In diverse industrial material handling scenarios including open-air cargo yards, cold storage transfer stations and high-altitude operation areas, ambient temperature often fluctuates sharply in short periods, driven by changing seasons, day-night temperature difference or cross-scenario operation requirements. Such temperature variations pose clear challenges to the normal operation of lithium-ion powered forklifts, as inappropriate working temperature will affect battery output performance, operation continuity and the overall use experience of handling equipment. A targeted, highly responsive thermal management system is the core supporting component to solve such pain points.

The BYD lithium-ion forklift thermal management system is equipped with fully distributed temperature sensing modules arranged across the whole battery pack, key electronic control components and air flow channels, which can collect real-time temperature data of each monitoring point at proper sampling frequency. The system can recognize subtle ambient temperature changes quickly, and trigger corresponding adjustment strategies immediately once the temperature fluctuation range exceeds the preset conventional working threshold, effectively avoiding the common lag problem of traditional temperature control schemes.

For scenarios where ambient temperature drops rapidly, the system will start the uniform preheating mechanism at low power consumption, to spread heat evenly to every area of the battery pack, and reduce local temperature difference to a reasonable level, so that the battery can always stay in the proper working temperature range to maintain stable discharge power output. For scenarios where ambient temperature rises fast, the system will activate graded heat dissipation adjustment, matching corresponding heat dissipation power gear according to the actual temperature rising rate, to take away excess heat efficiently while avoiding unnecessary extra energy consumption.

In long-term operation verification under various working conditions with frequent temperature fluctuations, the system can maintain the internal temperature difference of the battery pack within a reasonable and controllable range, effectively reduce the performance attenuation of the battery pack caused by frequent temperature shock. It supports the lithium-ion forklift to keep stable continuous operation even under working conditions such as driving out of low temperature cold storage to high temperature open-air site directly, or operating in open yards with more than 20 degrees Celsius of day-night temperature difference, cutting unnecessary downtime waiting period, and helping to extend the conventional service life of the whole power battery system, bringing more reliable operation experience for all kinds of industrial handling users.