Electric Forklift Components

An electric forklift consists of numerous components. Below is an introduction to some key components and their functions:

Power System Components

Battery: Supplies energy to the electric forklift and serves as the power source for its operation. Common types include lead-acid batteries and lithium-ion batteries. Lead-acid batteries are cost-effective and technologically mature, but they have relatively poor endurance and longer charging times. In contrast, lithium-ion batteries offer advantages such as longer endurance, faster charging, and a longer service life, though they come with a higher price tag.
Motor: Converts the electrical energy from the battery into mechanical power to drive the forklift's movement (e.g., forward/backward travel) and the lifting/lowering of the forks. Typically, either DC motors or AC motors are used. AC motors have advantages like high efficiency, low maintenance requirements, and excellent speed regulation performance.
Charger: Used to charge the battery, converting alternating current (AC) into direct current (DC) suitable for battery charging. The performance and charging efficiency of the charger affect the battery's service life and the forklift's work efficiency.

Wheels: Usually equipped with rubber tires or polyurethane tires. The front wheels are responsible for driving and steering, while the rear wheels provide support and stability. Different types of tires are suitable for different working scenarios: solid tires are ideal for harsh road conditions, while pneumatic tires offer better shock absorption and driving comfort.
Drive Axle: Connects the wheels to the motor and transmits the motor's power to the wheels, enabling the forklift to move forward and backward. The drive axle also includes components such as a reducer and a differential, which adjust the vehicle's speed and torque to allow the forklift to adapt to different load and driving conditions.
Steering System: Generally hydraulic or electric power-assisted, with steering controlled via a joystick or steering wheel. It includes components like a steering gear, steering cylinder, and steering knuckle, allowing the forklift to turn flexibly in narrow spaces.

Forks: The primary components used by the electric forklift to handle goods. Typically composed of two telescopic forks, they can move up and down and tilt forward/backward to adapt to stacking goods of different heights and shapes. Forks are usually made of high-strength steel, ensuring sufficient strength and rigidity.
Mast: Supports the lifting movement of the forks and consists of an inner mast, outer mast, rollers, and other parts. There are various mast structures, such as two-stage masts and three-stage masts. Different mast structures offer different lifting heights and visibility.
Hydraulic System: Includes components like an oil pump, oil cylinder, and hydraulic valve, providing power for the lifting/lowering and tilting of the forks. The working pressure and flow rate of the hydraulic system determine the lifting speed and load-carrying capacity of the forks. The cleanliness of the hydraulic oil is crucial for the normal operation of the hydraulic system.

Controller: Acts as the "brain" of the electric forklift. It adjusts the motor's operating speed, direction, and torque to achieve precise control of the forklift. The controller also has functions such as overload protection, short-circuit protection, and undervoltage protection to ensure the safe operation of the forklift.
Instrument Panel: Installed in the driver's cab, it displays various operating parameters of the forklift, such as battery power, vehicle speed, oil pressure, and water temperature. Drivers can use the instrument panel to monitor the forklift's working status in real time, detect issues promptly, and take appropriate measures.
Joysticks and Buttons: Drivers use joysticks and buttons to control the forklift's travel, steering, and the lifting/tilting of the forks. The layout and operation method of the joysticks and buttons should comply with ergonomic principles, allowing drivers to operate the forklift easily and accurately.

Brake Pads: Cooperate with brake discs or brake drums to slow down or stop the rotation of the wheels through friction, achieving the forklift's braking function. Brake pads are generally made of wear-resistant and high-temperature-resistant materials, such as asbestos, semi-metallic materials, and ceramics. Different materials result in different braking performance and service life of the brake pads.
Brake Discs / Brake Drums: Installed on the wheels, they interact with the brake pads to generate braking force. Brake discs are typically used in disc brake systems, offering advantages like fast heat dissipation and good braking effect. Brake drums are used in drum brake systems, featuring a relatively simple structure and low cost.

Load Sensor: Installed on the forks or mast, it detects the weight of the goods to prevent the forklift from being overloaded. When the weight of the goods exceeds the set value, the load sensor emits an alarm signal to remind the driver to pay attention to safety.
Warning Lights and Alarms: Include turn signals, brake lights, reverse lights, and buzzers. They are used to send warning signals to personnel in the surrounding area during the forklift's operation, improving safety in the workplace.
Emergency Stop Button: In case of an emergency, the driver can press the emergency stop button to immediately cut off the forklift's power supply, stopping the forklift's operation and avoiding accidents. The emergency stop button is usually installed in an easily accessible location within the driver's cab.