Physical Isolation Measures for Dust Protection of Electric Forklift Batteries
The core principles of physical isolation are dust separation, unobstructed heat dissipation, easy disassembly and assembly, and full coverage. All measures are divided into universal models (suitable for lead-acid/lithium batteries) and battery-type-specific models (tailored to the structural characteristics of different batteries), with clear specifications for materials and dimensions, as well as installation/usage requirements. They can be directly installed on-site, adapted to daily cleaning and maintenance, and fully comply with the on-site SOP implementation standards.I. Universal Physical Isolation Measures (Applicable to All Battery Types, Core for Preventing External Dust Contact)
Applicable to general parts such as battery compartments, terminal blocks, and ventilation openings, these are the basic dust protection measures. After one-time installation, only daily integrity checks and monthly disassembly/assembly for cleaning are required.1. Install Dust-proof Shields with Heat Dissipation Holes in Battery Compartments
Material & Specifications: Adopt 304 stainless steel or hard temperature-resistant plastic (temperature resistance ≥60℃, anti-collision for forklift operation). The shield features a semi-enclosed structure (reserving battery wiring and charging ports) with circular through holes as heat dissipation holes (aperture ≤5mm to block fine dust/metal shavings) and the total area of heat dissipation holes ≥80% of the battery compartment's ventilation opening area (to ensure heat dissipation efficiency).
Installation Requirements: Reserve a 10-15cm heat dissipation gap between the shield and the inner wall of the battery compartment, fix with buckles/screws for easy disassembly and assembly (meeting daily cleaning needs); edge of the shield is edged to avoid scratching the battery case.
Core Function: Block floating dust during operation and dust carried by tires from entering the battery compartment, covering more than 90% of the battery main body area.
2. Install Dust-proof and Anti-oxidation Protective Sleeves on Terminal Blocks/Plugs and Sockets
Material & Specifications: Adopt temperature-resistant rubber/silicone (temperature resistance ≥80℃, anti-aging), custom-made according to the size of terminals/plugs, with an elastic opening design for a gap-free fit on the terminal surface.
Usage Requirements: Put on immediately after forklift operation and when the battery is idle; remove during charging/wiring; a small amount of insulating silicone grease can be applied inside the protective sleeve (to prevent dust adhesion and oxidation).
Core Function: Fully cover the terminal contact parts to prevent dust from adhering to the conductive surface and avoid an increase in contact resistance.
3. Install Replaceable Dust-proof Filters at Ventilation Openings of Battery Compartments/Battery Bodies
Material & Specifications: Adopt non-woven primary efficiency filters (good air permeability, easy to clean); for scenarios with high dust content, metal mesh + non-woven composite filters (more wear-resistant) are optional, with filter dimensions fully matching the ventilation openings.
Installation Requirements: Fix on the inner/outer side of the ventilation opening with a card slot, no tools required for disassembly and assembly, and the filter can be removed separately for cleaning/replacement.
Core Function: Filter the air entering the battery compartment/battery interior and block dust from entering the heat dissipation channel through the ventilation opening.
4. Sealing and Dust-proof Treatment for Gaps in Battery Compartments
Material & Specifications: Adopt temperature-resistant sealant (temperature resistance ≥60℃) or detachable foam dust-proof sealing strips, suitable for gaps between the battery compartment and forklift body, as well as splicing gaps of shields.
Installation Requirements: Fill gaps with a width ＜5mm with sealant and paste foam sealing strips for gaps with a width ＞5mm; only fill non-ventilation gaps to avoid blocking heat dissipation channels.
Core Function: Seal dust "dead corners" and prevent dust from drilling into the battery compartment through gaps and accumulating inside.
II. Battery-type-specific Physical Isolation Measures (Tailored to Battery Structures, Preventing Dust from Entering Internal Core Components)
In view of the structural differences between lead-acid and lithium batteries, exclusive protection is provided for the internal reaction zones and precision electronic zones of the batteries to prevent dust from entering the battery body and causing electrolyte contamination and cell/sensor malfunctions. All protection measures take into account the battery's own operating characteristics (e.g., exhaust of lead-acid batteries, BMS detection of lithium batteries).(1) Special Measures for Lead-acid Batteries (Applicable to Flooded/Valve-regulated Types, Core for Preventing Dust from Entering Electrolyte)
The core dust risk points of lead-acid batteries are the liquid injection ports and exhaust valves (open/semi-open structures where dust can easily enter and contaminate the electrolyte). The key protection focus is air permeability and dust proofing, and complete sealing is prohibited (to avoid excessive internal pressure of the battery).Install Air-permeable Dust-proof Caps on Liquid Injection Ports/Exhaust Valves
Material & Specifications: Adopt plastic air-permeable material (with micro air holes to ensure battery exhaust/pressure relief); the cap features a screw-on/buckle design for a gap-free fit on the liquid injection port/exhaust valve, and some models can be equipped with a filter liner (double dust protection).
