Hydraulic 48V DC Power Pack
Hydraulic 48V DC Power Pack
What is a 48V DC Hydraulic Power Pack?
A Hydraulic 48V DC Power Pack is a compact, battery-operated hydraulic power source that generates and regulates hydraulic fluid flow and pressure using a 48-volt DC electric motor. These are specially designed for mobile equipment such as electric garbage tippers, scissor lifts, wheelchairs, forklifts, and other off-grid or vehicle-mounted hydraulic systems.
How It’s Made – Components & Manufacturing
Key Components:
| Component | Description |
|---|---|
| DC Electric Motor (48V) | Brushless or brushed motor that drives the hydraulic pump |
| Hydraulic Pump | Typically gear pump or piston pump, rated up to required flow/pressure |
| Oil Reservoir | |
| Relief Valve | Prevents over-pressure, maintains system safety |
| Solenoid Valve | Controls fluid direction electrically |
| Check Valve | Prevents backflow in system |
| Pressure Gauge | Monitors system pressure |
| Manifold Block | Compact integration of all hydraulic flow paths |
| Remote/Controller | Optional wired or wireless operation interface |
Manufacturing Process:
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Design & Engineering:
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Circuit layout for directional control
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Component Selection:
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Matched low-noise gear or piston pump
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Lightweight aluminum reservoir
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Assembly:
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Mount pump-motor on base frame
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Electrical wiring with connectors and relays
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Testing:
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Flow test, leak test, safety valve calibration
Working Principle
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48V DC battery powers the electric motor.
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Motor rotates the hydraulic pump, creating flow.
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Pressurized oil is directed via solenoid valves to actuators (cylinders/motors).
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The oil returns to the tank through filters for reuse.
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Pressure relief valve ensures the system doesn’t exceed safe limits.
Uses of 48V DC Hydraulic Power Pack
| Application | Function |
|---|---|
| Electric Garbage Vehicles | Powering tipping mechanisms |
| Mobile Hydraulic Equipment | |
| fire Trucks | Ladder and water jet actuation |
| Wheelchairs & Lifting Chairs | Raising and lowering mechanisms |
| Compact Brick/Block Machines | Hydraulic compaction in off-grid locations |
| Material Handling Carts | Lifting platforms |
| Mini Agricultural Machines | Hydraulic tool actuation in field environments |
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Battery Operated: Ideal for mobile, off-grid or low-voltage situations
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Compact & Lightweight: Easy integration in vehicles and portable equipment
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Energy Efficient: 48V system balances power and safety
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Zero Emission: No fuel combustion; supports eco-friendly operations
Advantages
| Advantage | Description |
|---|---|
| Battery-Operated | Works with electric vehicles and solar-powered systems |
| Efficient & Powerful | Suitable for medium-duty hydraulic tasks |
| Low Noise | Quiet operation due to low-voltage motor |
| Modular Design | Can be configured as single, double-acting or reversible |
| Safe Voltage | |
| Easy Maintenance | Plug-and-play components, minimal upkeep |
| Space-Saving | Integrated tank, valve, and motor system |
Where It’s Used
| Industry | Equipment/Use Case |
|---|---|
| Municipal Vehicles | Electric garbage rickshaws, tipper trucks |
| Construction | Mini loaders, compact lifters, mobile hydraulic tools |
| Block Industry | Portable fly ash brick machines or paver machines |
| Healthcare | Hydraulic beds, stretchers, wheelchairs |
| Agriculture | |
| Logistics | Pallet trucks, portable lifts, material carts |
Significance
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Enabler for Electric Vehicles: As more systems shift from fuel to electric, 48V DC is the standard in e-rickshaws and utility trucks.
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Compact Automation: Makes hydraulic automation possible in remote or off-grid locations.
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Eco-Friendly & Sustainable: Supports zero-emission initiatives.
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Enhances Accessibility: Used in mobility devices for the disabled and elderly.
Key Qualities of a Good 48V DC Power Pack
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Long Battery Runtime with optimized motor efficiency
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High Pressure Capability (up to 180–220 bar)
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Precision Flow Control using digital solenoids
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Overload Protection for motor and pump
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IP65 Rated Enclosure for outdoor/weatherproof usage
Quick Connectors for field serviceability
FAQs
Q1: What battery type is needed for a 48V DC power pack?
A: Generally, deep-cycle lead-acid or lithium-ion battery banks with 48V output and 50–150Ah capacity.
Q2: Can it power dual hydraulic cylinders?
A: Yes, with proper valve configuration (dual-acting), it can operate two or more cylinders.
Q3: What is the lifespan of a 48V DC hydraulic power pack?
A: Typically 3–7 years depending on usage, maintenance, and environmental conditions.
Q4: Is it suitable for cold weather?
A: Yes, with appropriate low-temperature hydraulic oil and enclosure heating options.
Q5: Can it be remotely operated?
A: Absolutely. It supports wired remote, joystick, or wireless control systems.
Conclusion
The Hydraulic 48V DC Power Pack is a vital innovation for modern mobile and electric hydraulic systems. Its compact size, low-voltage safety, high power output, and clean energy compatibility make it the preferred solution for industries moving toward electrification and automation.
Whether you're operating garbage tippers, mobile lifts, or battery-operated construction tools, this power pack brings mobility, performance, and sustainability into a single package.
