The control system of an electric forklift is comparable to its "brain and safety hub"—it not only precisely regulates core actions such as power output, lifting, and steering but also safeguards personnel safety, equipment stability, and compliant operation through comprehensive protection functions. Missing key protection features can lead to minor issues like battery swelling and motor burnout, or even serious safety accidents such as rollovers and electric shocks. Today, we’ll break down the 5 essential categories of protection functions that an electric forklift control system must have, helping you understand the core value of "safety configurations"!

I. Personnel Safety Protection: Building the "First Line of Defense" for Operators

The core mission of the control system is to protect personal safety, and these 3 functions are essential "safety guarantees":

1. Misoperation Prevention: Avoid risks from unqualified or improper operation

- Equipped with a "key start + seat belt interlock" mechanism: The forklift cannot start or only creeps at low speed if the seat belt is not fastened;

- Hierarchical operation permissions: Distinguish between administrator and operator permissions via passwords or IC cards to prevent novices from mistakenly triggering advanced functions (e.g., high-speed mode, heavy-load lifting);

- Misoperation lockout: Automatically locks after 3 consecutive incorrect startup passwords to avoid unauthorized use.

2. Anti-Rollover and Attitude Protection: The "stability core" for complex working conditions

- Real-time monitoring of forklift tilt angle (horizontal and vertical): When the tilt angle exceeds the safety threshold (usually ≥15°) during heavy-load turning or ramp driving, it automatically limits speed, prohibits sudden steering, and even triggers braking;

- Fork lifting height linkage: When the lifting height exceeds 2 meters, automatically reduces driving speed (≤3km/h) to avoid rollover caused by center-of-gravity shift with high loads.

3. Human-Machine Distance Sensing Protection: Proactively avoid collision risks

- Infrared or millimeter-wave sensors installed around the vehicle: When personnel or obstacles approach the operating area (distance ≤50cm), the system automatically decelerates and issues an audible and visual alarm;

- Reverse linkage protection: Automatically activates reverse buzzers + warning lights when shifting to reverse gear; directly cuts off reverse power and forces a stop if there are obstacles behind.

4. Emergency Brake Protection: The "last line of defense" for unexpected situations

- Equipped with an emergency power cut/brake button independent of regular brakes: Pressing it immediately cuts off power to the motor and hydraulic system while locking the wheels to prevent inertial sliding;

- Brake failure warning: When abnormal brake pedal travel or insufficient brake fluid pressure is detected, immediately limits speed, issues an alarm, and prohibits heavy-load operations.

II. Core Equipment Component Protection: Extend Lifespan and Reduce Downtime

The control system must real-time monitor key components such as the motor and hydraulic system to avoid damage from overload and overheating:

1. Motor Overload/Overheating Protection: Prevent "motor burnout"

- Real-time monitoring of motor operating current: When the current exceeds 120% of the rated value due to overloading, climbing, etc., automatically limits power (reduces output torque) and alarms;

- Motor temperature monitoring: When the housing temperature exceeds 65℃ (core component temperature ≥85℃), automatically cuts off power or switches to "cooling mode" until the temperature drops to a safe range before resuming normal operation.

2. Hydraulic System Protection: Avoid component damage from abnormal pressure

- Hydraulic system pressure monitoring: When the pressure exceeds the safety threshold (usually 110% of the rated pressure) during lifting or tilting, automatically stops the action and relieves pressure to prevent oil pipe burst and mast deformation;

- No-load/heavy-load adaptation: Automatically adjusts hydraulic lifting speed according to fork load to avoid impacting components due to "sudden lifting/lowering" when unloaded and ensure stable power output when loaded.

3. Steering System Protection: Prevent mechanical structure damage

- Steering limit protection: When the steering angle reaches the mechanical limit (usually ±45°), automatically cuts off steering power to avoid fracture of steering rods and ball joints due to excessive force;

- Steering assist failure backup: When electric power steering fails, automatically switches to manual steering mode (retains basic steering function) while alarming for maintenance, allowing the forklift to evacuate the operating area.

III. Specialized Battery Protection: Safeguard the "Power Heart" and Avoid Safety Hazards

The battery is the core consumable of an electric forklift, and the control system must be equipped with targeted protection to avoid damage from overcharging, over-discharging, etc.:

1. Overcharge/Over-Discharge Protection: Extend battery life and prevent fire risks

- Overcharge protection: Automatically cuts off the charging circuit when the battery is fully charged (100%) to avoid lithium battery swelling and lead-acid battery leakage; supports "trickle charge mode" to maintain stable power without damaging cells;

- Over-discharge protection: When the power is below 20% (customizable threshold), automatically limits forklift speed and lifting functions, retaining only basic power for "returning to the charging area" to avoid battery failure due to undercharging.

