A condition monitoring device and method for a forklift battery management system

Abstract

This invention discloses a status monitoring device and method for a forklift battery management system. The device includes a mounting plate located at the lower end of the vehicle fuse box. A current sensor detects current data in the cables, enabling continuous circuit monitoring and ensuring functional integrity. The current sensor, along with indicator lights, facilitates short-circuit location and timely repair, reducing maintenance time and enhancing the device's practicality and ease of maintenance. A rotating rod allows for quick fuse replacement, improving efficiency and eliminating the need for personnel to search for new fuses, thus shortening maintenance time and enabling faster deployment of electric forklifts in production. A drive motor rotates the rod, ensuring functional integrity and further simplifying maintenance, ultimately achieving automatic fuse replacement.

Description

Technical Field

[0001] This invention relates to the field of forklift battery testing devices, specifically a status monitoring device and monitoring method for a forklift battery management system. Background Technology

[0002] Forklifts are industrial material handling vehicles, referring to various wheeled handling vehicles used for loading, unloading, stacking, and short-distance transportation of palletized goods. With the rise of new energy vehicles, battery-powered forklifts have emerged on the market. Currently, electric forklifts operate entirely through batteries, and their efficiency is controlled by the batteries.

[0003] However, when a short circuit occurs in an existing electric forklift, the on-board fuse at the top of the battery will blow, causing the entire electric forklift to lose power. When replacing the on-board fuse, the operator needs to locate the short circuit, which is extremely inconvenient and affects the rapid use of the electric forklift. Therefore, this does not meet the current requirements. To address this, we propose a condition monitoring device and monitoring method for a forklift battery management system. Summary of the Invention

[0004] The purpose of this invention is to provide a status monitoring device and monitoring method for a forklift battery management system, in order to solve the problem mentioned in the background art that when a short circuit occurs in an electric forklift, the on-board fuse at the top of the electric forklift battery will blow, causing the entire electric forklift to be in a power-off state. When the operator replaces the on-board fuse, it is extremely inconvenient to locate the short circuit, which affects the rapid use of the electric forklift.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a status monitoring device for a forklift battery management system, including an on-board fuse box;

[0006] A mounting plate is installed at the lower end of the vehicle fuse box. The vehicle fuse box is fixedly connected to the mounting plate. Current sensors are installed at both ends of the upper surface of the mounting plate, and the current sensors are fixedly connected to the mounting plate. An upper bracket is installed at the upper end of the vehicle fuse box, and the upper bracket is fixedly connected to the vehicle fuse box. A rotating rod is installed inside the upper bracket. A mounting slider is installed at both ends of the rotating rod, and the mounting slider is rotatably connected to the rotating rod. A connecting spring is installed at both ends of the mounting slider, and the connecting spring is fixedly connected to both the mounting slider and the upper bracket. The mounting slider and the upper bracket are slidably connected up and down through a slot. Vehicle fuses are installed at both ends of the rotating rod, and the vehicle fuses are connected to the rotating rod by screws.

[0007] An electric telescopic rod is installed on both sides of the upper support. The electric telescopic rod is fixedly connected to the upper support. A control bracket is installed at the lower end of the upper support. A drive motor is installed inside the control bracket. The drive motor is fixedly connected to the mounting slider. The drive motor is connected to the rotating rod through a coupling.

[0008] Preferably, wire connection screws are installed at the lower ends of both the front and rear ends of the vehicle fuse box. The wire connection screws are connected to the vehicle fuse box by screws, and a connecting clamping piece is provided at the lower end of the outside of the wire connection screw.

[0009] Preferably, circuit switches are installed at both the front and rear ends of the upper surface of the mounting plate, and the circuit switches are fixedly connected to the mounting plate.

[0010] Preferably, a temporary backup power supply is installed at the upper end of the upper support, and the temporary backup power supply is fixedly connected to the upper support.

[0011] Preferably, a top bracket is installed at the upper end of the upper bracket, and the top bracket is fixedly connected to the upper bracket.

