Electric control hardware redundancy system of forklift

Abstract

The invention discloses a forklift electronic control hardware redundancy system, and relates to the field of forklift control. Comprising a main control module which processes a driving instruction and sensor data in real time, generates an execution mechanism control signal and synchronizes parameters to a standby module through a high-speed bus; the standby control module realizes non-inductive control right takeover through a dynamic thermal synchronization method when the main system fails; the multi-channel fault detection module is used for carrying out fault detection on system operation through the sensor module, and the arbitration switching module is used for carrying out control switching after the multi-channel fault detection module detects a system fault. The failure state of the main control channel is accurately judged on the basis of parameters calculated in real time, the control right is switched to the standby module in an undisturbed mode through the arbitration switching module, the fatal defect that a traditional system is shut down when a fault occurs is broken through, a forklift is kept in a continuous controllable state under sudden faults such as controller short circuit and signal distortion, and the system reliability is improved. And the systematic collapse risk of a single channel architecture is fundamentally eliminated.

Description

Technical Field

[0001] This invention relates to the field of forklift control, and more particularly to a forklift electronic control hardware redundancy system. Background Technology

[0002] With the development of industrial control technology, the operational reliability of automated equipment has become a core competitive advantage. In forklift electronic control systems, the single-channel control architecture remains the mainstream technical solution. This architecture relies on a single control path to complete core functions such as sensor data acquisition, logic operations, and execution drive. Its operating mechanism is as follows: the central controller processes operation commands in real time, which are then converted by the signal conditioning module to drive the actuator. All control flows and data flows are concentrated on the same physical channel.

[0003] However, this single-channel architecture has a fundamental flaw: the system lacks backup mechanisms and fault tolerance. Specifically: The system exhibits significant vulnerability to failure. When any node in Channel 1 (such as a sensor, processor, or communication line) experiences a hardware failure (e.g., short circuit, open circuit) or a software failure (e.g., program crash), the entire control link is interrupted. Since there is no parallel path to take over control, the system will immediately lose its ability to control critical functions such as vehicle steering and lifting.

[0004] The mandatory shutdown during maintenance cycles requires the entire machine to be stopped before any further operations can be carried out. In continuous logistics scenarios (such as cold chain warehousing and port freight), this "zero-tolerance" design directly leads to a loss of production efficiency.

[0005] Therefore, this invention proposes a forklift electronic control hardware redundancy system. Summary of the Invention

[0006] The purpose of this invention is to address the shortcomings of existing technologies by proposing a redundant forklift electronic control hardware system.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: A forklift electronic control hardware redundancy system, comprising: The main control module processes driving commands and sensor data in real time, generates control signals for actuators, and synchronizes parameters to the backup module via a high-speed bus. The backup control module achieves seamless takeover of control in the event of a failure of the main system through a dynamic hot synchronization method. A multi-channel fault detection module, which uses sensor modules to detect faults in system operation; The arbitration switching module switches control after the multi-channel fault detection module detects a system fault, and then uses the backup control module for control. The dual-circuit power supply module supplies power to both the main control module and the backup control module.

[0008] Preferably, the main control module includes: Multi-core processors execute the same instructions simultaneously on multiple cores, cross-check the calculation results every cycle, and initiate hardware self-reset when the error exceeds the limit. The signal conditioning circuit receives the sensor signal and samples it with high precision after common-mode rejection, thus eliminating motor brush noise interference. The PWM generator generates 12 channels of 0-10kHz PWM waves and has a built-in optocoupler isolation drive circuit. The PWM signal is output after optocoupler isolation. The CAN bus controller has a built-in TVS diode array and a transient voltage suppressor deployed at the CAN bus interface to clamp ESD surge voltage within a safe range.

[0009] Preferably, the hardware layer of the backup control module includes: The core FPGA layer employs a hardware parallel computing architecture and can process 16 control algorithms simultaneously. The data synchronization layer is a primary-backup data sharing layer, where data from the main control module is synchronized to the data synchronization layer in real time. The signal acquisition layer directly acquires raw sensor signals, forming an independent sampling channel with the main control module to eliminate the risk of common path failure. The clock reference layer has a built-in independent high-frequency clock source, ensuring that it is independent of the main control module's clock.

[0010] Preferably, the dynamic thermal synchronization method for the backup module includes the following steps: A1: Parameter dynamic mapping, the main control module transmits the core control parameters in real time through the high-speed SPI bus and writes them into the data synchronization layer inside the FPGA; A2: Control quantity pre-calculation. A parallel computing engine is deployed inside the FPGA to simultaneously acquire raw sensor data and calculate the theoretical control quantity in real time based on the latest parameters. The calculation results are temporarily stored in the output register but the output channel is physically isolated. A3: Status self-check. A self-diagnostic loop is executed every Δt time period. The test items include checking the integrity of the clock signal, verifying the RAM data check code, testing the function of the PWM generator, and updating the power LED and fault log when an abnormality occurs.

