How to Reduce the Replacement Frequency of Batteries in Electric Articulating Boom Lifts?

How to Reduce the Replacement Frequency of Batteries in Electric Articulating Boom Lifts?

To reduce the replacement frequency of batteries in electric articulating boom lifts, the core lies in extending the cycle life and performance stability of the batteries through scientific usage habits, standardized maintenance, and reasonable environmental management. The specific methods are as follows:

I. Optimize Usage Habits to Reduce Battery Loss

Avoid Overcharging and Overdischarging

For lead-acid batteries: It is strictly forbidden to leave them in a state of low charge for a long time (not recharged when the power is below 20%), as this will cause plate sulfation and irreversibly reduce capacity. It is recommended to recharge in time when the power drops to 30%-50% and avoid "recharging only after being fully depleted".

For lithium batteries: Although they support deep discharge, frequently using the power down to below 10% will accelerate the aging of the cells. It is advisable to keep more than 20% of the power in daily use and maintain the power at 50%-60% during long-term storage.

Control the Intensity of Charging and Discharging

Try to use the original charger of the equipment and avoid frequent use of fast charging (especially for lithium batteries). Fast charging will cause the internal temperature of the battery to rise sharply, affecting the consistency of the cells.

During operation, reduce high-intensity operations such as sudden stops, sudden acceleration, and frequent lifting to reduce the impact of instantaneous high-current discharge on the battery (especially for lead-acid batteries, high-current discharge can easily cause the active material of the plates to fall off).

Reasonably Plan the Operation Rhythm

When the single operation time is long (e.g., more than 6 hours), you can pause for 10-15 minutes midway to let the battery cool down (especially in high-temperature environments in summer) to avoid continuous high-load operation.

Avoid driving for a long time on extremely sloped (e.g., >5°) or soft ground to reduce the high-energy consumption discharge of the battery caused by motor overload.

II. Strengthen Daily Maintenance to Delay Battery Aging

Regular Inspection and Cleaning

For lead-acid batteries: Check the electrolyte level weekly (except for maintenance-free lead-acid batteries). If the liquid level is lower than the plates, add distilled water (do not add tap water or electrolyte). Clean the battery terminals monthly and apply vaseline to prevent corrosion.

For lithium batteries: Check the tightness of the battery compartment monthly (to prevent water or dust accumulation). Regularly clean the dust on the interface of the Battery Management System (BMS) to avoid poor contact affecting charge and discharge protection.

Standardize Storage and Maintenance

For short-term storage (1-2 weeks): Keep the battery power at 50%-70%, disconnect the main power supply of the equipment to avoid standby power consumption. Store in a dry and ventilated place, away from fire sources and metal conductors.

For long-term storage (more than 1 month): Lead-acid batteries need to be recharged once a month to prevent sulfation due to low charge. Lithium batteries need to be recharged every 2-3 months to avoid cell damage caused by over-discharge.

Regularly Calibrate Battery Performance

For lead-acid batteries: Perform "balanced charging" once every six months (prolong the charging time through special equipment to make the voltage of each battery cell consistent) to avoid the overall performance degradation caused by differences in cell capacity.

For lithium batteries: Contact the manufacturer to calibrate the BMS every year to ensure the accuracy of charge and discharge protection parameters and avoid over-charging or over-discharging of the battery due to misjudgment.

III. Improve the Usage Environment to Reduce External Damage

Control the Impact of Temperature

Avoid long-term operation in environments below -10℃ or above 40℃. Low temperatures will cause a sharp drop in battery capacity, and high temperatures will accelerate the evaporation of electrolyte (for lead-acid batteries) or cell attenuation (for lithium batteries).

Before operation in winter, the battery can be preheated in advance (e.g., stored indoors for 1-2 hours). After operation in summer, transfer the equipment to a cool place in time to avoid direct sunlight on the battery compartment.

Avoid Physical Damage

During operation, be careful to avoid protrusions or sharp objects to prevent the battery compartment from being collided and causing the battery shell to rupture (especially for lithium batteries, a broken shell may cause a short circuit and fire).

Regularly check the battery fixing devices (such as bolts and buckles) to prevent the battery from shaking when the equipment is running, which may cause loosening of the terminals or damage to the internal structure of the battery.

IV. Choose High-Quality Batteries and Compatible Equipment

When replacing batteries, prioritize original certified or well-known brand products (such as Tianneng and Chaowei for lead-acid batteries, CATL and BYD for lithium batteries) to avoid shortened service life of inferior batteries due to material or process issues.

If the equipment supports it, you can upgrade to a lithium battery with higher capacity under the same voltage (it is necessary to confirm that the equipment circuit is compatible). Its cycle life is longer (1500-2000 times), and its low-temperature performance is better than that of lead-acid batteries, which can reduce the cost caused by frequent replacement.

Through the above measures, the service life of the batteries in electric articulating boom lifts can be effectively extended (lead-acid batteries from 3-4 years to 4-5 years, lithium batteries from 4-5 years to 5-6 years), significantly reducing the replacement frequency. The core principle is: "Avoid extreme operations, do a good job in regular maintenance, and adapt to environmental needs" to keep the battery in a stable working state.