge of the battery (continuing operation when the power is below 20%): Excessively high discharge current intensifies internal reactions and causes heating.
• Frequent rapid acceleration, sudden braking, or long-term full-load operation: The battery outputs large instantaneous current, producing excessive heat.
• Forced charging or high-intensity operation in low-temperature environments (below 5℃): Reduced battery activity lowers energy conversion efficiency, leading to heat accumulation.

3. Issues with the Battery's Own Status

• Battery aging (used for more than 2-3 years): Sulfation of internal plates and decreased capacity increase internal resistance during charging and discharging, making the battery prone to heating.
• Insufficient electrolyte in lead-acid batteries: Unbalanced internal chemical reactions cause a rise in local temperature.
• Internal short circuit of the battery (e.g., deformed plates, mixed impurities): Abnormal current flow leads to rapid temperature rise, and there is even a risk of bulging.

4. Environmental Factors

• Poor ventilation in the charging or operation environment (e.g., enclosed warehouses, narrow spaces): Heat generated by the battery cannot be dissipated.
• Long-term exposure of the battery to high-temperature environments (e.g., direct sunlight, proximity to heat sources): The battery's base temperature is high, and heat accumulates during charging and discharging.