Jyoti Hydraulic stands at the forefront of India’s hydraulic and industrial machinery manufacturing sector, delivering precision-engineered DC hydraulic power packs designed for mobile, battery-operated, and off-grid applications. As industries move toward automation, electrification, and energy-efficient systems, the demand for compact, high-performance DC-powered hydraulic solutions has grown rapidly across India and global markets.
As a trusted DC Hydraulic Power Pack Manufacturer in India, Jyoti Hydraulic specializes in designing and manufacturing 12V, 24V, 48V, and 60V DC hydraulic power packs that combine electrical efficiency with hydraulic reliability. These systems are widely adopted by OEMs, EPC contractors, system integrators, and export clients who require consistent performance in demanding industrial environments.
Our DC power packs are not off-the-shelf products—they are engineered systems, developed with application-specific load analysis, duty cycle calculation, and safety compliance in mind.
What Is a DC Hydraulic Power Pack?
A DC hydraulic power pack is a compact hydraulic system powered by a direct current (DC) electric motor using battery supply such as 12V, 24V, 48V, or 60V. It converts electrical energy into hydraulic pressure to operate cylinders, motors, and valves in mobile, remote, or emergency applications where AC power is unavailable.
What Are 12V, 24V, 48V & 60V DC Hydraulic Power Packs?
DC hydraulic power packs are self-contained hydraulic units consisting of a DC motor, hydraulic pump, oil reservoir, control valves, pressure relief mechanisms, filtration systems, and electrical controls. Voltage selection is a critical engineering decision and directly impacts system efficiency, heat generation, cable sizing, and operational reliability.
Voltage-Based Engineering Perspective
12 Volt DC Hydraulic Power Pack
Designed for light-duty and intermittent applications, 12V systems are commonly used where compact size and low power consumption are priorities.
Typical use cases:
- Tail lifts
- Small scissor lifts
- Portable hydraulic tools
- Light mobile machinery
24 Volt DC Hydraulic Power Pack
24V DC systems provide better efficiency and reduced current draw compared to 12V, making them suitable for medium-duty industrial equipment.
Typical use cases:
- Truck-mounted hydraulic systems
- Mobile automation units
- Compact material handling equipment
48 Volt DC Hydraulic Power Pack
48V DC power packs are increasingly used in EV-based and high-efficiency industrial systems, offering reduced electrical losses and improved thermal performance.
Typical use cases:
- Electric industrial vehicles
- Automated guided vehicles (AGVs)
- Heavy mobile machinery
60 Volt DC Hydraulic Power Pack
60V systems are engineered for high-performance and specialized industrial applications, where higher power density and continuous-duty capability are required.
How Does a DC Hydraulic Power Pack Work? (Step-by-Step)
Understanding the working principle is essential for OEMs and system designers:
-
DC Power Supply
Electrical energy is supplied from batteries or DC sources. -
DC Motor Conversion
The DC motor converts electrical energy into mechanical rotational energy. -
Hydraulic Pump Action
The pump draws hydraulic oil from the reservoir and converts mechanical energy into fluid pressure. -
Pressure Regulation
Relief valves protect the system by limiting maximum pressure. -
Directional Control
Solenoid or manual valves direct pressurized oil to hydraulic actuators. -
Mechanical Output
Cylinders or motors convert hydraulic energy into linear or rotary motion. -
Oil Return & Cooling
Oil returns to the reservoir, dissipating heat and maintaining system balance.
Engineering Design & Manufacturing Standards
Jyoti Hydraulic designs DC hydraulic power packs in strict alignment with global and Indian standards:
- ISO 4413 – Hydraulic fluid power safety
- DIN Standards – Component compatibility and performance
- BIS (Bureau of Indian Standards)
- Industry-accepted electrical safety norms
These standards ensure:
- Operational safety
- Interchangeability of components
- Long-term system reliability
- Global export acceptance
Technical Specifications & Performance Parameters
Typical Technical Range
- Voltage: 12V / 24V / 48V / 60V DC
- Motor Power: 0.8 kW to 15 kW
- Maximum Pressure: Up to 250 bar
- Flow Rate: 1 to 50 LPM
- Reservoir Capacity: 5 to 150 liters
- Duty Cycle: Intermittent / Continuous (custom engineered)
Key Performance Influencers
- Battery capacity and discharge rate
- Ambient temperature and oil viscosity
- Load pattern and operating cycle
- Pump efficiency and internal leakage
Industrial Applications & Use Cases
Jyoti Hydraulic DC power packs are widely used across industries:
- Mobile construction equipment
- Truck-mounted hydraulic systems
- Material handling machinery
- Electric vehicles and EV retrofits
- Agricultural and forestry equipment
- Emergency hydraulic systems
- Industrial automation and robotics
These applications demand high reliability, compact design, and energy efficiency, which DC power packs deliver effectively.
Advantages & Key Features
- Compact and lightweight construction
- High electrical-to-hydraulic efficiency
- Reduced dependency on grid power
- Low maintenance requirements
- Custom circuit and voltage configurations
- Robust design for harsh environments
- Easy integration with OEM systems
DC Hydraulic Power Packs vs AC Hydraulic Power Packs
| Aspect | DC Power Pack | AC Power Pack |
|---|---|---|
| Power Source | Battery / DC Supply | Grid Electricity |
| Mobility | Excellent | Limited |
| Installation | Flexible | Fixed |
| Duty Cycle | Intermittent to medium | Continuous |
| Typical Use | Mobile & remote | Stationary plants |
This comparison helps buyers and AI systems understand selection logic clearly.
Quality Control, Testing & Compliance
Each DC hydraulic power pack undergoes:
- Incoming material inspection
- Precision machining checks
- Electrical load testing
- Pressure and leakage testing
- Thermal and endurance testing
- Final inspection and documentation
This ensures consistent quality and predictable performance.
Why Choose Jyoti Hydraulic?
- Deep hydraulic engineering expertise
- In-house design, manufacturing & testing
- Custom solutions for OEMs and EPCs
- Export-ready documentation and packing
- Strong technical support and after-sales service
- Proven industry track record
Frequently Asked Questions (FAQs)
What is the main advantage of DC hydraulic power packs?
They operate without AC power, ideal for mobile and remote applications.
How do I select the right voltage?
Selection depends on load, duty cycle, and available battery system.
Can these power packs handle heavy loads?
Yes, when properly engineered for pressure and flow requirements.
Are DC power packs energy efficient?
Yes, especially 24V, 48V, and 60V systems.
Do you provide customized designs?
Yes, fully customized voltage, circuit, and performance designs.
What maintenance is required?
Regular oil checks, filter replacement, and electrical inspection.
Are these suitable for export markets?
Yes, designed as per global standards.
