HIGH-PERFORMANCE FORKLIFT 10KW&20KW ON-BOARD CHARGING SOLUTIONS

2026-06-10 10:51

How LONGRUN 10Kw 20Kw On-Board Charger (LR-M3F5-10K) Powers High-Voltage Lithium Forklift Platforms

1、Customer Background

A leading warehouse logistics operator was upgrading its electric forklift fleet from traditional lead-acid batteries to high-voltage lithium battery systems. The core objectives of this modernization project were to improve operational efficiency, reduce maintenance costs, and support intensive, 24/7 continuous warehouse operations.

Forklift Charging System Architecture.jpg

Figure 1: High-voltage lithium-powered forklift fleet operating in a modern logistics warehouse.

To successfully execute this transition, the operator required an industrial-grade, highly efficient charging solution capable of rapid charging, intelligent battery protection (via BMS integration), and reliable performance in challenging industrial environments.

To meet these rigorous requirements, LONGRUN CHARGER LiFePO4 Forklift Battery (48V 500Ah) and LR-M3F5-10K 10kW On-Board Charger were selected as the core power and charging system for this new-generation forklift platform.

“Conventional external charging systems required forklifts to remain idle for extended periods, severely reducing fleet utilization and interrupting warehouse throughput.”

2、Key Technical Challenges

Harsh Operating Environments: The forklift fleet frequently operates in dusty warehouses, cold storage facilities, and outdoor loading zones. The charging equipment must withstand high vibration, moisture, and extreme temperature fluctuations.
Intelligent Battery Protection: To maximize the lifespan of the high-capacity 48V 500Ah lithium battery and ensure operational safety, the charger must deliver precise charging control and real-time communication with the Battery Management System (BMS).

3、The LONGRUN Solution

Figure 2: Seamless integration of the LR-M3F5-10K on-board charger and 48V battery within the forklift chassis.

The LR-M3F5-10K charger was integrated directly into the forklift platform. This on-board configuration allows operators to charge the vehicle using available three-phase AC power infrastructure throughout the facility. By enabling ‘opportunity charging’ during short breaks, this solution completely eliminates the need for dedicated charging rooms and specialized transport to remote charging stations.

Figure 3: LONGRUN CHARGER industrial-grade LR-M3F5-10K 10kW On-Board Charger.

Through high-speed CAN communication, the charger continuously exchanges data with the battery management system. It dynamically adjusts the charging voltage and current in real-time according to the battery’s State of Charge (SoC), cell temperatures, and health status, ensuring both high charging speeds and complete operational safety.

4、Key Benefits & Results

Minimized Equipment Downtime: Enabled fast opportunity-charging capability, allowing forklifts to be powered up quickly during shift handovers or short breaks, maximizing vehicle uptime.
Industrial-Grade Durability: With robust shock absorption and high-level ingress protection (IP67), the charger operates reliably in extreme cold storage and high-dust environments.
Extended Battery Lifespan: Smart multi-stage charging algorithms and real-time thermal monitoring prevent overcharging and overheating, prolonging battery life by up to 25%.