Lithium-ion battery is a complex and delicate electrochemical energy storage device, and its structure is mainly composed of the following key parts:
Common anode materials include lithium cobaltate (LiCoO₂), lithium iron phosphate (LiFePO₄), lithium manganate (LiMn₂O₄), and so on.
These materials have high potentials, and during the charging process, lithium ions will be detached from the negative electrode, migrate through the electrolyte and embedded in the lattice structure of the positive electrode material; while during discharge, lithium ions move in the opposite direction, detaching from the positive electrode and returning to the negative electrode, realizing the release of electrical energy in the process.
Negative electrode materials usually use graphite and other carbon materials. Graphite has a layered structure that allows lithium ions to be embedded in the gaps between these layers for storage during charging, and to be smoothly removed from them and returned to the electrolyte during discharge.
The electrolyte is a bridge for the transmission of lithium ions between the positive and negative electrodes. It is generally a solution formed by lithium salt dissolved in an organic solvent. Commonly used lithium salts include lithium hexafluorophosphate (LiPF₆), etc., while organic solvents include ethylene carbonate (EC), dimethyl carbonate (DMC) and other ester compounds.
The diaphragm is located between the positive and negative electrodes and mainly plays an isolating role. Its main function is to prevent the positive and negative electrodes from directly contacting and triggering a short circuit, to ensure the safe operation of the battery. Common diaphragm materials include polyethylene (PE), polypropylene (PP) and other microporous membranes.
The diaphragm needs to have good ion permeability to allow lithium ions to pass through smoothly, thus maintaining charge transfer within the battery.
For forklift lithium-ion batteries, the selection of cathode material needs to consider various factors. As forklift trucks need larger power output and better cycle stability, lithium iron phosphate cathode materials are more widely used. The olivine structure of lithium iron phosphate makes it highly thermally stable, and it can maintain good performance in the frequent charging and discharging process of forklift trucks, as well as in the high-temperature working environment that they may face.
At the same time, its long cycle life can meet the demand of forklift trucks for long time use, and generally can reach thousands or even tens of thousands of charge/discharge cycles, which effectively reduces the frequency of battery replacement and improves the overall service life and economy of forklift trucks.
Multiple lithium iron phosphate cells are combined in series and/or parallel to form a battery module. Series connection can increase the voltage of the battery pack to meet the operating voltage requirements of equipment such as forklift motors.
BMS mainly includes the main control unit and various sensors. The sensors include voltage sensors, current sensors, temperature sensors, etc. The voltage sensor is used to monitor each battery cell in real time. Voltage sensors are used to monitor the voltage of each battery cell in real time to ensure that the battery will not be overcharged (too high voltage) or over-discharged (too low voltage).
The BMS maintains a relatively balanced charge of each battery cell through active or passive equalization, thus extending the overall service life of the battery pack.
The battery pack shell is usually made of metal (such as aluminum alloy) or high-strength plastic materials. Metal shell has good mechanical strength and heat dissipation properties, can effectively protect the internal components of the battery from external physical collision, extrusion and other injuries, and can help disseminate the heat generated by the battery work process.
In addition, the battery pack will also set up some protective structures, such as waterproof, dustproof, shock-resistant design.
Including the positive and negative output terminals of the battery pack, communication interface, etc.
Forklift trucks require continuous and stable power output in logistics handling and other work scenarios. The high energy density of lithium-ion batteries enables them to store more power. Compared with traditional lead-acid batteries, lithium-ion batteries can provide longer power supply under the same volume or weight. This means that forklifts are able to carry out more loads on a single charge, reducing the number of recharging cycles, which significantly improves the efficiency and continuous operation of the forklift.
Lithium-ion batteries have the advantage of fast charging and can be replenished with a large amount of power in a short period of time. In general, lithium-ion battery forklifts can be charged during rest breaks or work breaks using fast-charging technology, such as during lunch breaks or cargo loading and unloading breaks, it only takes a few minutes to a few hours to charge the battery power to a higher level, greatly reducing operational downtime.
Traditional lead-acid batteries require regular maintenance work such as adding water, checking electrolyte density, cleaning electrodes, etc. during the use process to ensure their performance and life. Lithium-ion batteries in forklift applications almost eliminate the need for these cumbersome maintenance operations, which reduces operating costs and improves economic efficiency for the enterprise.
Lithium-ion batteries do not produce harmful gases during operation, such as hydrogen and sulfuric acid mist and other pollutants that may be produced during the charging and discharging process of lead-acid batteries. Forklifts using lithium-ion batteries can effectively improve the air quality in the workplace, providing a healthier and safer working environment for operators.
At the same time, from the perspective of environmental protection, the production and use of lithium-ion batteries are less polluting to the environment than traditional lead-acid batteries, which is in line with the requirements of modern society for green energy applications.
In summary, lithium-ion batteries, with their unique structure and excellent performance, have shown great advantages in the field of forklift applications, and with the continuous progress of technology, their composition and structure are also continuously optimized, and they are expected to play a more important role in the forklift and more industrial fields in the future.