[0012] Preferably, a protective bracket is installed on the upper end of the mounting plate, the protective bracket is connected to the mounting plate by screws, and an indicator light is installed on the front end face of the protective bracket, and several indicator lights are provided.

[0013] Preferably, a control button is installed on one side of the front end face of the top bracket, the control button is fixedly connected to the top bracket, an alarm buzzer is provided on one side of the control button, the alarm buzzer is fixedly connected to the top bracket, and a vehicle battery is installed at the lower end of the mounting plate, the vehicle battery is fixedly connected to the mounting plate.

[0014] A monitoring method for a forklift battery management system using a condition monitoring device includes the following steps:

[0015] Step 1: During installation, the worker electrically connects the output terminal of the vehicle battery to the input terminal of the vehicle fuse box, and then electrically connects the output terminal of the vehicle fuse box to the input terminal of the circuit switch. Next, the worker electrically connects the output terminal of the circuit switch to the input terminal of the electric forklift's electrical components. A current sensor is installed on the outside of the cable connecting the circuit switch and the electric forklift's electrical components. At the same time, the worker electrically connects the output terminal of the current sensor to the input terminal of the electric forklift's central control unit connected to the device. Finally, the worker installs the protective bracket on the upper part of the mounting plate with screws.

[0016] Step 2: When a short circuit occurs during the use of an electric forklift, the current sensor detects an abnormal current and sends a signal to the electric forklift central control unit connected to the device. The electric forklift central control unit selectively illuminates the indicator light of the corresponding circuit based on the current sensor that detected the abnormal signal. At the same time, the large amount of heat generated in the circuit causes the vehicle fuse to blow and the circuit switch to close, protecting the safety of the electric forklift's electrical appliances.

[0017] Step 3: Staff quickly locate the short circuit based on the lit indicator lights and repair the circuit;

[0018] Step 4: After the short-circuit circuit is repaired, when the staff needs to replace the vehicle fuse, the electric telescopic rod retracts, causing the rotating rod to move upward, pulling the old vehicle fuse out of the vehicle fuse box. Then, the drive motor rotates the rotating rod so that the new vehicle fuse faces downward. Then, the electric telescopic rod extends, causing the rotating rod to move downward, inserting the new vehicle fuse into the vehicle fuse box, completing the quick replacement of the vehicle fuse. The staff can then turn on the circuit switch to restore the circuit and quickly resume production.

[0019] Step 5: When staff have free time to maintain the electric forklift later, they can simply replace the damaged vehicle fuse with a new one.

[0020] Compared with the prior art, the beneficial effects of the present invention are:

[0021] 1. This invention uses a current sensor to detect current data in cables, enabling the device to constantly monitor the circuit and ensure its functionality. The current sensor, along with indicator lights, facilitates the location of short circuits, allowing for timely repairs and reducing maintenance time. This enhances the device's practicality and makes maintenance more convenient. The rotating rod allows for quick replacement of vehicle fuses, improving replacement efficiency and eliminating the need for staff to search for new fuses. This shortens maintenance time and allows electric forklifts to be deployed to production more quickly. The drive motor rotates the rod, ensuring the device's functionality and making maintenance more convenient, thus achieving the goal of automatically replacing vehicle fuses.

[0022] 2. This invention uses a connecting clamping plate to secure the cable connected to the device in conjunction with the wire connecting screw, ensuring the integrity of the device's functionality. The top bracket enhances the device's protective capabilities, preventing damage from external impacts and avoiding accidental contact with the device by staff, thus ensuring their safety. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of a status monitoring device for a forklift battery management system according to the present invention;

[0024] Figure 2 This is a front view of a status monitoring device for a forklift battery management system according to the present invention;

[0025] Figure 3 This is a three-dimensional perspective view of a status monitoring device for a forklift battery management system according to the present invention;

[0026] Figure 4 A three-dimensional perspective view of the slider installed in this invention;

[0027] Figure 5 This is an enlarged view of part A of the present invention.

