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48V / 60V / 72V platforms compared · 3000W at the axleAt 3000W: 16S 58.6A / 24S 39.1ABus current −33.3%Harness copper loss −55.6%Efficiency 89.4%

48V, 60V or 72V?the voltage decision for two- and three-wheelers, answered

The short answer: fix the voltage from motor rating, daily distance and everyday payload, not from “higher is better”. On one dynamometer channel at an equal 3000W at the axle, the 16S platform (48V and 60V share one pack) carries about 58.6A and the 24S platform (72V) about 39.1A. Going from 48V to 72V cuts continuous bus current 33.3%, harness copper loss 55.6% and lifts system drive efficiency to 89.4%. The cost is just as real: a 72V pack reaches 87.6V at full charge, so the controller MOSFETs must be rated 100V–120V automotive, the bay has to take a 24S pack, and the charger must be replaced. For light, short-route duty, staying at 48V or 60V is cheaper and lighter.

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16S platform bus currentabout 58.6A
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24S platform bus currentabout 39.1A
speed
72V drive efficiency89.4%
request_quoteGet a voltage selection and quotationtable_chartSee the full 48V / 60V / 72V matrix

verifiedBench figures come from one dynamometer channel at the same 3000W rated load and can be independently re-checked; your vehicle parameters and the signed specification sheet govern the final build.

Test bench for 48V, 60V and 72V powertrain comparison
show_chartBench delta at equal 3000W

What the three platforms actually compare

electric_bolt58.6A → 39.1AContinuous bus current (16S → 24S)Same 3000W axle load per platform
trending_down−33.3%Bus current reductionThe direct result of raising voltage
local_fire_department−55.6%Harness copper lossVerified against P = I²R
speed89.4%System drive efficiencyA +5.2% system-level gain

Specification notice:The figures above are engineering reference values. They may differ with production batch, configuration and actual duty cycle, and the percentages for life, efficiency, availability and coverage are engineering estimates and bench references. Contact us for the detailed specification sheet.

account_treeVoltage decision table

The decision table: motor power × daily distance × payload

Read the motor rating first, confirm with daily distance and payload, then close out on controller rating and harness cross-section. Bus current is calculated at an equal 3000W at the axle.

Typical platform figures · 3000W at the axle
Motor ratingEveryday payloadTypical daily distanceRecommended platformBus current at 3000WEconomical cruise speedController MOSFET ratingRecommended main harness
800W – 1500WOne rider · cargo ≤ 30kg40 – 70 km48V (16S LiFePO4 · 51.2V / 58.4V full charge)About 58.6A (16S platform baseline)25 – 35 km/h≥ 75V≥ 16 – 25 mm²
1500W – 2500WRider plus delivery box · ≤ 100kg70 – 120 km60V (16S LiFePO4 · 51.2V / 58.4V full charge)40 – 50 km/h≥ 75V≥ 10 – 16 mm²
2500W – 5000W+Two-up / mountain grades · ≥ 150kg90 – 160 km72V (24S LiFePO4 · 76.8V / 87.6V full charge)About 39.1A (33.3% lower than the 16S platform)55 – 75 km/h+Must be ≥ 100V – 120V automotive≥ 6 – 10 mm²

The gain from 48V to 72V follows from Joule heating itself, not from control-strategy tuning. MOSFET rating must cover the full-charge voltage plus the back-EMF peak: a 72V system reaches 87.6V at full charge and 98.4V transient Vpeak during downhill regeneration, so 100V-rated MOSFETs are required. Check the motor back-EMF constant (Ke) and the stator enamel temperature class before raising voltage. The full process is in the working voltage selection guide.

Specification notice:The figures above are engineering reference values. They may differ with production batch, configuration and actual duty cycle, and the percentages for life, efficiency, availability and coverage are engineering estimates and bench references. Contact us for the detailed specification sheet.

Battery pack under test in an environmental test chamber
warningThe cost of raising voltage

Raising voltage is not free performance: three things change together

Fitting a 72V pack to a 48V vehicle buys lower current at the expense of the vehicle electrical system. Controller, battery bay and charger must all be settled before a quotation is issued — miss any one of them and it becomes rework.

