As the continuous popularization of high-output lithium-ion forklifts in heavy-duty material handling scenarios, reasonable cooling system parameter matching has become a core link to ensure the long-term stable operation of motor assemblies. Unmatched parameters may lead to insufficient heat dissipation under long-time full-load operation, or cause unnecessary energy consumption and extra wear of cooling components due to excessive redundant configuration.

The first step of parameter matching is to complete working condition load baseline measurement. Technicians need to collect the actual operation data of the target forklift model in typical application scenarios, including the duration of peak output, average load rate in continuous operation, maximum climbing gradient and corresponding lasting time, as well as the highest ambient temperature in the service area. These basic data can support subsequent parameter calculation to avoid deviation caused by only referring to theoretical rated values.

The second step is to finish heat exchange capacity matching based on accurate heat loss data. According to the measured thermal loss value of the motor assembly under different load states, including heat generated by motor windings, transmission friction and current loss of matching controller, calculate the total heat that needs to be taken away per unit time. Then confirm the reasonable parameters of the cooling system, including the flow rate of cooling medium, the effective heat exchange area of the radiator, and the air supply volume of the cooling fan, to keep the temperature rise of the motor assembly within the allowable design range under all conventional working conditions.

The third step is to implement temperature control interconnection parameter calibration. It is not recommended to set the cooling system to run at full power all the time. Technicians can set multi-stage start and shift thresholds by associating the real-time temperature data of motor windings, core components of the controller and cooling medium, to adjust the operating power of cooling components dynamically. This mode can not only meet the heat dissipation demand, but also reduce the extra energy consumption of the whole vehicle.

The final step is to carry out full-condition test and fine-tuning. After the preliminary parameter setting, conduct continuous cycle operation test under different ambient temperatures and different load states, record the temperature change data of each key component, and make tiny adjustment to relevant parameters, to ensure the cooling system has appropriate and reasonable redundancy, and provide reliable support for the long-term operation of the high-output lithium-ion forklift.