Choosing the right industrial battery is vital for efficiency when using forklifts, whether for one truck or a fleet. The appropriate electric forklift battery can save time and money in the long run.
In this article, we will cover various forklift batteries, their key differences, and price ranges.
Forklift Battery Types
While propane, diesel, and gas are other options, two-thirds of forklifts put into service each year are electric.
Electric forklifts are powered mainly by two battery types: lead-acid and lithium-ion.
Der Batterietyp beeinflusst die Austauschhäufigkeit: Lithium-Ionen-Batterien können über 3.000 Zyklen aushalten, während Blei-Säure-Batterien etwa 1.500 Zyklen halten. Darüber hinaus müssen Lithium-Ionen-Batterien seltener ausgetauscht werden, weshalb sie für viele Geschäftsinhaber Blei-Säure-Batterien vorzuziehen sind.
Spannungen der Gabelstaplerbatterie
Die Auswahl der Batteriepakete für Gabelstapler richtet sich in der Regel nach der Hubausrüstung und ihrem Verwendungszweck. Es gibt vier gängige Spannungsoptionen:
- 24 V: Geeignet für kleine elektrische Hebegeräte wie End- und Mittelfahrgeräte, Handhubwagen und Handhubwagen.
- 36 V: Konzipiert für mittelgroße Elektrogeräte wie Schmalgangstapler und Stand-Gegengewichtsstapler.
- 48 V: Wird für große elektrische Geräte einschließlich Gegengewichtsstapler verwendet.
- 80 V: Reserviert für schwere Elektrogeräte wie große Gegengewichtsstapler.
Aufladen der Gabelstaplerbatterie
Die Art und Weise, wie die Batterie eines Elektrostaplers aufgeladen wird, wirkt sich auf die Betriebseffizienz und den Bedarf an Ladestationen aus.
Lithium-Ionen-Akkus laden sich schneller auf und können bei Bedarf aufgeladen werden, ohne dass eine vollständige Aufladung erforderlich ist. Im Gegensatz dazu müssen Blei-Säure-Batterien vor dem Abklemmen vollständig geladen werden und können nicht opportunistisch geladen werden.
Beide Typen verschlechtern sich, wenn sie unsachgemäß aufgeladen werden. Für Blei-Säure-Geräte gelten jedoch strengere Richtlinien.
Anforderungen an die Batterieladestation für Gabelstapler
Der Standort Ihres Gabelstapler-Batterieladesystems ist entscheidend.
Lead-acid batteries require specific setups that lithium-ion packs do not. Lithium-ion batteries can charge directly while still in the lift truck, with no additional steps needed.
Lead-acid batteries must be removed for charging on separate chargers capable of equalization. Businesses with many forklifts need multiple chargers and space for units to cool after recharging. This process is time-consuming, as employees need special equipment to manage battery swaps regularly.
Additionally, lead-acid charging areas need proper ventilation due to heat and harmful fumes produced during charging. Conversely, lithium-ion batteries can charge directly in the lift truck without needing dedicated space or cooling periods. They can recharge immediately on-site when discharged.
Forklift Battery Watering System
Charging isn’t the only maintenance required for lead acid batteries; their fluid needs regular attention.
Unlike sealed lithium-ion batteries, lead acid batteries require a watering system. Employees must learn to properly water these batteries to ensure optimal performance and longevity.
Key practices for maintaining lead acid forklift battery watering include:
- Topping off with water only after fully charged and cooled.
- Refilling regularly to keep the top of the plates covered, usually every 10 charge cycles.
- Avoiding overfilling to allow for liquid expansion during use.
- Using water with a pH between 5 and 7.
Forklift Battery Safety
Safety is crucial when handling forklift batteries due to the powerful chemicals involved. Let’s compare lithium-ion and lead-acid batteries in terms of workplace safety.
Lead-acid battery safety risks are as follows:
1. Spills: Sulfuric acid can spill from these batteries, especially since they require weekly watering. Improper handling increases employee risk, necessitating a chemical washing station.
2. Overheating: These batteries can become extremely hot while charging and may leak explosive gas after peak charge, making temperature control essential for safety.
3. Gefährliche Gase: Überladen kann giftige Gase wie Schwefelwasserstoff, Wasserstoff und Schwefeldioxid in schlecht belüftete Bereiche freisetzen. Ein Geruch nach faulen Eiern weist auf das Vorhandensein von Schwefelwasserstoff hin. Es sollten sofort Vorsichtsmaßnahmen getroffen werden. Installieren Sie standardmäßige katalytische LEL-Gassensoren oder elektrochemische Sensoren in Laderäumen, um den Gasgehalt zu überwachen.
4. Alte oder korrodierte Batterien: Während neue Blei-Säure-Batterien bei korrekter Ladung ein minimales Risiko darstellen, sind alte oder korrodierte Batterien gefährlich und sollten sofort entsorgt werden.
Im Gegenteil, Lithium-Ionen-Gabelstaplerbatterien sind versiegelt, wodurch das Risiko von Säureaustritt oder Korrosion ausgeschlossen ist.
Preise für Gabelstaplerbatterien
Forklift battery costs vary significantly by type. A lead-acid battery ranges from $2,000 to $6,000, while a lithium battery costs between $17,000 and $20,000.
However, these prices don’t reflect the total cost of ownership (TCO). Managers should consider the long-term expenses associated with each type before making a decision.
In warehouse operations, labor is the largest cost, measured in time. Purchasing lead-acid batteries will increases overall forklift costs since they require extensive man-hours for proper operation. Each battery lasts about 8 hours and needs 16 hours to charge and cool down, necessitating at least three batteries per forklift for 24/7 operations. Extra batteries are also needed for maintenance, leading to more paperwork and a dedicated team for tracking.
Lead-acid batteries are large and require designated storage space that meets Canadian Center for Occupational Health and Safety guidelines, incurring additional costs. And specialized equipment is necessary to monitor these batteries.
Moreover, there’s an occupational risk due to their corrosive liquids; spills can halt operations and incur further time costs.
While initial battery costs are low, they last only about 1,500 cycles with proper maintenance, requiring replacements every 2-3 years along with disposal costs for old units.
A lithium-ion forklift battery, on the other hand, is 55% lighter than lead-acid batteries and offers benefits such as reduced space requirements, faster charging, higher energy efficiency, improved worker safety, better cold performance, and increased productivity.
Abschluss
Lithium-ion batteries, while initially pricier, provide long-term savings through efficiency and lower maintenance. Their fast charging, durability, and safety make them ideal for forklifts.
When choosing between lead-acid and lithium-ion, consider your usage frequency and safety needs. A smart battery investment boosts productivity and reduces downtime, helping your business stay competitive in the electric forklift market.