  • Controller MOSFET rating: a 72V system reaches 87.6V at full charge with a 98.4V transient Vpeak during downhill regeneration, so the controller must be rated 100V – 120V automotive; the 75V MOSFETs of a 48V platform carry a breakdown risk.
  • Battery bay volume: a 24S pack differs from 16S in string count and outline, so length and height must be re-checked even at equal capacity. If the bay will not take it, the options are modifying the bay, dropping a capacity step, or splitting the pack.
  • Charger: a CC-CV lithium charger matched to the new string count is mandatory (24S for 72V). A lead-acid constant-voltage unit must never be reused, and 16S / 24S chargers are not interchangeable.
  • Insulation and the low-voltage circuit: 72V crosses into the high-voltage zone, so reinforced insulation and a matching DC-DC step-down module are required or lights, horn and instrument cluster will fail first.
memory≥ 100V – 120V72V controller rating
battery_charging_full24S CC-CV only72V charger
fact_checkWhen not to raise voltage: four cases to rule out first
  • Within 40 – 70km a day, one rider, cargo under 30kg: 48V is already enough, and raising voltage only adds cost and more than ten kilos of pack.
  • Routine delivery or passenger duty at 70 – 120km a day: 60V is already the widest-coverage step and the gain from 72V rarely covers the controller work.
  • The bay will not take a 24S pack and has no reinforcement position: modifying the bay usually costs more than fitting a larger pack at the same voltage.
  • An older vehicle whose controller and cluster were never rated for the higher platform and cannot be replaced or reflashed: solve the electronics before the voltage.
helpVoltage choice FAQ

The five questions we are asked most about 48V / 60V / 72V

At the same 3000W output, how much does 72V actually save over 48V?expand_more
On one dynamometer channel at the same 3000W at the axle: the 16S platform carries about 58.6A against about 39.1A on 24S, a 33.3% reduction; harness copper loss falls 55.6% (P = I²R); and system drive efficiency reaches 89.4%, a gain of 5.2 percentage points. The current you save turns into lower cable temperature and a thinner harness — not into free acceleration.
My vehicle is 48V — can I just fit a 72V pack?expand_more
No. Raising voltage requires three things at once: controller MOSFETs rated ≥ 100V – 120V and able to cover the 87.6V full-charge voltage plus the 98.4V transient peak, an instrument cluster and DC-DC rated for the new input range, and a bay that accepts a 24S pack. Only then is the upgrade worth it; otherwise check the motor back-EMF constant (Ke) and the enamel temperature class first, because reversing that order causes batch rework.
Do the controller and charger have to change when the voltage goes up?expand_more
The charger must change — a CC-CV lithium charger matched to the new string count is mandatory, because a lead-acid constant-voltage unit has no CC-CV knee and no BMS handshake and will drive the pack straight into protection. Most controllers can stay, provided the current limit matches the motor and the MOSFET rating covers the new full-charge voltage; in practice a voltage change usually means replacing or at least re-verifying the controller.
Who is 60V actually for?expand_more
60V covers motors of 1500W – 2500W at 70 – 120km a day with a delivery box or passengers — the widest-coverage step for delivery and swap two-wheelers and passenger tricycles. Economical cruise is 40 – 50km/h, the controller only needs 85V – 100V MOSFETs, and the harness runs ≥ 10 – 16mm². It avoids the high-current heating of 48V while saving the high-voltage capacitor and MOSFET premium that 72V carries.
Does a higher voltage automatically mean more torque and more range?expand_more
Neither follows directly. Climbing ability comes from the power and current limit the controller and motor can deliver, and range comes from total energy (kWh) — 48V 100Ah and 72V 66.7Ah are both about 5.12kWh, with identical energy and theoretical mass. The value of 72V is that at equal power it draws less current, generates less heat and allows a thinner harness, which is what supports a higher cruise speed. It is not a capacity multiplier.
library_booksRelated pages

Once the voltage is fixed, check these three pages

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72V LiFePO4 battery packs

24S at 76.8V nominal, 40 – 200Ah matrix for heavy and high-speed duty, with MOSFET and bay checks.

See the 72V platformarrow_forward
battery_full

60V LiFePO4 battery packs

16S, 58.4V full charge, 50 – 140Ah matrix — the widest-coverage step for delivery, swap and passenger duty.

See the 60V platformarrow_forward
account_tree

Working voltage selection guide

Engineering basis, the three voltage-upgrade mistakes, the four-step decision tree and back-EMF matching.

Open the selection guidearrow_forward
Browse all specificationsarrow_forward
request_quoteVoltage matching enquiry

Send your vehicle parameters and get a voltage conclusion with pricing

Give us the destination port, motor rating, daily distance and everyday payload. We will recommend the voltage platform and capacity step, then return FOB / CIF pricing, container allocation and the shipping document list.

  • Voltage selection advice and pricing within 24 hours on working days
  • Engineering sample packs available to prove climbing and range before a container order
  • Vehicle parameters and market-access documents are strictly confidential; NDA available first
mailExport desk: sales@erickshawtrikebattery.com
callDirect / WhatsApp: +86 13922702227
location_onEBattery Office, Room 310I, Huilange BLDG, No. 273, Huangpu Blvd W, Tianhe District, Guangzhou 510620, Guangdong, China
scheduleReply within 24 hours on working daysscienceSelected on payload and distance, not on the highest voltageverified_userUN38.3 / MSDS / dangerous-goods packing certificate with every container

Specification notice:The figures above are engineering reference values. They may differ with production batch, configuration and actual duty cycle, and the percentages for life, efficiency, availability and coverage are engineering estimates and bench references. Contact us for the detailed specification sheet.