machine maintenance

Deep cycle battery pack replacements often represent the largest expense in maintaining a fleet of electric forklifts. Extending the lifespan of these battery packs is crucial to reducing operating costs. Two key concepts to understand for maintaining your forklift’s battery health are the State of Charge (SOC) and over-discharging.

Understanding State of Charge (SOC)

What is SOC?
State of Charge (SOC) refers to the amount of charge a battery has at any given time, expressed as a percentage. For example, a battery with an 80% SOC is charged to 80% of its full capacity, similar to the battery indicator on your smartphone.

Importance of Maintaining SOC
Maintaining a high SOC is essential for battery longevity. Ideally, you should keep your battery pack at 80% SOC. However, in practical scenarios, aiming to maintain at least 50% SOC can help preserve battery health and extend its lifespan.

The Impact of Over-Discharging

What is Over-Discharging?
Over-discharging occurs when the battery pack is used until it can no longer provide power. Although batteries typically retain about 20% charge for emergencies, frequent over-discharging can severely impact battery performance.

Signs of Over-Discharging

1. Long Charging Times: A significant increase in the time required to charge the battery fully. For instance, a new battery may take 4 hours to charge from 0% to 100% SOC, but if it starts taking 6 hours or longer, it’s a sign of over-discharging.
2. Reduced Work Capacity: A noticeable drop in the forklift’s performance on a full charge. If a forklift that previously operated for an entire 8-hour shift now only lasts 4 hours, over-discharging might be the cause.

Strategies to Extend Battery Life

Monitor and Maintain SOC
Regularly monitoring the SOC and maintaining it above 50% can prevent the detrimental effects of over-discharging. Training forklift operators to keep an eye on the battery charge indicator and recharge when necessary can make a significant difference.

Implementing a Battery Management Plan
Using tools like Repnotes Fleet Management Solutions can help track battery consumption and identify forklifts that replace an unusual number of battery packs. Implementing a comprehensive battery management plan can further reduce the frequency of battery replacements.

Training and Awareness

Educating Forklift Operators
Training operators about the importance of maintaining SOC and avoiding over-discharging is crucial. By understanding their role in preserving battery health, operators can actively contribute to reducing costs and improving the efficiency of the warehouse operations.

Ongoing Monitoring and Adjustment
Regularly reviewing battery performance and adjusting practices based on real-time data can optimize battery usage. Using fleet management software helps in maintaining oversight and making informed decisions to extend battery life.

By understanding and managing SOC and preventing over-discharging, you can significantly reduce the costs associated with battery replacements for your electric forklifts. Training your team and implementing a robust battery management plan are key steps in achieving these savings.