STRUCTURE OF A 24V-205AH BATTERY FOR FORKLIFTS

A 24V-205Ah battery for forklifts (especially electric forklifts) is typically either a lithium battery or a lead-acid battery, depending on the technology. Each type has a different structure, but to provide the most accurate answer, here’s the basic construction:

1. With Lithium Battery (LiFePO₄ or NMC)

Main components of a 24V-205Ah battery pack:

• Battery cells:
  A single lithium cell has a nominal voltage of about 3.2V (LiFePO₄) or 3.7V (NMC).
  To create 24V, multiple cells are connected in series:

  • Example with LiFePO₄: 24V/3.2V ≈ 8 cells (actually 8S = 25.6V).

  • If using NMC: about 7S (7 × 3.7V = 25.9V).
    Capacity of 205Ah is achieved by connecting multiple parallel branches of cells.

• Battery modules:
  Small cells are grouped into modules for easier management and maintenance.

• BMS (Battery Management System):
  Manages the battery: balances cells, and protects against overcharge, overdischarge, overcurrent, and overheating.

• Protective casing:
  Made of durable metal, resistant to vibration, impact, water, and oil (rated IP54–IP67 depending on model).

• Cooling system:
  Some packs have fans, thermal gel, or ventilation slots to ensure stable operation.

• Cables and connectors:
  High-power cables (often Anderson, REMA standard) and charging ports.

2. With Lead-Acid Battery (Flooded/AGM/Gel)

Construction of a 24V-205Ah battery pack:

• Individual cells:
  Each cell provides 2V (single cell) or 6V/12V (pre-assembled types).
  Typically 12 × 2V cells are connected in series to achieve 24V.

• Lead plates:
  Positive and negative plates made from lead alloy coated with active material (e.g., lead oxide).

• Electrolyte solution:
  Diluted sulfuric acid (H₂SO₄).
  For AGM/Gel types: the solution is absorbed into fiberglass mats or transformed into gel.

• Battery casing:
  Made of acid-resistant, impact-resistant ABS or PP plastic.

• Gas release system:
  One-way gas release valves (for AGM/Gel types).

• Cables and connectors:
  Similar to lithium batteries, industrial-grade connectors are used.

Quick comparison: