The 48 volt DC hydraulic power unit can provide a stable and reliable power source for your mobile devices and industrial systems. Now, let’s thoroughly explore everything about the 48 volt DC hydraulic power unit.
What is a 48 Volt DC Hydraulic Power Unit?
A 48 volt DC hydraulic power unit is an independent system that supplies power to the motor through 48 volts of direct current. This then drives the hydraulic pump to generate hydraulic fluid power. It can provide you with continuous and stable power in scenarios without an external power source, mobile devices or battery power supply.
Key Components of the 48 Volt DC Hydraulic Power Unit
DC Motor
The 48V DC motor converts electrical energy into mechanical energy, directly driving the hydraulic pump to operate at high speed. It provides a continuous and stable power output for the entire hydraulic system.
Meanwhile, due to its 48V high-voltage characteristic, it can achieve lower current consumption during operation. This can reduce line losses and also lower its own heat generation.
If you use it in conjunction with the S3 working schedule, it can also maintain stable performance in intermittent or continuous operation scenarios. There will be no overheating that would affect the lifespan of the equipment.
Hydraulic Pump
The hydraulic pump can convert mechanical energy into hydraulic energy. It is connected to the DC motor and sucks in hydraulic oil from the oil tank. After undergoing precise internal pressure treatment, it conveys the high-pressure hydraulic oil to the subsequent valve components. The hydraulic pump supplies sufficient hydraulic power to the hydraulic cylinder and other actuating components.
The hydraulic gear pump is the most commonly used type, and its working pressure can typically reach 250 bar. You can also choose hydraulic piston pumps or hydraulic vane pumps according to your needs.
Under the customized design scheme, you can adjust the pressure parameters according to the specific working conditions to meet the hydraulic output requirements for different load scenarios.
Hydraulic Oil Tank
The design of the hydraulic oil tank is adapted to the compact structure characteristics of the 48 volt dc hydraulic power unit. It is capable of storing enough hydraulic oil and also performs the functions of system heat dissipation and oil purification.
When the high-pressure hydraulic oil flows back to the oil tank, the oil temperature can be reduced through the heat exchange between the tank wall and the air. The sedimentation structure at the bottom of the oil tank enables the impurities in the hydraulic oil to naturally settle. This reduces the probability of impurities entering the hydraulic pump and valve components.
Valves
Valve components can control the flow, pressure and on-off of hydraulic oil. They are usually integrated onto multi-functional valve blocks.
The electromagnetic valve is responsible for receiving electrical signals and achieving remote control of the hydraulic oil flow path. It can be adapted to the remote control function of your device.
The hydraulic pressure reducing valve can monitor the system pressure in real time. When the pressure exceeds the set value, it will automatically open to relieve the pressure, preventing the system from being damaged due to overpressure.
The hydraulic check valve can prevent the reverse flow of hydraulic oil, thus avoiding unexpected movements of the actuating elements due to the backflow of the oil.
The hydraulic directional valve changes the flow direction of the hydraulic oil, thereby controlling the operating direction of the single-acting or double-acting hydraulic system.
Types of the 48 Volt DC Hydraulic Power Unit
Classified by the Mode of Action
Single-Acting 48 Volt DC Hydraulic Power Unit
Single-acting devices only provide a unidirectional hydraulic output, and the return stroke relies on gravity or a spring reset mechanism. Its structural design is simple and it is compatible with the hydraulic single acting cylinder. It is applicable in situations where simple actions such as unidirectional pushing, pushing up, and lifting need to be achieved.
It can meet the requirements of a light-load unidirectional drive. You can use it in scenarios such as trailer tilting mechanisms, simple lifting platforms, and unidirectional clamping devices.
Double-Acting 48 Volt DC Hydraulic Power Unit
The double-acting device can provide bidirectional hydraulic power. It can control the two actions of extending and retracting the hydraulic cylinder. This usually requires the use of a dual electromagnetic directional valve to switch the oil flow direction. And then control the movement of the actuating element back and forth.
Because it can provide both bidirectional and controllable force, its functionality is more powerful and its applications are more extensive. You can see it in scenarios such as industrial robotic arms, car tailboards and precision hydraulic platforms.
Classified by Motor Type
Brushless Motor Type
The brushless motor type 48 volt DC hydraulic power unit is equipped with a permanent magnet brushless DC motor. Its efficiency is over 90%, and its service life can exceed 8,000 hours. The carbon brush wear-free design enables maintenance-free operation.
It can support continuous speed adjustment ranging from 0 to 5000 rpm, providing more precise flow control for your hydraulic system. Its low-noise operation feature and compact structure make it very suitable for applications where noise sensitivity and space constraints are both factors.
Brushed Motor Type
The brush motor type 48 volt DC hydraulic power unit uses traditional DC brush motors as its power source. The structure is mature and the manufacturing cost is relatively low. The maintenance process of this model is simple. It only requires the regular replacement of carbon brushes to ensure stable operation.
It is suitable for entry-level applications such as small hydraulic tools and basic lifting equipment. It is a practical hydraulic solution catering to medium and low-load, low-cost requirements.
Advantages of the 48 Volt DC Hydraulic Power Unit
High Efficiency and Energy Conservation
The 48V voltage level is within the safe voltage range and is at a relatively high level. Compared to higher voltage systems, it can reduce energy losses caused by insulation and wiring.
The power consumption is very low in standby or low-load conditions. For mobile devices that rely on battery power, this can effectively extend the battery life after a single charge. It also helps you reduce operating costs.
High Compatibility
48V voltage has now become the standard auxiliary power supply configuration for numerous electric forklifts, off-road machinery, and hybrid vehicles. This equipment can also be easily integrated with solar panels or lithium battery packs.
This compatibility makes system integration very easy. You don’t need to configure any complex voltage conversion devices. You can directly draw power from the main power supply of the device. This simplifies the overall system architecture and reduces the design and manufacturing costs.
Compact Structure
The motor, hydraulic pump, oil tank and control valve assembly are highly integrated into a single hydraulic device. This compact design concept offers greater flexibility in the internal layout of your equipment. It enhances the efficiency of space utilization.
Precise Control
You can use the 48 volt dc hydraulic power unit to achieve high-precision motion control such as smooth start-stop processes and seamless speed changes. It is suitable for automation application scenarios that require precise positioning, smooth movement, or collaboration with PLC and sensors. It enhances the automation level and process quality of the equipment.
Safe and Reliable
48V is an industrial safety voltage, which reduces the risk of electric shock accidents caused by damaged wiring or moisture. The built-in pressure relief valves, check valves and electrical protection devices in the equipment can prevent the execution elements from acting accidentally.
Low Noise
The brushless DC motor and the precise gear pump can reduce noise at the source. Compared with the AC power device, its operating noise has been reduced by approximately 40%. It can be used in scenarios that are sensitive to noise, such as indoor work, night construction or densely populated areas. It creates a more comfortable working environment for you.
Intelligentize
You can select the integrated intelligent controller in the 48V DC hydraulic power unit. Pressure and temperature sensors, along with intelligent diagnostic functions, can monitor the equipment status in real time and issue early warnings for potential failures. You can remotely monitor the system’s operation status in real time and adjust the working parameters.
The Application of the 48 Volt DC Hydraulic Power Unit
Engineering Machinery
The 48 volt DC hydraulic power unit has become the preferred power solution for small excavators, compact loaders, and various aerial work platforms. It can provide you with reliable hydraulic power to complete key actions such as levelling the outriggers, extending and retracting the boom, and raising and lowering the platform.
Logistics Transportation and Special Vehicles
The 48 volt DC hydraulic power unit plays a crucial role in electric sanitation vehicles, garbage collection and transportation vehicles, and other specialized vehicles. It can drive the rotation of the drum, the compression of garbage, and the lifting of the carriage.
