Project Info
Project Name: Tailgate Hydraulic Power Unit & Hydraulic Cylinders
Client Industry: Special Vehicle
Requirement：
- Reliable lift/lower performance under frequent duty cycles
- Stable load holding without platform drift
- Compact installation with low maintenance requirements
- Compatibility with 12V/24V vehicle electrical systems
AiSoar Solution:
AiSoar provided a complete tailgate hydraulic solution, including:
Tailgate Hydraulic Power Unit (HPU)
- Optimized motor-pump matching for required lifting force and speed
- Integrated valve block for pressure relief, load holding, and controlled lowering
- 12V/24V DC options for different vehicle platforms
- Compact design with stable output and low noise operation
Tailgate Hydraulic Cylinders
- High-strength cylinder tube and rod for high-cycle durability
- Enhanced sealing system to reduce internal/external leakage
- Customized stroke, mounting type, and bore size based on tailgate mechanism
- Optional cushioning design for smoother end-of-stroke movement
Project Overview
To meet increasing demand for safer, smoother, and more efficient cargo handling, this solution provides a complete electro-hydraulic architecture for vehicle tailgate actuation.
The system combines a compact DC hydraulic power unit with a high-reliability hydraulic cylinder to deliver:
- Stable lifting force
- Controlled lowering speed
- Reliable load holding under commercial operating conditions
This integrated solution is suitable for light- and medium-duty trucks, logistics vehicles, and special-purpose transport platforms where uptime, safety, and repeatable performance are critical.
Vehicle Tailgate Challenges
Vehicle tailgate systems typically face the following issues:
- High and variable loads during lifting/lowering
- Sudden impact at start/stop positions
- Tailgate drifting or dropping due to leakage or valve instability
- Limited installation space on vehicle chassis
- Exposure to harsh environments (dust, rain, vibration, temperature changes)
- Need for emergency operation in case of electrical failure
- The proposed hydraulic architecture is designed to directly address these challenges.
Hydraulic Solution For Vehicle Tailgate
Integrated Tail Lift Hydraulic Power Unit Solution
Our tail lift hydraulic power unit (HPU) solution is designed as a compact electro-hydraulic assembly for commercial vehicles and logistics fleets. Each unit integrates a DC motor, gear pump, manifold block, directional solenoid valves, relief valve for overload protection, check valve for load holding, and reservoir with breather and oil level management. When lifting is activated, the motor-driven pump delivers stable pressure flow to the hydraulic cylinder; during lowering, the solenoid valve opens a controlled return path for smooth and safe descent. This highly integrated architecture reduces hose routing complexity and potential leak points, while improving pressure consistency and repeatable lift performance. With modular valve block options, our tail lift HPU can be configured for different platform mechanisms, control logic, and 12V/24V vehicle power systems.
| Model | Volt | Power | Speed | Displacement | Pressure | Tank | Solenoid Valve Volt |
| HPU-2-D24-2.5-16-HS/12-Y9-G1/4 | 24VDC | 2kW | 2000RPM | 2.5CC/REV | 16MPa | 12L | – |
| HPU-1.6-D12-1.6-20-HS/4-Y7-G1/4 | 12VDC | 1.6kW | 2500RPM | 1.6CC/REV | 20MPa | 4L | 12/24V |
Tail Lift Hydraulic Cylinder Engineering Solution
We provide application-matched tail lift hydraulic cylinders engineered around real operating requirements: lifting load, stroke, linkage geometry, duty cycle, and installation space. Typical cylinder features include a high-strength honed tube, precision piston assembly, and hard chrome plated rod for wear and corrosion resistance in outdoor environments. By optimizing bore-to-rod ratio, the cylinder delivers reliable output force while maintaining structural stability under dynamic loads. Optional end-of-stroke cushioning helps reduce impact and extends service life. We also offer customizable mounting types—clevis, trunnion, flange, and spherical bearing—and single-acting or double-acting configurations to match different tail lift control strategies. Combined with our HPU platform, this solution improves lifting smoothness, safety, uptime, and total lifecycle efficiency for truck tail lift systems.
Typical cylinder features include:
- High-strength honed tube
- Precision piston assembly
- Hard chrome-plated rod for wear and corrosion resistance
- Optimized bore-to-rod ratio for force output and structural stability
- Optional end-of-stroke cushioning for lower impact and longer service life
- Available mounting options include clevis, trunnion, flange, and spherical bearing types.
Projected Results / Customer Value
By adopting AiSoar’s integrated hydraulic power unit and cylinder solution, customers can achieve more stable lifting and lowering performance under rated loads, improved load-holding safety with minimized tailgate drift, and lower leakage risk with reduced maintenance frequency. The system also delivers smoother operation to protect both cargo and mechanical components, while shortening installation and commissioning time through optimized system matching. Overall, this solution helps fleet and vehicle operators improve reliability, increase uptime, and reduce total lifecycle costs.
