The core power source of electric forklifts is rechargeable batteries. According to different battery technology routes, mainstream models are divided into two categories, while there are also a few auxiliary power forms for special scenarios. The specific classification is as follows:

Mainstream Power Sources

Lead-acid batteries: As the mainstream power source for electric forklifts in the early stage and the current mid-to-low-end market, they feature low cost and mature technology. They are widely used in warehouses and workshops that are cost-sensitive and have moderate operation intensity.

Lithium batteries: Including lithium iron phosphate batteries and ternary lithium batteries, they are upgraded power solutions in recent years. Relying on the advantages of high energy density and long service life, they are rapidly popularized in the mid-to-high-end market and high-intensity operation scenarios.

Special Auxiliary Power Forms

Hybrid power (rarely used): Some customized electric forklifts are equipped with small fuel generators as range extenders to address the shortcoming of pure electric endurance. However, due to their complex structure and high cost, they are only used in outdoor scenarios in remote areas without charging conditions.

Supercapacitors (auxiliary energy storage): A small number of forklifts with high-frequency start-stop operations are equipped with supercapacitors, which assist batteries in meeting the demand for instantaneous large currents and improving power response speed. They are not the core power source.

Core Differences Between Lead-Acid Battery and Lithium Battery Electric Forklifts

Cost and Service Life

Lead-acid batteries: Low procurement cost—the price of a single battery pack is only 1/3–1/2 that of a lithium battery pack of the same capacity. However, they have a short cycle life, with a regular charge-discharge cycle of about 500–800 times and a service life of 2–3 years, requiring regular battery replacement.

Lithium batteries: High procurement cost with large initial investment. They have a long cycle life, with a charge-discharge cycle of up to 2000–3000 times and a service life of 5–8 years, resulting in lower amortized cost for long-term use.

Charging and Endurance Characteristics

Lead-acid batteries: Low charging efficiency, requiring 8–10 hours to fully charge and not supporting fast charging. They have a memory effect and need to be fully discharged before recharging; otherwise, the battery capacity will be affected. Endurance time is greatly affected by temperature, with significant endurance attenuation in low-temperature environments.

Lithium batteries: High charging efficiency, supporting fast charging technology that can charge to 80% of the power in 1–2 hours. They have no memory effect and support charging at any time, and endurance can be extended by supplementing power during operation intervals. They have better low-temperature performance, with much smaller endurance attenuation than lead-acid batteries.

Maintenance and Usability

Lead-acid batteries: High maintenance frequency, requiring regular inspection of electrolyte levels and timely replenishment of distilled water. The batteries are large in size and heavy in weight, requiring tools for replacement. There is also a risk of acid leakage, which is corrosive to the operating environment to a certain extent.

Lithium batteries: Maintenance-free, requiring no operations such as fluid replenishment or acid adjustment. They are small in size and light in weight, with a modular design of battery packs for easy replacement. They have good sealing performance and no leakage risk, making them suitable for scenarios with high cleanliness requirements such as food and pharmaceutical industries.

Performance and Applicable Scenarios

Lead-acid batteries: Average power output stability and weak instantaneous discharge capacity, suitable for light-load, low-frequency and short-distance handling operations, such as daily replenishment in small warehouses and e-commerce sorting centers.

Lithium batteries: Fast power response and strong instantaneous discharge capacity, able to meet the needs of heavy-load, high-frequency and long-distance continuous operations, such as high-intensity handling requirements in large logistics parks, cold chain warehouses and manufacturing production lines.

Safety and Environmental Friendliness

Lead-acid batteries: Containing heavy metal lead and sulfuric acid electrolyte, improper disposal after scrapping is likely to cause environmental pollution. A small amount of hydrogen is generated during charging, so charging must be carried out in a well-ventilated environment to avoid open flames.

Lithium batteries: Free of heavy metals, with better environmental friendliness. The Battery Management System (BMS) can monitor voltage, current and temperature in real time, with overcharge, over-discharge and short-circuit protection functions, resulting in higher safety. No harmful gas is emitted during charging, allowing charging in indoor enclosed environments.