This is an overview of the risky maintenance for lead-acid batteries:

• The fluid level is extremely important and a safe level requires regular watering. Overwatering and underwatering can both damage the battery. If too much water was added before charging, the electrolyte levels will expand and cause the battery to overflow and damage the battery.
• Conventional batteries contain a liquid “electrolyte” which is a mixture of sulfuric acid and water. The plates in a lead battery contain an active material that should be continuously bathed in electrolytes while oxygen and hydrogen gas are released during charging.
• When batteries are being recharged, they generate hydrogen gas that is explosive in certain concentrations in air, so the ventilation system must provide enough fresh air to prevent an explosion.
• The electrical voltage created by batteries can ignite flammable materials and cause severe burns. Workers have been injured and killed when loose or sparking battery connections ignited gasoline and solvent fumes during vehicle maintenance.
• Wear personal protection equipment such as protective eyewear and gloves when working on batteries. Splashing acid is a risk, and personal protective equipment like chemical splash goggles, a face shield and gloves must be worn when working on batteries.
• First aid facilities, eye wash stations, and emergency showers are necessary to reduce the severity of accidental contacts.

Safety Features of Li-ion Batteries

Li-ion batteries are becoming more and more common because of their long cycle life and short charge times, but they also greatly reduce the risk to the workforce when they are implemented in a warehouse environment. Li-ion batteries are made up of cells, just like lead-acid batteries. Large format Li-ion cells, used to manufacture batteries used for motive applications, are shown in the picture. The cells have an anode and a cathode with a separator and electrolyte in between. Unlike flooded lead acid cells, the li-ion cells are sealed and have many safety factors designed in them. The cathode material is the main determining factor in the cell’s performance. In the battery power market today, there is a myriad of available battery cathode chemistries to choose from.

It is a critical decision which not only impacts how well the product will operate but also how safely it can operate. Factors such as how much power is required, the time required to charge, operating temperatures, operating environment, packaging dimensions, and weight are all examples of key parameters that must be considered.