[0011] Preferably, the multi-channel fault detection module includes: Electrical layer diagnostics, which includes a voltage monitoring unit, a current monitoring unit, and a signal integrity monitoring unit; Data layer diagnostics, which includes a communication verification unit and a data rationality verification unit; Physical layer diagnostics, which includes a temperature monitoring unit, a humidity monitoring unit, a vibration monitoring unit, and a noise monitoring unit; The comprehensive diagnostic tool receives diagnostic data from the electrical layer, data layer, and physical layer, and outputs diagnostic results.

[0012] Preferably, the working logic of the multi-channel fault detection module is as follows: B1: Establish a backup startup model library. The model library contains multiple backup startup trigger conditions. Each trigger condition corresponds to the monitoring status of one or more monitoring units. The monitoring status is normal / abnormal. B2: Real-time monitoring of data from the electrical, data, and physical layers through multiple monitoring units, and determination of normal or abnormal monitoring status based on monitoring values; B3: Statistically monitor the normal or abnormal results of the monitoring unit and compare them with the model library. If a successful match is found in the model library, a backup is initiated.

[0013] Preferably, in step B2, the monitoring data of the monitoring unit is transmitted to the comprehensive diagnostic unit through dual channels, and the comprehensive diagnostic unit determines the final sensor output value based on the comparison of the data from the two channels.

[0014] Preferably: In step B2, the output value is S1 and S2 are the data from the two channels, S0 is the output data, and k1 and k2 are the weighting coefficients.

[0015] Preferably: in step B2, , , where e is the base of the natural logarithm. .

[0016] Preferably, the dual-circuit power supply module adopts a hybrid power supply architecture, specifically: The main control module is powered by the main channel, and the main power supply is a lithium battery pack; The backup control module is powered by a backup channel, and the main power supply is a supercapacitor array.

[0017] The beneficial effects of this invention are as follows: This invention accurately determines the failure status of the main control channel based on real-time calculated parameters, and seamlessly switches control to the backup module through an arbitration switching module. This overcomes the fatal flaw of the traditional system that "stops immediately upon failure," enabling the forklift to maintain a continuously controllable state under sudden failures such as controller short circuits and signal distortion, fundamentally eliminating the risk of systemic collapse in a single-channel architecture. Attached Figure Description

[0018] Figure 1 This is a logic diagram of a redundant hardware structure for a forklift electronic control system proposed in this invention. Detailed Implementation

[0019] The technical solution of the present invention will be further described in detail below with reference to specific embodiments.

[0020] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "setting" should be interpreted broadly. For example, they can refer to a fixed connection or setting, a detachable connection or setting, or an integral connection or setting. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0021] Example 1: A forklift electronic control hardware redundancy system, comprising: The main control module processes driving commands and sensor data in real time, generates control signals for actuators, and synchronizes parameters to the backup module via a high-speed bus. The backup control module achieves seamless takeover of control in the event of a failure of the main system through a dynamic hot synchronization method. A multi-channel fault detection module, which uses sensor modules to detect faults in system operation; The arbitration switching module switches control after the multi-channel fault detection module detects a system fault, and then uses the backup control module for control. The dual-circuit power supply module supplies power to both the main control module and the backup control module.

[0022] The main control module includes: Multi-core processors execute the same instructions simultaneously on multiple cores, cross-check the calculation results every cycle, and initiate hardware self-reset when the error exceeds the limit. The signal conditioning circuit receives the sensor signal and samples it with high precision after common-mode rejection, thus eliminating motor brush noise interference. The PWM generator generates 12 channels of 0-10kHz PWM waves and has a built-in optocoupler isolation drive circuit. The PWM signal is output after optocoupler isolation, with an isolation withstand voltage of 5000Vrms, blocking the power circuit from impacting the control chip. The CAN bus controller has a built-in TVS diode array and a transient voltage suppressor deployed at the CAN bus interface to clamp ESD surge voltage within a safe range.

[0023] The hardware layer of the backup control module includes: The core FPGA layer employs a hardware parallel computing architecture and can process 16 control algorithms simultaneously. The data synchronization layer is a primary-backup data sharing layer, where data from the main control module is synchronized to the data synchronization layer in real time. The signal acquisition layer directly acquires raw sensor signals, forming an independent sampling channel with the main control module to eliminate the risk of common path failure. The clock reference layer has a built-in independent high-frequency clock source, ensuring that it is independent of the main control module's clock.