2. Over-Temperature/Over-Current Protection: Adapt to extreme working conditions

- Battery temperature monitoring: Automatically stops charging/discharging and activates cooling fans when the temperature exceeds 45℃ (lithium batteries)/50℃ (lead-acid batteries) during charging or discharging; resumes operation only when the temperature drops below 35℃;

- Short-circuit protection: Triggers fusing or power cut within 10ms in case of accidental short-circuit between positive and negative battery terminals to avoid fire and explosion.

3. Balanced Charging Protection: For multi-cell battery packs

- Real-time monitoring of individual cell voltages in the battery pack: Automatically adjusts the charging current of single cells during charging to avoid overcharging of some cells and undercharging of others, extending the overall service life of the battery pack (especially important for lithium batteries).

IV. Working Condition Adaptation Protection: Cope with Complex Environments and Avoid "Operation with Faults"

The control system must automatically adjust protection strategies according to the operating environment to meet the needs of different scenarios:

1. Heavy-Load/Light-Load Adaptive Protection:

When the load exceeds 80% of the rated load, automatically switches to "heavy-load mode"—limits driving speed, extends braking distance, and enhances anti-rollover warning sensitivity; maintains efficient operation when unloaded to balance efficiency and safety.

2. Ramp Protection: Prevent slipping and loss of control

Detects when the forklift is on a slope ≥5° and automatically activates "ramp parking" function: Briefly locks the wheels after releasing the brake and releases slowly when starting to avoid slipping; limits acceleration when going uphill and automatically assists braking when going downhill.

3. Special Environment Protection:

- Low-temperature protection (≤0℃): Automatically reduces battery discharge power to avoid cell damage from high-current discharge at low temperatures, while prompting "operate after preheating";

- Water/ dust protection: Automatically cuts off non-essential power and retains emergency functions only when water ingress or excessive dust in electrical components is detected to prevent short-circuit and burnout of the control system.

V. Intelligent Early Warning and Fault Protection: Proactively Avoid Risks and Simplify Maintenance

A high-quality control system not only provides "passive protection" but also "active early warning" to reduce operation and maintenance costs:

1. Real-Time Status Monitoring and Alarm:

The dashboard synchronously displays key data such as battery voltage, motor temperature, and hydraulic pressure; issues audible and visual alarms + on-screen pop-up prompts (e.g., "Motor Overheating", "Battery Undervoltage") when abnormalities occur, allowing operators to quickly locate problems.

2. Automatic Power Limiting and Fault Isolation:

When a non-fatal fault is detected (e.g., insufficient hydraulic oil, abnormal sensor), it does not shut down directly but limits some functions (e.g., prohibits heavy loads, reduces speed), allowing the forklift to complete the current operation before evacuating for maintenance, reducing downtime losses.

3. Fault Recording and Traceability:

Automatically stores fault codes, occurrence time, and operating conditions (load, speed, temperature); data can be exported via USB or IoT module during maintenance to quickly locate the root cause of faults and shorten repair time.

VI. Key Selection Criteria: How to Judge Whether Protection Functions Are "Practical, Not Gimmicky"?

1. Compliance: Protection functions must meet national standards such as GB/T 38894-2020 "Industrial Vehicles - Safety Requirements" and have third-party inspection and certification;

2. Scenario Adaptability: Supports customizing protection parameters (e.g., tilt threshold, low-power alarm point) according to your own operating scenarios (e.g., cold chain, heavy load, narrow aisles);

3. Expandability: Supports upgrading protection functions via IoT, such as adding "remote lockout" and "electronic fence for operating areas" later.

Summary: Protection Functions ≠ Additional Cost, But a "Long-Term Money-Saving Tool"

The protection functions of an electric forklift control system may seem like "additional configurations", but they are actually the core of reducing accident rates, extending equipment life, and controlling operation and maintenance costs. A comprehensive protection system can reduce more than 80% of human operation errors and component damage caused by overload, allowing the forklift to maintain stability during high-frequency operations while aligning with the trend of "safety first, low carbon, and high efficiency" in modern logistics.

When choosing an electric forklift, don’t just focus on load capacity and battery life—pay more attention to whether the control system’s protection functions are comprehensive and suitable for your own scenarios. This is the "invisible guarantee" for the long-term safe operation of the equipment.