[0028] In the diagram: 1. Vehicle fuse box; 2. Mounting mold plate; 3. Vehicle battery; 4. Wire connection screw; 5. Connecting clamp; 6. Current sensor; 7. Circuit switch; 8. Upper bracket; 9. Temporary backup power supply; 10. Top bracket; 11. Protective bracket; 12. Electric telescopic rod; 13. Rotating rod; 14. Vehicle fuse; 15. Control button; 16. Alarm buzzer; 17. Mounting slider; 18. Connecting spring; 19. Drive motor; 20. Control bracket; 21. Indicator light. Detailed Implementation

[0029] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0030] Please see Figure 1-5 The present invention provides an embodiment of a status monitoring device for a forklift battery management system, comprising an on-board fuse box 1;

[0031] Mounting plate 2 is installed at the lower end of the vehicle fuse box 1. The vehicle fuse box 1 is fixedly connected to mounting plate 2. Current sensors 6 are installed at both the front and rear ends of the upper surface of mounting plate 2. The current sensors 6 can detect the current data in the cable, allowing the device to constantly monitor the circuit and ensure the integrity of the device's functionality. The current sensors 6, together with indicator lights 21, facilitate the location of short circuits by operators, enabling timely maintenance, shortening maintenance time, enhancing the practicality of the device, and making maintenance more convenient. The current sensors 6 are fixedly connected to mounting plate 2. An upper bracket 8 is installed at the upper end of the vehicle fuse box 1 and is fixedly connected to the vehicle fuse box 1. The upper bracket 8 is internally installed with... The device has a rotating rod 13, which allows for quick replacement of the vehicle fuse 14, improving the efficiency of fuse replacement. It eliminates the need for staff to search for new fuses, shortening maintenance time and facilitating faster deployment of electric forklifts into production. Both ends of the rotating rod 13 are equipped with mounting sliders 17, which are rotatably connected to the rotating rod 13. Connecting springs 18 are installed at both the upper and lower ends of the mounting sliders 17, and are fixedly connected to both the mounting sliders 17 and the upper bracket 8. The mounting sliders 17 and the upper bracket 8 are slidably connected via slots. Vehicle fuses 14 are installed at both the upper and lower ends of the rotating rod 13, and are connected to the rotating rod 13 via screws.

[0032] The electric telescopic rod 12 is installed on both sides of the upper bracket 8 and is fixedly connected to the upper bracket 8. The lower end of the upper bracket 8 is equipped with a control bracket 20, and the control bracket 20 is equipped with a drive motor 19. The drive motor 19 can drive the rotating rod 13 to rotate, ensuring the integrity of the device's functionality, making device maintenance more convenient, and achieving the purpose of automatically replacing the vehicle fuse 14. The drive motor 19 is fixedly connected to the mounting slider 17, and the drive motor 19 is connected to the rotating rod 13 through a coupling.

[0033] Please see Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5The lower ends of both the front and rear faces of the vehicle fuse box 1 are equipped with wire connection screws 4. The wire connection screws 4 are connected to the vehicle fuse box 1 by screws. The lower end of the wire connection screw 4 is provided with a connecting clamping piece 5. Installing the connecting clamping piece 5 so that it cooperates with the wire connection screw 4 can fix the cable of this device and ensure the integrity of the device's functionality. The front and rear ends of both sides of the upper face of the mounting plate 2 are equipped with circuit switches 7. The circuit switches 7 are fixedly connected to the mounting plate 2. The upper end of the upper bracket 8 is equipped with a temporary backup power supply 9. The temporary backup power supply 9 is fixedly connected to the upper bracket 8. The upper end of the upper bracket 8 is equipped with a top bracket 10. Installing the top bracket 10 can enhance the device's protection capability and prevent the device from being damaged. To prevent damage from external impacts and to ensure the safety of personnel by preventing accidental contact with the device, the top bracket 10 is fixedly connected to the upper bracket 8. A protective bracket 11 is installed on the upper end of the mounting plate 2, and the protective bracket 11 is connected to the mounting plate 2 by screws. Several indicator lights 21 are installed on the front end of the protective bracket 11. A control button 15 is installed on one side of the front end of the top bracket 10, and the control button 15 is fixedly connected to the top bracket 10. An alarm buzzer 16 is installed on one side of the control button 15, and the alarm buzzer 16 is fixedly connected to the top bracket 10. A vehicle battery 3 is installed on the lower end of the mounting plate 2, and the vehicle battery 3 is fixedly connected to the mounting plate 2.

