Industrial material handling scenarios usually require forklift fleets to operate for long consecutive hours, with frequent full discharge followed by full recharge cycles during peak order processing periods, which puts high requirements on the overall reliability and performance consistency of supporting battery packs.

The whole observation project was arranged in a standard 2-shift operating warehouse site, with 12 units of target lithium-ion forklift battery packs installed on standard counterbalance forklifts for full real-scenario test. All units followed unified usage rules during the 12-month observation period: each full working cycle included 8 hours of continuous load carrying operation, with the discharge depth kept between 85% and 90% before connected to matched dedicated charging piles for full constant current recharge, no irregular partial charge or over-discharge operation was allowed in the whole process.

For core performance indicators, the monthly tracked capacity retention data shows that after 500 standard deep cycles, the average residual capacity of all observed battery packs remains above 92% of the nominal rated capacity, no sudden abnormal capacity drop is recorded on any single unit. The discharge voltage stability stays at a steady level across all usage phases, the voltage difference between single internal cells maintains within the normal safe threshold even after hundreds of repeated cycles, no obvious floating or lagging abnormal cell situation appears during routine inspection.

For other practical usage performances, the shell surface temperature of the battery packs keeps within the standard normal working temperature range even during days of high-intensity continuous operation, no overheating related abnormal warning is triggered throughout the entire observation period. The daily charging efficiency stays stable, the full recharge duration does not show obvious extension trend with the increase of cycle times, which will not bring extra waiting cost for logistics operation teams that arrange cross-shift forklift usage.

This long-term real working condition observation provides first-hand credible data for fleet managers to make reasonable usage plans for the relevant lithium-ion battery packs. Users can formulate scientific cycle charging and maintenance schemes according to actual operational intensity, so as to make full use of the performance advantages of the products, further extend the service life of battery packs, and reduce the overall operational cost of the material handling system.