[0024] The multi-channel fault detection module includes: Electrical layer diagnostics, which includes a voltage monitoring unit, a current monitoring unit, and a signal integrity monitoring unit; Data layer diagnostics, which includes a communication verification unit and a data rationality verification unit; Physical layer diagnostics, which includes a temperature monitoring unit, a humidity monitoring unit, a vibration monitoring unit, and a noise monitoring unit; The comprehensive diagnostic tool receives diagnostic data from the electrical layer, data layer, and physical layer, and outputs diagnostic results.

[0025] The dual-circuit power module adopts a hybrid power supply architecture, specifically: The main control module is powered by the main channel, and the main power supply is a lithium battery pack; The backup control module is powered by a backup channel, and the main power supply is a supercapacitor array.

[0026] Example 2: A forklift electronic control hardware redundancy system, comprising: The main control module processes driving commands and sensor data in real time, generates control signals for actuators, and synchronizes parameters to the backup module via a high-speed bus. The backup control module achieves seamless takeover of control in the event of a failure of the main system through a dynamic hot synchronization method. A multi-channel fault detection module, which uses sensor modules to detect faults in system operation; The arbitration switching module switches control after the multi-channel fault detection module detects a system fault, and then uses the backup control module for control. The dual-circuit power supply module supplies power to both the main control module and the backup control module.

[0027] The main control module includes: Multi-core processors execute the same instructions simultaneously on multiple cores, cross-check the calculation results every cycle, and initiate hardware self-reset when the error exceeds the limit. The signal conditioning circuit receives the sensor signal and samples it with high precision after common-mode rejection, thus eliminating motor brush noise interference. The PWM generator generates 12 channels of 0-10kHz PWM waves and has a built-in optocoupler isolation drive circuit. The PWM signal is output after optocoupler isolation, with an isolation withstand voltage of 5000Vrms, blocking the power circuit from impacting the control chip. The CAN bus controller has a built-in TVS diode array and a transient voltage suppressor deployed at the CAN bus interface to clamp ESD surge voltage within a safe range.

[0028] The hardware layer of the backup control module includes: The core FPGA layer employs a hardware parallel computing architecture and can process 16 control algorithms simultaneously. The data synchronization layer is a primary-backup data sharing layer, where data from the main control module is synchronized to the data synchronization layer in real time. The signal acquisition layer directly acquires raw sensor signals, forming an independent sampling channel with the main control module to eliminate the risk of common path failure. The clock reference layer has a built-in independent high-frequency clock source, ensuring that it is independent of the main control module's clock.

[0029] The dynamic hot synchronization method for the backup module includes the following steps: A1: Parameter dynamic mapping, the main control module transmits the core control parameters (such as PID gain, speed curve coefficient) in real time through the high-speed SPI bus and writes them into the data synchronization layer inside the FPGA. A2: Control quantity pre-calculation. A parallel computing engine is deployed inside the FPGA to simultaneously acquire raw sensor data and calculate the theoretical control quantity in real time based on the latest parameters. The calculation results are temporarily stored in the output register but the output channel is physically isolated. A3: Status self-check. A self-diagnostic loop is executed every Δt time period. The test items include checking the integrity of the clock signal, verifying the RAM data check code, testing the function of the PWM generator, and updating the power LED and fault log when an abnormality occurs.

[0030] The multi-channel fault detection module includes: Electrical layer diagnostics, which includes a voltage monitoring unit, a current monitoring unit, and a signal integrity monitoring unit; Data layer diagnostics, which includes a communication verification unit and a data rationality verification unit; Physical layer diagnostics, which includes a temperature monitoring unit, a humidity monitoring unit, a vibration monitoring unit, and a noise monitoring unit; The comprehensive diagnostic tool receives diagnostic data from the electrical layer, data layer, and physical layer, and outputs diagnostic results.

[0031] The working logic of the multi-channel fault detection module is as follows: B1: Establish a backup startup model library. The model library contains multiple backup startup trigger conditions. Each trigger condition corresponds to the monitoring status of one or more monitoring units. The monitoring status is normal / abnormal. B2: Real-time monitoring of data from the electrical, data, and physical layers through multiple monitoring units, and determination of normal or abnormal monitoring status based on monitoring values; B3: Statistically monitor the normal or abnormal results of the monitoring unit and compare them with the model library. If a successful match is found in the model library, a backup is initiated.