[0034] A monitoring method for a forklift battery management system using a condition monitoring device includes the following steps:

[0035] Step 1: During installation, the worker electrically connects the output terminal of the vehicle battery 3 to the input terminal of the vehicle fuse box 1, and then electrically connects the output terminal of the vehicle fuse box 1 to the input terminal of the circuit switch 7. Then, the worker electrically connects the output terminal of the circuit switch 7 to the input terminal of the electric forklift electrical appliance, and installs the current sensor 6 on the outside of the cable connecting the circuit switch 7 and the electric forklift electrical appliance. At the same time, the worker electrically connects the output terminal of the current sensor 6 to the input terminal of the electric forklift central control unit connected to the device. Then, the worker installs the protective bracket 11 on the upper end of the mounting plate 2 with screws.

[0036] Step 2: When a short circuit occurs during the use of the electric forklift, the current sensor 6 detects an abnormal current and sends a signal to the electric forklift central control unit connected to the device. The electric forklift central control unit selectively illuminates the indicator light 21 of the corresponding circuit based on the current sensor 6 that detected the abnormal signal. At the same time, a large amount of heat generated in the circuit causes the vehicle fuse 14 to blow and the circuit switch 7 to close, thus protecting the safety of the electric forklift's electrical appliances.

[0037] Step 3: Staff quickly locate the short circuit based on the lit indicator light 21 and repair the circuit;

[0038] Step 4: After the short-circuit circuit is repaired, when the staff needs to replace the vehicle fuse 14, the electric telescopic rod 12 retracts, causing the rotating rod 13 to move upward, so that the old vehicle fuse 14 is pulled out of the vehicle fuse box 1. Then, the drive motor 19 drives the rotating rod 13 to rotate, so that the new vehicle fuse 14 faces downward. Then, the electric telescopic rod 12 extends, causing the rotating rod 13 to move downward, so that the new vehicle fuse 14 is inserted into the vehicle fuse box 1, completing the quick replacement of the vehicle fuse 14. The staff turns on the circuit switch 7 to restore the circuit and quickly resume production.

[0039] Step 5: When staff have free time to maintain the electric forklift later, they can replace the damaged vehicle fuse 14 with a new one.

