1 Characteristics and market analysis of battery forklifts Battery forklifts have the advantages of high energy conversion efficiency, low noise, no exhaust emission, convenient control, etc., which require high environmental conditions in workshops, warehouses, food, pharmaceuticals, microelectronics and instrumentation. The occasion has been widely used and become the tool of choice for indoor material handling.
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With people's deep understanding of the dangers of environmental pollution, environmental protection has become the focus of common concern in the world. Therefore, battery forklifts with low noise and no exhaust emissions will become the mainstream of the market. In addition, the establishment of automated warehousing systems and large supermarkets has also stimulated the demand for indoor material handling machinery, battery forklifts. At present, the output of battery forklifts in the world has accounted for more than 40% of the total output of forklifts. In developed countries such as Europe and the United States, the proportion of battery forklifts has reached 60%; in China, the proportion of battery forklifts is about 20%. The battery forklift has now broken through the limitations that could only be used for small tonnage operations, and gradually moved from indoor to outdoor, and market demand has increased year by year.
2 Development trend of battery forklift technology 2.1 Drive motor and electronic control from DC to AC development AC power control can improve productivity, accelerate faster, increase vehicle speed and gantry lifting speed, and output torque at high speed . The energy consumption is small under the same working conditions, which can prolong the use time of the battery pack in a single shift. In addition, the AC motor has no brushes and commutators, and does not require regular maintenance, which reduces the operating cost of the entire AC control system. Linde, Jungheinrich, Hyster, Toyota and other well-known forklift companies have introduced AC battery forklift products.
2.2 The whole vehicle communication develops in the direction of network. The CAN (Control Area Network) network is used for communication between the control modules of the battery forklift. All the electronic functional components become a whole virtual unit, which can exchange control information in real time and realize synchronous control. With the connection of two high-speed communication buses, each individual function is very convenient to access information from other functional components.
The CAN bus is a serial data communication protocol developed to solve the data exchange between many control and test instruments in modern automobiles. The communication medium can be twisted pair, coaxial cable or optical fiber, and the communication speed can reach 1Mbit/ s. The most important feature is to abolish the traditional station address coding and instead encode the communication data block. The CAN protocol uses CRC checking and provides corresponding error handling functions to ensure the reliability of data communication.
Applying CAN to the battery forklift control system, the reliability and communication speed of data communication are improved, the cost of the control system is reduced, and the control level of the battery forklift is greatly improved. Both Linde and Anhui Forklift Group have successfully applied CAN bus technology to battery forklifts.
2.3 Steering system moves toward electronics Traditional battery forklift steering systems use mechanical steering or hydraulic power steering. The disadvantage of mechanical steering is that the steering force is large and the operator is prone to fatigue; and the disadvantage of hydraulic power steering is wasting energy. The use of electronic steering not only has a small operating force, but also saves about 25% more energy than hydraulic power steering. At present, there are two main types of electronic power steering systems: one is position feedback electronic power steering system, the products of Jungheinrich Company and Anhui Forklift Group Company adopt this electronic power steering system; the other is torque feedback electronic power steering system. Linde and TCM's products use this electronic power steering system.
2.4 The development of the control system to the integration direction With the increasing requirements of operators for the comfort of operation, integrated operation has become a development trend. The so-called integrated operation is to use the joystick to complete all control actions of the battery forklift: forklift forward/reverse, gantry forward/reverse, gantry ascending/descending, fork forward/rear, fork left shift/right Side shift. In this way, the labor intensity of the operator can be reduced, thereby improving labor efficiency.
At present, the products of Jungheinrich and Anhui Forklift Group have adopted this comfortable and convenient integrated control system.
2.5 Development of the brake system to the electronic direction In order to reduce the brake shock and enhance the applicability, the braking torque of the transmission system is required to be adjusted, thereby promoting the development of the adjustable torque electromagnetic brake. The adjustable torque brake consists of a spring-applied brake and an electronic control unit, the torque controller. This electromechanical brake system can also be used to adjust the brake torque. The wear and tear are monitored to improve the reliability of the system and reduce the operation and maintenance costs. In addition, the adjustable torque brake can also be equipped with a CAN bus interface for remote diagnosis and control of the brakes and networked operation of the brake control.
2.6 Application of Hydraulic Pump Motor Controller The hydraulic pump motor controller can control the motor to realize the stepless speed regulation of the gantry lifting/forward/reverse movement, etc., and can also set the motor speed to control the fork tilt/side shift speed. The hydraulic pump motor controller can save 25% energy, extend the battery pack single shift time, and reduce the heat generated by the hydraulic system. The battery forklifts of Linde, Jungheinrich, TCM, Anhui Forklift Group, etc. all use hydraulic pump motor controllers.
2.7 The decline of the gantry adopts the load potential energy recovery technology. The gantry is reduced. The load potential energy recovery technology can realize the stepless speed regulation of the gantry drop and save 5% of energy. The principle of load potential energy recovery is: when the gantry is lowered, the hydraulic pump becomes a hydraulic motor, and the electric motor becomes a generator, which converts the potential energy of the load into electric energy to charge the battery to save energy.
3 Conclusion The needs of users have promoted the development of battery forklifts, saving energy, improving reliability, reducing the use and maintenance costs, and improving the comfort of operation have become the development direction of battery forklifts.