[0032] The dual-circuit power module adopts a hybrid power supply architecture, specifically: The main control module is powered by the main channel, and the main power supply is a lithium battery pack; The backup control module is powered by a backup channel, and the main power supply is a supercapacitor array.

[0033] Example 3: A forklift electronic control hardware redundancy system, comprising: The main control module processes driving commands and sensor data in real time, generates control signals for actuators, and synchronizes parameters to the backup module via a high-speed bus. The backup control module achieves seamless takeover of control in the event of a failure of the main system through a dynamic hot synchronization method. A multi-channel fault detection module, which uses sensor modules to detect faults in system operation; The arbitration switching module switches control after the multi-channel fault detection module detects a system fault, and then uses the backup control module for control. The dual-circuit power supply module supplies power to both the main control module and the backup control module.

[0034] The main control module includes: Multi-core processors execute the same instructions simultaneously on multiple cores, cross-check the calculation results every cycle, and initiate hardware self-reset when the error exceeds the limit. The signal conditioning circuit receives the sensor signal and samples it with high precision after common-mode rejection, thus eliminating motor brush noise interference. The PWM generator generates 12 channels of 0-10kHz PWM waves and has a built-in optocoupler isolation drive circuit. The PWM signal is output after optocoupler isolation, with an isolation withstand voltage of 5000Vrms, blocking the power circuit from impacting the control chip. The CAN bus controller has a built-in TVS diode array and a transient voltage suppressor deployed at the CAN bus interface to clamp ESD surge voltage within a safe range.

[0035] The hardware layer of the backup control module includes: The core FPGA layer employs a hardware parallel computing architecture and can process 16 control algorithms simultaneously. The data synchronization layer is a primary-backup data sharing layer, where data from the main control module is synchronized to the data synchronization layer in real time. The signal acquisition layer directly acquires raw sensor signals, forming an independent sampling channel with the main control module to eliminate the risk of common path failure. The clock reference layer has a built-in independent high-frequency clock source, ensuring that it is independent of the main control module's clock.

[0036] The dynamic hot synchronization method for the backup module includes the following steps: A1: Parameter dynamic mapping, the main control module transmits the core control parameters (such as PID gain, speed curve coefficient) in real time through the high-speed SPI bus and writes them into the data synchronization layer inside the FPGA. A2: Control quantity pre-calculation. A parallel computing engine is deployed inside the FPGA to simultaneously acquire raw sensor data and calculate the theoretical control quantity in real time based on the latest parameters. The calculation results are temporarily stored in the output register but the output channel is physically isolated. A3: Status self-check. A self-diagnostic loop is executed every Δt time period. The test items include checking the integrity of the clock signal, verifying the RAM data check code, testing the function of the PWM generator, and updating the power LED and fault log when an abnormality occurs.

[0037] The multi-channel fault detection module includes: Electrical layer diagnostics, which includes a voltage monitoring unit, a current monitoring unit, and a signal integrity monitoring unit; Data layer diagnostics, which includes a communication verification unit and a data rationality verification unit; Physical layer diagnostics, which includes a temperature monitoring unit, a humidity monitoring unit, a vibration monitoring unit, and a noise monitoring unit; The comprehensive diagnostic tool receives diagnostic data from the electrical layer, data layer, and physical layer, and outputs diagnostic results.

[0038] The working logic of the multi-channel fault detection module is as follows: B1: Establish a backup startup model library. The model library contains multiple backup startup trigger conditions. Each trigger condition corresponds to the monitoring status of one or more monitoring units. The monitoring status is normal / abnormal. B2: Real-time monitoring of data from the electrical, data, and physical layers through multiple monitoring units, and determination of normal or abnormal monitoring status based on monitoring values; B3: Statistically monitor the normal or abnormal results of the monitoring unit and compare them with the model library. If a successful match is found in the model library, a backup is initiated.

[0039] In step B2, the monitoring data from the monitoring unit is transmitted to the integrated diagnostic unit through dual channels. The integrated diagnostic unit determines the final sensor output value based on the comparison of the data from the two channels.

[0040] In step B2, the output value is S1 and S2 are the data from the two channels, S0 is the output data, and k1 and k2 are the weighting coefficients.

[0041] In step B2 , , where e is the base of the natural logarithm. .

[0042] The dual-circuit power module adopts a hybrid power supply architecture, specifically: The main control module is powered by the main channel, and the main power supply is a lithium battery pack; The backup control module is powered by a backup channel, and the main power supply is a supercapacitor array.

