Industry solution: forestry
Lithium batteries for forestry & cable cranes – when standard batteries fail on steep slopes.
Custom lithium batteries for cable crane systems – vibration-proof, regen-capable and engineered for the toughest use in alpine terrain.
Request a free initial assessmentThe challenge
Extreme vibration
Cable operation creates constant mechanical stress – cables work loose and components break.
Thermal stress
Regenerative currents above 100 A cause thermal problems in standard batteries.
No access
Steep slopes without forest roads make recharging on site impossible.
Our solution
Developed together with MM Forsttechnik – for real-world use on cable crane systems in alpine terrain.
Rugged steel enclosure
Mechanical fixing protects the battery, cables and components against vibration on the cableway.
Damped mounting
Dedicated damping ensures stability even under continuous cable movement.
Regen-capable BMS
A purpose-tuned battery management system handles high charge currents safely.
PLC-compatible
Control functions integrated directly into the battery, compatible with modern PLC technology.
Customer story
MM Forsttechnik
With around 30,000 hectares of forest, the Mayr-Melnhof Group is the largest private forest owner in Austria – its engineering division MM Forsttechnik has been developing cable crane systems with its own carriage system for alpine terrain for over 20 years.
Standard batteries failed regularly in daily cable crane operation: vibration worked cables loose, and regenerative currents above 100 A caused thermal overloads.
From 2024, Hellpower Energy developed a purpose-tuned battery solution in close collaboration with MM Forsttechnik: a rugged steel enclosure with damped mounting, a BMS for high regenerative currents and direct PLC compatibility.
Confirmed in real-world use under extreme conditions: zero vibration issues, zero thermal failures – since series introduction in 2024.
Requirement · Solution · Result
Requirement: Battery supply for cable crane carriages on alpine steep slopes – continuous vibration from cable operation, regenerative currents above 100 A when lowering loads, no vehicle access for recharging in the field.
Solution: Custom lithium battery pack in a steel enclosure with vibration damping, purpose-tuned BMS for high regenerative currents, direct PLC compatibility – developed in close collaboration with MM Forsttechnik from 2024.
Result: Zero vibration issues, zero thermal failures – confirmed in field use under extreme conditions. Joint development of fully field-rechargeable battery solutions is ongoing.
Hellpower understood what others failed to hear. Our work in extreme terrain takes more than off-the-shelf technology – it takes partners who think along with you. The battery solution doesn't just work – it delivers exactly what it promises.
Mechanical Engineering Project Manager, MM Forsttechnik
Your benefits
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Vibration-proof
> 100 A
Regenerative currents
BMS
Thermal protection
Frequently asked questions
- Why do standard batteries fail on cable crane systems in forestry?
- Cable crane systems generate continuous vibration through cable operation, which mechanically destroys cable connections and cell brackets in standard batteries. Added to this are regenerative currents above 100 A when lowering loads, which trip the charge protection of off-the-shelf BMS units or cause thermal overloads. Hellpower addresses both failure modes through a purpose-engineered enclosure and a purpose-tuned BMS.
- What does regeneration mean on a cable crane and why is it relevant to the battery?
- When lowering loads on a cable crane, the drive motor acts as a generator – returning electrical energy. This regenerative energy flows as a charge current into the battery. In alpine forestry operation, currents above 100 A can occur. A standard BMS blocks the charge path at such currents; a BMS designed for regeneration safely routes this energy into the cells.
- What IP rating does a battery need for outdoor use in forestry?
- For continuous outdoor use in forestry, at least IP54 (protection against spray water and dust) is recommended, and IP65 or higher in particularly exposed locations. At the same time the enclosure must be mechanically robust against impacts and vibration – a high IP rating alone is not sufficient. Hellpower combines both: a sealed steel enclosure with vibration damping.
- Can the battery be connected directly to the cable crane control system?
- Yes. The battery packs developed by Hellpower for MM Forsttechnik are PLC-compatible – control functions are integrated directly into the battery system. This allows operating states, state of charge and protection functions to be integrated into the higher-level cable crane control system without external interface hardware.
- Is it possible to swap the battery in the field (without a workshop)?
- Hellpower develops swap concepts tailored to each system. In forestry operations where the cable crane often stands in difficult terrain, clear connectors and tool-free quick-release fittings are important. The swap concept is defined during engineering – not after the first breakdown.
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Updated
Ready for a battery that never fails on the steep slope?
As proven with MM Forsttechnik: we develop custom lithium batteries for cable crane systems – vibration-proof, regen-capable and unique to your application.
Request a free initial assessmentOr call us directly: +43 2265 20775 0