TL;DR: If you want to modernise your existing fleet of forklifts and retrofit laptops or vehicle terminals, standard chargers will let you down fast. The solution is a rugged DC/DC converter that reliably handles the common forklift battery voltages – whether 24 V, 36 V, 48 V or 80 V. Our unit tames the voltage chaos with an ultra-wide input range of 21 to 100 volts and delivers clean 19 volts at up to 10 amps. It comes in a fully potted aluminium housing, withstands vibrations without complaint and cools itself passively through the baseplate – all at an efficiency of up to 97% without derating.
Why Standard Chargers Fail on Forklifts
Imagine you need to modernise an existing fleet of forklifts and retrofit laptops for the warehouse management system. Suddenly you are facing a massive problem: where does the power for the mobile IT come from? You might think a standard off-the-shelf power supply would do the job. Unfortunately, that is a costly mistake.
The typical traction batteries in electric forklifts have nominal voltages of 24 volts, 36 volts, 48 volts, or even 80 volts on heavy-duty equipment. When the forklift lifts heavy loads, brakes abruptly or engages regenerative energy recovery, the on-board electrical system produces massive voltage spikes and deep sags. A conventional laptop charger immediately shuts down under these conditions – or worse: it damages the connected hardware.
The Challenges of Retrofitting IT on Forklifts
We almost exclusively build DC/DC converters here. It is a true niche product. But once you look at the space constraints inside a forklift cab, you immediately understand why retrofitting mobile data capture requires precisely these tailor-made solutions. The cabs of older models were often never designed for additional technology.
The biggest headaches with these retrofit projects are:
- Electromagnetic compatibility (EMC): The drive electronics generate significant interference in the on-board electrical system. A DC/DC converter without an integrated EMI filter can render the connected notebook or vehicle terminal unusable.
- Extreme lack of space: There is no room in the cab for a bulky power supply with a fan. The power source must be compact and fanless.
- Voltage diversity across the fleet: A single operation often runs forklifts with 24 V, 48 V and 80 V batteries. Ideally, you need one single converter type for all vehicles.
This is exactly why we developed the DC-Converter 145-19-SD. It accepts the on-board voltage of typical 24 V to 80 V forklift batteries and covers the entire voltage chaos with its ultra-wide input range of 21 to 100 volts – including spikes up to 125 volts. The output is always a reliable 19 volts at up to 10 amps: a clean 190 watts for your laptop, notebook or vehicle terminal.
Fully Potted Aluminium Housing Instead of Plastic
Warehouse environments are harsh. Heat, cold, dust and constant vibrations quickly destroy conventional electronics. Our answer is an extremely compact aluminium housing with a complete potting compound fill. This potting protects the sensitive internals from dirt and moisture while significantly dampening the shocks encountered during operation.
Another critical factor is heat dissipation. Where power is converted, heat is generated. We channel this heat intelligently through the baseplate – entirely without a fan. You do not need a bulky additional enclosure or a ventilator that sucks in dust. The converter delivers its full 190 watts with absolute stability and zero power derating, whether the ambient temperature sits at −40 °C in a cold storage facility or climbs to +85 °C in direct sunlight. The thermal shutdown only kicks in at +90 °C.
With an efficiency of up to 97%, barely any energy is lost as waste heat. This is particularly important for battery-powered vehicles, because every wasted watt directly reduces operating time per charge cycle.
Permanently Safe in Operation: Open-Circuit and Short-Circuit Proof
In hectic warehouse operations, it happens constantly: a laptop gets unplugged, a cable gets kinked, a connector gets ripped out while climbing in and out of the cab. The 145-19-SD is designed to be permanently open-circuit and short-circuit proof. This means that neither an accidentally disconnected load nor a short circuit at the output will damage the converter. It simply resumes normal operation once the fault is cleared.
On top of that, the integrated CC/CV charging characteristic allows the converter not only to power a laptop but also to charge its battery gently – with constant current in the first phase and constant voltage in the second. This protects the laptop battery and significantly extends its lifespan.
Why Investing in Mission-Critical IT Pays Off
Let us be honest: nobody buys a highly reliable industrial device just to run a simple receipt printer on a forklift. When retrofitting, it is always about the heart of mobile logistics. The laptop or vehicle terminal running the warehouse management system (WMS) is absolutely mission-critical. If the 19 V supply fails, the warehouse operator no longer knows which order to pick next – and the forklift effectively stands still.
For precisely this expensive and sensitive IT equipment, a fully potted DC/DC converter with an integrated EMI filter is indispensable. We have also deployed 12 volt and 24 volt converters in similar projects when specialised industrial sensors or other truly critical systems need to be integrated on the vehicle. But the main task usually remains the same: the sensitive IT hardware must survive the rough life on an electric forklift – regardless of how much the on-board battery sags when lifting a pallet.
Is This Converter Right for Your Project?
The DC-Converter 145-19-SD is the right choice if you want to retrofit laptops, notebooks or vehicle terminals on electric forklifts, tow tractors or other industrial trucks with battery voltages between 24 V and 80 V. It is equally suited for use in wind power, rail transport, aerial tramways or other battery-powered electrical systems.
Need a different output voltage or have specific requirements? Get in touch – we also develop custom DC/DC converters.
