Battery is the core power component of electric forklifts, and its health status directly affects the daily operation efficiency, operation safety and overall use cost of handling scenarios in factories, warehouses and logistics parks. Effective and regular battery health monitoring can avoid unexpected sudden power failure during heavy load handling, and effectively extend the overall service life of the battery pack.

The first and most basic monitoring measure is daily visual inspection, which can be completed by on-site operators during shift handover. Operators need to check whether the battery shell has obvious deformation, crack or electrolyte leakage marks, confirm that the connection terminals are free of obvious oxidation, looseness or burning traces, wipe off the accumulated dust and sundries on the battery surface in time, and ensure that the heat dissipation vents around the battery pack are not blocked by sundries. This inspection only takes 3 to 5 minutes every day, which can eliminate most early hidden dangers that may cause battery damage.

The second measure is real-time tracking of core operating parameters. Operators need to regularly record key data including remaining battery level, real-time working voltage, total charge and discharge cycles, and operating ambient temperature during daily use. Avoid long-term over-discharge that keeps the remaining battery level below 5% after operation, and do not make the battery run continuously beyond the normal temperature range specified by the manufacturer. When the total number of charge and discharge cycles of the battery reaches 80% of the nominal cycle life, the monitoring frequency should be appropriately increased to pay close attention to the performance changes of the battery pack.

The third measure is regular professional performance verification. Every 10 to 15 working days, professional maintenance personnel can use special testing equipment to check the voltage difference between single cells and the internal resistance change of the whole battery pack. If the internal resistance of some cells increases by more than 20% compared with the initial factory value, targeted inspection and adjustment shall be carried out in time, so as to avoid the sudden drop of the overall performance of the whole battery pack caused by the attenuation of individual cells.

Adhering to the normalized battery health monitoring mechanism can effectively reduce the probability of unexpected shutdown of electric forklifts in operation, and bring stable and reliable operation support for the material handling work of the site. We are Jianshu New Energy, focusing on BYD electric forklifts. If you have any consultation demands related to electric forklift product selection or battery daily maintenance, you can send an email to [email protected] to obtain professional and targeted technical guidance.