Lithium-ion power batteries are widely applied in modern electric forklift scenarios for their stable energy output, low self-discharge rate and relatively low maintenance threshold compared with traditional lead-acid batteries. A large number of frontline operators find that some batteries cannot reach the nominal usable cycle in actual use, and their capacity attenuation accelerates far earlier than expected, which directly increases the operating cost of logistics and warehousing enterprises. The abnormal shortening of battery usable cycle is not caused by product quality problems in most cases, but closely related to the actual use behavior and working conditions.

Improper charging operation is one of the most common factors that reduce the battery usable cycle. Even though most standard battery management systems have overcharge protection mechanism, long-term connection to the power supply after full charge will keep the battery in a high voltage state for a long time, which will accelerate the decomposition of internal electrolyte and the aging of positive and negative electrode materials. In addition, frequent deep discharge that drains the remaining power below the standard lower limit will cause irreversible damage to the internal material structure of the battery, and the cumulative effect of this operation will significantly reduce the total usable cycle. Some operators choose to use non-matched charging equipment to save temporary cost, the mismatch of charging current and voltage will also bring extra load to the battery internal structure, and accelerate the capacity attenuation speed.

The complex industrial working environment will also affect the actual usable cycle of lithium-ion forklift power batteries. If the battery runs in a high temperature environment above 45℃ for a long time, the activity of the internal chemical substances will be abnormal, which will increase the side reaction probability inside the battery. On the contrary, if the battery works in a low temperature environment below -10℃ for a long time without corresponding insulation measures, the lithium ion activity will be reduced, and lithium precipitation may occur on the negative electrode surface under charging state, which will permanently damage the battery capacity. In addition, if the battery is frequently exposed to strong vibration and impact in daily handling operation without proper fixing protection, the internal connection structure and electrode material layer may fall off, which will also lead to the reduction of usable cycle.

Irregular daily maintenance is also an important inducement for the shortened usable cycle. Many operators ignore the regular inspection of battery surface and wiring terminal, if there is long-term accumulated dust, sewage corrosion on the battery shell, the insulation performance of the shell will be reduced, and local short circuit may occur in serious cases, which will consume the effective capacity of the battery invisibly. Some operators do not arrange regular balance maintenance for the battery pack after long-term use, the inconsistency of the voltage of each single cell in the battery pack will gradually expand, and the overall performance of the battery pack will decline rapidly, resulting in the overall usable cycle far lower than the design standard. To avoid the abnormal shortening of the usable cycle, operators can formulate standardized operation specifications according to the actual working scene, arrange regular maintenance work to give full play to the performance advantages of lithium-ion batteries.