Hangcha Group has introduced a new line of high-voltage (80V) lithium-ion counterbalance forklifts, aimed at heavy-duty logistics and manufacturing sectors. Traditionally, electric forklifts in the 2.5 to 3.5-ton range have used 48V or 72V systems. However, as loads get heavier and duty cycles get longer, the current draw increases, leading to excessive heat build-up in the cables and motors (Joule heating). This often forces the machine to enter a "thermal derating" mode, reducing travel speed and lift power to cool down.
By switching to an 80V architecture, Hangchao has reduced the current required by approximately 30% for the same power output (P=VI). The engineering highlights include the use of rare-earth permanent magnet synchronous motors (PMSM) for both traction and hydraulics. These motors are paired with silicon carbide (SiC) power modules in the inverter. SiC modules have lower switching losses compared to traditional silicon IGBTs, further reducing heat generation.
A key benefit for fleet managers is the "Opportunity Charging" capability. The 80V system supports a high-current DC fast charger (up to 150A). During a driver's 15-minute break, the battery management system (BMS) can recover 15-20% of the charge. The system also features a liquid-cooling circuit for the battery pack, allowing it to accept fast-charge currents even when the ambient temperature is high, ensuring the forklift does not slow down during the critical afternoon shift changeover.