[0040] Working Principle: During installation, the operator electrically connects the output terminal of the vehicle battery 3 to the input terminal of the vehicle fuse box 1, and then connects the output terminal of the vehicle fuse box 1 to the input terminal of the circuit switch 7. Next, the output terminal of the circuit switch 7 is electrically connected to the input terminal of the electric forklift's electrical components. A current sensor 6 is installed externally on the cable connecting the circuit switch 7 and the electric forklift's electrical components. Simultaneously, the operator electrically connects the output terminal of the current sensor 6 to the input terminal of the electric forklift's central control unit connected to the device. The operator then installs the protective bracket 11 on the upper end of the mounting plate 2 using screws. When a short circuit occurs during the use of the electric forklift, the current sensor 6 detects an abnormal current and sends a current signal to the electric forklift's central control unit. The vehicle's central control system sends a signal, and based on the current sensor 6 detecting the abnormal signal, the central control system selectively illuminates the indicator light 21 corresponding to the circuit. Simultaneously, the large amount of heat generated in the circuit causes the on-board fuse 14 to blow, and the circuit switch 7 to close, protecting the electrical components of the electric forklift. Workers quickly locate and repair the short-circuited circuit based on the illuminated indicator light 21. After the short-circuit repair is completed, when workers need to replace the on-board fuse 14, the electric telescopic rod 12 retracts, causing the rotating rod 13 to move upwards, pulling the old on-board fuse 14 out of the fuse box 1. Then, the drive motor 19 rotates the rotating rod 13, making the new on-board fuse 14 face downwards. Finally, the electric telescopic rod 12 extends, causing the rotating rod 13 to move downwards, placing the new fuse... The vehicle fuse 14 is inserted into the vehicle fuse box 1, completing the quick replacement of the vehicle fuse 14. The operator then turns on the circuit switch 7 to restore the circuit and quickly resume production. When the operator has free time to maintain the electric forklift later, they can simply replace the damaged vehicle fuse 14 with the new one. The device is equipped with a current sensor 6 to detect current data in the cables, allowing the device to constantly monitor the circuit and ensure its functionality. The current sensor 6, along with the indicator light 21, helps operators locate short circuits, facilitating timely repairs, reducing maintenance time, enhancing the device's practicality, and making maintenance more convenient. A rotating rod 1 is also installed. 3. The vehicle fuse 14 can be quickly replaced, improving the replacement efficiency of the vehicle fuse 14. It can be quickly replaced without the need for staff to find a new vehicle fuse 14, shortening maintenance time and facilitating the faster deployment of electric forklifts into production. The installation of the drive motor 19 can drive the rotating rod 13 to rotate, ensuring the integrity of the device's functionality and making device maintenance more convenient, achieving the purpose of automatically replacing the vehicle fuse 14. The installation of the connecting clamp 5, which, together with the wire connecting screw 4, can fix the cable connected to this device, ensuring the integrity of the device's functionality. The installation of the top bracket 10 can enhance the device's protective capabilities, preventing the device from being damaged by external impacts, and at the same time preventing staff from accidentally touching the device, ensuring the safety of the staff.

[0041] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A condition monitoring device for a forklift battery management system, comprising an on-board fuse box (1), characterized in that: A mounting plate (2) is installed at the lower end of the vehicle fuse box (1). The vehicle fuse box (1) is fixedly connected to the mounting plate (2). Current sensors (6) are installed at both the front and rear ends of the upper surface of the mounting plate (2). The current sensors (6) are fixedly connected to the mounting plate (2). An upper bracket (8) is installed at the upper end of the vehicle fuse box (1). The upper bracket (8) is fixedly connected to the vehicle fuse box (1). A rotating rod (13) is installed inside the upper bracket (8). 13) has mounting sliders (17) installed at both ends. The mounting sliders (17) are rotatably connected to the rotating rod (13). The mounting sliders (17) have connecting springs (18) installed at both ends. The connecting springs (18) are fixedly connected to the mounting sliders (17) and the upper bracket (8). The mounting sliders (17) and the upper bracket (8) are slidably connected up and down through slots. The rotating rod (13) has vehicle fuses (14) installed at both ends. The vehicle fuses (14) are connected to the rotating rod (13) through screws. An electric telescopic rod (12) is provided on both sides of the upper bracket (8). The electric telescopic rod (12) is fixedly connected to the upper bracket (8). A control bracket (20) is installed at the lower end of the upper bracket (8). A drive motor (19) is installed inside the control bracket (20). The drive motor (19) is fixedly connected to the mounting slider (17). The drive motor (19) is connected to the rotating rod (13) through a coupling. Installing a current sensor (6) can detect the current data in the cable, so that the device can detect the circuit at all times and ensure the integrity of the device's functionality. The current sensor (6) is installed on the outside of the cable connecting the circuit switch (7) and the electric forklift's electrical appliances. At the same time, the operator electrically connects the output end of the current sensor (6) to the input end of the electric forklift's central control unit connected to the device. When the current sensor (6) detects an abnormal current, it sends a signal to the electric forklift's central control unit connected to the device. The electric forklift's central control unit selectively lights up the indicator light (21) of the corresponding circuit based on the current sensor (6) that detected the abnormal signal.

