Assembly and manufacturing 48V traction batteries

What is a 48V traction battery?

The 48V traction batteries are made by connecting 24 cells of 2V each in series. They are designed to withstand deep discharges (up to 80% of their capacity) and numerous charge/discharge cycles, making them ideal for heavy-duty applications.

They are suitable batteries for demanding environments where high power, continuous reliability and mechanical resistance are required. Their internal structure allows them to withstand vibrations and impacts without compromising performance.

Components of a 48V Lead Traction Battery

A 48V traction battery includes:

• Metal housing or enclosure where all battery components are housed
• 2V elements (normally 24 units to reach 48V)
• Flexible connections and insulated cables
• Specific screws with PVC protection
• Optional: automatic filling system, power cables and machine connectors.

Step-by-step assembly process

1. Manufacture of the metal housing.

Selection of a new housing according to battery dimensions; at Rebatex Energy we have all models of metal boxes for most machines on the market.

2. Assembly of the elements

Inside the metal housing the 2V elements are placed, following the series connection scheme to achieve 48V. It is essential to respect polarity and the arrangement of the terminals for a safe and efficient connection.

3. Electrical connection

The elements are joined using flexible insulated cables, firmly tightening each connection. Screws with PVC heads provide extra safety, preventing short circuits and facilitating future maintenance interventions.

4. Installation of accessories

Optionally, an automatic filling system can be incorporated to facilitate maintenance of the electrolyte level and caps with level indicators, which help monitor the battery status.

5. Quality control

Before delivery, the total voltage, connection tightness and correct functioning of all components are verified. Only in this way is it guaranteed that the battery is ready to work immediately.

Benefits of 48V traction batteries

– Robust construction: they withstand vibrations, impacts and frequent electrical abuse.

– Greater durability: designed for daily charge and discharge cycles, outperforming other battery types in longevity.

– Versatility: suitable for forklifts, platforms, scrubbers, pallet trucks and other industrial electric vehicles.

– Ease of maintenance: thanks to automatic filling systems and accessible connections.

Industrial battery technical service

We offer a comprehensive service for traction batteries, from pre-sales to final commissioning:

– Personalized advice to select the right battery according to each customer’s needs and industrial application.

– Supply and logistics: short delivery times for batteries, chargers and all accessories necessary for their proper operation.

– Technical support and after-sales assistance: quick response to incidents and technical queries for the personnel responsible for battery use and maintenance.