[0043] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A forklift electronic control hardware redundancy system, characterized in that, include: The main control module processes driving commands and sensor data in real time, generates control signals for actuators, and synchronizes parameters to the backup module via a high-speed bus. The backup control module achieves seamless takeover of control in the event of a failure of the main system through a dynamic hot synchronization method. A multi-channel fault detection module, which uses sensor modules to detect faults in system operation; The arbitration switching module switches control after the multi-channel fault detection module detects a system fault, and then uses the backup control module for control. The dual-circuit power supply module supplies power to both the main control module and the backup control module.

2. The forklift electronic control hardware redundancy system according to claim 1, characterized in that, The main control module includes: Multi-core processors execute the same instructions simultaneously on multiple cores, cross-check the calculation results every cycle, and initiate hardware self-reset when the error exceeds the limit. The signal conditioning circuit receives the sensor signal and samples it with high precision after common-mode rejection, thus eliminating motor brush noise interference. The PWM generator generates 12 channels of 0-10kHz PWM waves and has a built-in optocoupler isolation drive circuit. The PWM signal is output after optocoupler isolation. The CAN bus controller has a built-in TVS diode array and a transient voltage suppressor deployed at the CAN bus interface to clamp ESD surge voltage within a safe range.

3. The forklift electronic control hardware redundancy system according to claim 1, characterized in that, The hardware layer of the backup control module includes: The core FPGA layer employs a hardware parallel computing architecture and can process 16 control algorithms simultaneously. The data synchronization layer is a primary-backup data sharing layer, where data from the main control module is synchronized to the data synchronization layer in real time. The signal acquisition layer directly acquires raw sensor signals, forming an independent sampling channel with the main control module to eliminate the risk of common path failure. The clock reference layer has a built-in independent high-frequency clock source, ensuring that it is independent of the main control module's clock.

4. A forklift electronic control hardware redundancy system according to claim 3, characterized in that, The dynamic hot synchronization method for the backup module includes the following steps: A1: Parameter dynamic mapping, the main control module transmits the core control parameters in real time through the high-speed SPI bus and writes them into the data synchronization layer inside the FPGA; A2: Control quantity pre-calculation. A parallel computing engine is deployed inside the FPGA to simultaneously acquire raw sensor data and calculate the theoretical control quantity in real time based on the latest parameters. The calculation results are temporarily stored in the output register but the output channel is physically isolated. A3: Status self-check. A self-diagnostic loop is executed every Δt time period. The test items include checking the integrity of the clock signal, verifying the RAM data check code, testing the function of the PWM generator, and updating the power LED and fault log when an abnormality occurs.

5. A forklift electronic control hardware redundancy system according to claim 1, characterized in that, The multi-channel fault detection module includes: Electrical layer diagnostics, which includes a voltage monitoring unit, a current monitoring unit, and a signal integrity monitoring unit; Data layer diagnostics, which includes a communication verification unit and a data rationality verification unit; Physical layer diagnostics, which includes a temperature monitoring unit, a humidity monitoring unit, a vibration monitoring unit, and a noise monitoring unit; The comprehensive diagnostic tool receives diagnostic data from the electrical layer, data layer, and physical layer, and outputs diagnostic results.

6. A forklift electronic control hardware redundancy system according to claim 5, characterized in that, The working logic of the multi-channel fault detection module is as follows: B1: Establish a backup startup model library. The model library contains multiple backup startup trigger conditions. Each trigger condition corresponds to the monitoring status of one or more monitoring units. The monitoring status is normal / abnormal. B2: Real-time monitoring of data from the electrical, data, and physical layers through multiple monitoring units, and determination of normal or abnormal monitoring status based on monitoring values; B3: Statistically monitor the normal or abnormal results of the monitoring unit and compare them with the model library. If a successful match is found in the model library, a backup is initiated.

7. A forklift electronic control hardware redundancy system according to claim 6, characterized in that, In step B2, the monitoring data from the monitoring unit is transmitted to the integrated diagnostic unit through dual channels. The integrated diagnostic unit determines the final sensor output value based on the comparison of the data from the two channels.

8. A forklift electronic control hardware redundancy system according to claim 7, characterized in that, In step B2, the output value is S1 and S2 are the data from the two channels, S0 is the output data, and k1 and k2 are the weighting coefficients.

9. A forklift electronic control hardware redundancy system according to claim 8, characterized in that, In step B2 , , where e is the base of the natural logarithm. .

10. A forklift electronic control hardware redundancy system according to claim 1, characterized in that, The dual-circuit power module adopts a hybrid power supply architecture, specifically: The main control module is powered by the main channel, and the main power supply is a lithium battery pack; The backup control module is powered by a backup channel, and the main power supply is a supercapacitor array.

Images