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Intro

How an electric lift truck’s battery is recharged for continued commercial use has a major effect on how efficiently a business can operate, especially if there are any battery charging station requirements.

As you can imagine, lithium-ion batteries are the newer of the two types of battery technology, so their charging is faster and less complicated. Let us take a look at how charging is different between these two forklift battery types:

Lithium-ion batteries can be opportunity charged and do not need to be recharged to 100% forklift battery capacity.

Lead acid batteries must not be disconnected from their forklift battery charger until they have reached full forklift battery capacity and in most cases cannot be opportunity charged.

Moreover, if either of these types of batteries are not charged correctly, they will deteriorate in quality as time goes by – with lead acid units having much stricter guidelines when it comes to the required charging technique.

Forklift Battery Charging Station Requirements

The physical location of your forklift battery charger system is a much bigger consideration than many business owners realize.

Lead acid batteries have specific forklift battery charging station requirements that lithium-ion battery packs do not. After all, lithium-ion battery packs are plugged straight into a charger, and they do not need to be removed from the lift truck to start recharging. There are not really any further actions that need to be taken in order to do a simple recharge.

With lead acid forklift batteries, however, the units must be removed from the vehicle completely and placed onto a separate forklift battery charger – many of which have the ability to perform equalization. If there are many forklifts in operation, then there will need to be multiple chargers as well as a space for multiple units to cool down after fully recharging. This will involve employees having to use special lift equipment to pick up discharged batteries and drop in charged batteries on a regular basis. While it is not physically straining the task is time-consuming to operations wanting to be more productive. 

Lead acid batteries need a dedicated charging space that ventilates and controls the temperature in the room. This is because lead acid batteries can get very hot while charging, producing harmful fumes.

Lithium-ion forklift batteries do not need a separate space, do not need to cool down, and do not require a fully-charged spare at the ready when another one fully discharges – it can be recharged on the spot.

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Definitions

Opportunity Charging: The practice of using natural periods of downtime, like operator meal breaks, to charge the battery for short periods of time throughout the day. This allows operators the continuous use of the same battery throughout multiple shifts.

Overcharging Battery: Overcharging a battery is charging a battery more than its designed capacity. This can create unstable conditions inside the battery, increase pressure, and cause thermal runaway. This can be damaging to the battery, the equipment, and the operator.

Battery Runtime: The length of time a battery charge will last while the forklift is in use.

Industrial Battery: A battery designed for industrial equipment use. Typically, these batteries will be subjected to harsher use conditions than a battery designed for consumer use.

Fast Charging Battery: A battery capable of charging faster than conventional charging standards. Typically, a battery pack will use a charger that has the capability to speed up the battery charging process.

Forklift Battery Charger: Feeds an electric current through a battery for a specific period of time.

Constant Current Constant Voltage (CC CV): A charger regulates the amount of current until the battery reaches a set voltage. Once the battery reaches the set voltage, the current is reduced.

Sulfation: The build-up of lead sulfate on the surface of a lead acid battery. Sulfation happens when a battery is not maintained. If left unattended, lead sulfate build-up can cause the battery to stop working.

Battery Plates: Positive and negative plates that generate electricity. The individual cells of the battery fit into these plates to create a chemical reaction that helps produce voltage.

Equalization Charge: Overcharging the battery after a full charging cycle at a higher-than-normal voltage. This step is necessary help remove built-up sulfate and balance the voltage of each cell in lead acid batteries.

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