Its high-performance feature extends the vehicle’s driving range. The compact structure makes it to be perfectly integrated into the limited space of the vehicle chassis.
Agricultural Machinery
As agricultural machinery is transitioning towards electricization, 48 volt dc hydraulic power units have been widely used in tractors, harvesters, planters and other equipment. It provides reliable hydraulic power for the lifting mechanisms and steering systems of agricultural machinery. This enables traditional agricultural machinery to operate with low noise and no pollution.
The device housing is designed with IP65/IP67 and other high-level protection features. This prevents erosion from dust and moisture in the field and keeps stable operation under harsh conditions.
Automated Warehousing and Logistics
The 48 volt dc hydraulic power unit provides the core power for automated guided vehicles and the lifting and handling systems of automated storage warehouses.
Its precise control characteristics meet the strict positioning accuracy requirements of automated equipment. The intelligent control function enables the equipment to integrate into the industrial Internet of Things system and achieve intelligent warehouse management.
A Simple Comparison between a 12V DC Hydraulic Power Unit and a 24V DC Hydraulic Power Unit
When the output power is the same, according to the formula P = U × I, the current required by the 48V system is much lower than that of the 12V and 24V devices. A lower current means:
Lower cable loss: There is less energy loss during transmission, resulting in higher overall energy efficiency.
Less heat generation: The heat generated by the components and the motor is effectively controlled. The system operates more stably and has a longer lifespan.
Extended battery life: For battery-powered devices, higher efficiency translates into longer single-charging operation time for the equipment.
You can make the comparison through this table.
| Comparison Dimension | 12V Equipment | 24V Equipment | 48V Equipment |
| Power Level | Low | Medium | High |
| Current Consumption | High | Medium | Low |
| Cable Requirements | Coarse Cable | Medium Cable | Fine Cable |
| Energy Efficiency | Low | Medium | High |
| Heat Dissipation Requirements | High | Medium | Low |
FAQ
What Preparations need to be made before the First Use of the 48 Volt DC Hydraulic Power Unit?
You need to complete the following key preparations:
- Please first check whether the oil tank level has reached the standard mark, and make sure that the specified type of hydraulic oil has been added.
- Then, make sure that the power connection is correct.
- After completing the above checks, you need to manually move the motor several times to remove the residual air from the hydraulic system.
- Finally, let the system run at a low load for 10 to 15 minutes. During this period, you need to monitor the operation status of the equipment. It can be put into normal use only after there is no abnormal noise, vibration or leakage.
What could be the Reasons for Severe Overheating when the Motor is Running?
- If the system’s pressure setting is too high, it will cause the motor to operate beyond its capacity. At this point, the current increases and causes heating.
- If the viscosity of the hydraulic oil is too high or it gets contaminated, it will increase the running resistance.
- The motor itself has mechanical faults such as bearing damage or internal friction.
We suggest that you first check and adjust the system pressure to a reasonable range, and use the appropriate viscosity of clean hydraulic oil. If the problem persists, you will need to have the motor professionally inspected and repaired.
What are the Safe Procedures for Resetting after a Malfunction Trip or Shutdown?
First, you need to immediately cut off the power supply of the equipment to ensure that the system is completely powered off. Then you must determine the underlying cause of the trip. Common faults include system overload, abnormal increase in pressure or overheating of the motor. After confirming that the fault has been resolved, you can perform the reset operation.
When resetting, you should strictly follow the instructions in the equipment operation manual. For some models, you may need to operate a dedicated reset button or execute a specific reset procedure.
If the fault cannot be identified or resolved by yourself, please contact professional technicians immediately.
Final Thoughts
By now, we believe you have a clear understanding of the 48 volt dc hydraulic power unit. Target Hydraulics is committed to providing you with compact, efficient and precise 48V DC hydraulic power units.
We understand the unique requirements of different application scenarios and offer professional customised services. We ensure that each solution can meet your requirements.
Please feel free to contact us at any time to jointly explore how to provide your project with stronger and more reliable hydraulic power support.