2. The condition monitoring device for a forklift battery management system according to claim 1, characterized in that: The lower ends of both the front and rear faces of the vehicle fuse box (1) are equipped with wire connection screws (4). The wire connection screws (4) are connected to the vehicle fuse box (1) by screws. The lower end of the wire connection screws (4) is provided with a connecting clamping piece (5).

3. The status monitoring device for a forklift battery management system according to claim 2, characterized in that: Circuit switches (7) are installed at both ends of the upper surface of the mounting plate (2), and the circuit switches (7) are fixedly connected to the mounting plate (2).

4. The condition monitoring device for a forklift battery management system according to claim 3, characterized in that: A temporary backup power supply (9) is installed at the upper end of the upper bracket (8), and the temporary backup power supply (9) is fixedly connected to the upper bracket (8).

5. The condition monitoring device for a forklift battery management system according to claim 4, characterized in that: The upper end of the upper bracket (8) is equipped with a top bracket (10), and the top bracket (10) is fixedly connected to the upper bracket (8).

6. The condition monitoring device for a forklift battery management system according to claim 5, characterized in that: A protective bracket (11) is installed on the upper end of the mounting plate (2). The protective bracket (11) is connected to the mounting plate (2) by screws. An indicator light (21) is installed on the front end face of the protective bracket (11). Several indicator lights (21) are provided.

7. The condition monitoring device for a forklift battery management system according to claim 6, characterized in that: A control button (15) is installed on one side of the front end face of the top bracket (10). The control button (15) is fixedly connected to the top bracket (10). An alarm buzzer (16) is provided on one side of the control button (15). The alarm buzzer (16) is fixedly connected to the top bracket (10). A vehicle battery (3) is installed at the lower end of the mounting plate (2). The vehicle battery (3) is fixedly connected to the mounting plate (2).

8. A monitoring method for a forklift battery management system using a condition monitoring device, implemented based on the condition monitoring device for a forklift battery management system as described in claim 7, comprising the following steps: Step 1: During installation, the staff electrically connects the output terminal of the vehicle battery (3) to the input terminal of the vehicle fuse box (1), and then electrically connects the output terminal of the vehicle fuse box (1) to the input terminal of the circuit switch (7). Then, the output terminal of the circuit switch (7) is electrically connected to the input terminal of the electric forklift electrical appliance. A current sensor (6) is installed on the outside of the cable connecting the circuit switch (7) and the electric forklift electrical appliance. At the same time, the staff electrically connects the output terminal of the current sensor (6) to the input terminal of the electric forklift central control connected to the device. Then, the staff installs the protective bracket (11) on the upper end of the mounting plate (2) with screws. Step 2: When a short circuit occurs during the use of the electric forklift, the current sensor (6) detects an abnormal current and sends a signal to the electric forklift central control unit connected to the device. The electric forklift central control unit selectively lights up the indicator light (21) of the corresponding circuit based on the current sensor (6) that detected the abnormal signal. At the same time, a large amount of heat generated in the circuit causes the vehicle fuse (14) to blow and the circuit switch (7) to close, thus protecting the safety of the electric forklift's electrical appliances. Step 3: Staff members quickly locate the short-circuited circuit based on the lit indicator light (21) and repair the circuit; Step 4: After the short-circuit circuit is repaired, when the staff needs to replace the vehicle fuse (14), the electric telescopic rod (12) retracts to move the rotating rod (13) upward, so that the old vehicle fuse (14) is pulled out of the vehicle fuse box (1). Then the drive motor (19) drives the rotating rod (13) to rotate, so that the new vehicle fuse (14) faces downward. Then the electric telescopic rod (12) extends to move the rotating rod (13) downward, inserting the new vehicle fuse (14) into the vehicle fuse box (1), completing the quick replacement of the vehicle fuse (14). The staff turns on the circuit switch (7) to restore the circuit and quickly resume production. Step 5: When staff have free time to maintain the electric forklift, they can replace the damaged vehicle fuse (14) with a new vehicle fuse (14).

Images