Installation Requirements: Screw/buckle directly on the liquid injection port/exhaust valve, no daily disassembly required; remove only when replenishing electrolyte/inspecting the battery, and clean dust inside the cap immediately after removal.
Paste Removable Dust-proof Protective Film on the Battery Surface
Material & Specifications: Adopt PE electrostatic dust-proof film (adhesive-free, no residue after tearing), cut according to battery dimensions to cover the dust-unprotected areas on the top/side of the battery.
Usage Requirements: ｒｅｐｌａｃｅ once a month or immediately when dust adhesion is severe; tear off directly during replacement without cleaning the battery surface.
(2) Special Measures for Lithium Batteries (Applicable to Lithium Iron Phosphate/Ternary Lithium Types, Core for Preventing Dust from Affecting Precision Components)
Lithium batteries are fully sealed structures, making it difficult for dust to enter the cell interior. The core risk points are cell heat dissipation openings, BMS displays/sensors, and tab interfaces. The key protection focus is dust proofing without affecting detection/heat dissipation.Install High-density Dust-proof Nets at Cell Heat Dissipation Openings
Material & Specifications: Adopt a composite structure of stainless steel high-density dust-proof nets (mesh ≤3mm) + non-woven filters, with dimensions matching the heat dissipation openings and adapted to the air intake direction of lithium battery fans.
Installation Requirements: Fix on the outer side of the heat dissipation opening without blocking the fan air intake channel; detachable separately for cleaning (once a month).
Core Function: Prevent dust from entering the heat dissipation channel and adhering to fan blades/cell surfaces, avoiding a decline in heat dissipation efficiency.
Install Transparent Dust-proof Shields on BMS Displays/Sensors
Material & Specifications: Adopt transparent temperature-resistant plastic (light transmittance ≥90%, without affecting data viewing/sensor detection), with a buckle structure and reserved sensor induction holes.
Installation Requirements: Buckle directly on the outer side of the BMS display/sensor; paste a dust-proof film inside the shield (to prevent dust from adhering to the transparent surface and affecting viewing).
Install Dust-proof and Insulating Sleeves on Tab Interfaces
Material & Specifications: Adopt flame-retardant insulating plastic, fully covering the tab wiring parts, with a plug-in design that does not affect current transmission.
Installation Requirements: Put on directly during battery assembly, no daily disassembly required; remove only when inspecting the tabs.
III. On-site Installation/Maintenance Requirements for Physical Isolation Accessories (Ensuring Uncompromised Protection Effect)
- All isolation accessories must be precisely matched with the forklift battery compartment; refitting that blocks charging ports and battery inspection ports is prohibited to avoid affecting daily charging and fault troubleshooting.
- The heat dissipation holes of dust-proof shields/filters must not be blocked; after installation, test the battery operating temperature — a temperature rise of ≤3℃ under the same working conditions compared with before installation is deemed qualified.
- Establish replacement cycles for consumable accessories (dust-proof filters, protective films, protective sleeves): clean filters once a month and ｒｅｐｌａｃｅ once every 3 months; ｒｅｐｌａｃｅ protective films once a month; ｒｅｐｌａｃｅ rubber protective sleeves once every 6 months (anti-aging).
- Key points of daily inspection: Check for damage to shields, loosening of buckles, proper fitting of protective sleeves, and blockage of filters; repair/ｒｅｐｌａｃｅ immediately if damage/loosening is found to prevent dust from entering through damaged parts.
IV. Upgraded Physical Isolation Schemes for Different Dust Scenarios (Adapted to Special High-dust Operating Environments)
For scenarios with high dust concentration (e.g., cement workshops, powder warehouses, ore terminals), simple upgrades are made on the basis of basic physical isolation measures to further improve the protection effect without major refitting:- Ultra-high dust scenarios: ｒｅｐｌａｃｅ the battery compartment shield with a fully enclosed sealed structure with air filtration, and install a small exhaust fan (to ensure internal air circulation), with filtered air entering the battery compartment.
- Mobile dust scenarios (e.g., forklifts operating frequently in powder areas): Install double-stage filters (primary + medium efficiency) at the air intake of the battery compartment to further filter fine dust.
- Metal shavings dust scenarios (e.g., mechanical processing workshops): Paste magnetic strips on the inner side of the shield to adsorb metal shavings dust and prevent it from entering the battery compartment.
