Safety self-adaptive control system for lifting and ramp running of electric forklift

Abstract

A safe self-adaptive control system for lifting and ramp running of an electric forklift comprises a whole forklift controller, a height collecting module, a weight collecting module, a pallet fork dip angle collecting module, a whole forklift dip angle collecting module, a rear wheel pressure collecting module, an alarm module, a lifting system control module and a driving system control module which are installed on the forklift. The real-time cargo height, the real-time cargo weight, the real-time inclination angle and the overturning limit can be monitored and calculated in real time, the maximum safe lifting height and the maximum safe inclination angle are calculated, the alarm height / angle smaller than the maximum height and the maximum inclination angle and the safety threshold value height / angle are set, the uphill and downhill states of the forklift can be automatically judged, and the safety of the forklift is guaranteed. The safety control is carried out when the forklift goes uphill and downhill, and when dangerous working conditions are detected, the forklift can quickly intervene in an operation system, so that the risk caused by misoperation of personnel or continuous operation under the dangerous working conditions is avoided, and the safety of the personnel and goods is fully guaranteed.

Description

Technical Field

[0001] The invention relates to the field of safety control of electric forklifts, and in particular to a safety adaptive control system for lifting and ramp operation of electric forklifts. Background Art

[0002] As an indispensable handling tool in the industrial field, forklifts have the ability to load, unload, stack and transport palletized goods over short distances, which greatly improves the work efficiency and reduces the labor burden of workers. Therefore, their application is becoming more and more extensive. In the process of using electric forklifts for transportation, safety accidents caused by improper operation or lack of safety awareness of operators are common. Vehicle rollover and overturning accidents caused by the height of cargo lifting are one of the common situations. In actual operation, due to the lack of effective protection measures, when the weight of the goods being transported is large and the forklift's fork is lifted to a higher position or there is a large tilt angle, forklift overloading often occurs, which may cause the goods to overturn or fall, and even the forklift itself may overturn, causing property losses and operator safety risks. In recent years, with the technological development of the industrial transportation industry and the introduction of various laws and regulations, various industries have attached more and more importance to the personnel safety of industrial transportation vehicles. Safety training for operators alone cannot completely avoid the occurrence of safety accidents. Various safety equipment or safety systems are also needed to minimize safety risks.

[0003] In order to avoid these risks, it is particularly important to develop a system that can monitor the lifting height and fork tilt angle of electric forklifts in real time, and provide early warning and power limit for overload conditions. Such a system can ensure that the forklift operates within a safe range, prevent material loss and potential threats to personal safety caused by overloading, or the risk of cargo sliding off the forks due to ramp travel, thereby improving the safety and reliability of forklift operations. Summary of the invention

[0004] The purpose of the present invention is to provide a safe adaptive control system for the lifting and ramp operation of an electric forklift, which can take active measures to prevent the electric forklift from overturning and the cargo from sliding off, thereby improving safety assurance.

[0005] The technical solution adopted by the present invention to solve the above technical problems is: a safety adaptive control system for lifting and ramp operation of an electric forklift, comprising a vehicle controller installed on the forklift, a height acquisition module, a weight acquisition module, a fork tilt angle acquisition module, a vehicle tilt angle acquisition module, a rear wheel pressure acquisition module, an alarm module, a lifting system control module and a drive system control module; The height acquisition module includes multiple laser sensors installed on the forks. The multiple laser sensors can cooperate to monitor the height of the forks and transmit the height data to the vehicle controller; The weight acquisition module includes multiple pressure sensors installed on the forks, which can cooperate to monitor the weight of the goods and transmit the weight data to the vehicle controller; The fork inclination angle acquisition module includes multiple inclination sensors installed on the forks. The multiple inclination sensors can cooperate to monitor the inclination angle of the forks and transmit the inclination angle data of the forks to the vehicle controller; The vehicle tilt angle acquisition module includes multiple tilt angle sensors installed on the vehicle body, which can cooperate to monitor the tilt angle of the vehicle body and transmit the vehicle tilt angle data to the vehicle controller; The rear wheel pressure acquisition module includes multiple rear wheel pressure sensors, which can monitor and transmit the rear wheel pressure data to the vehicle controller; The alarm module can send out an alarm based on the signal from the vehicle controller; The lifting system control module can control the lifting and lowering of the fork according to the signal of the vehicle controller; The drive system control module can control the power output of the throttle device and the braking action of the brake device according to the signal of the vehicle controller; The vehicle controller stores the mechanical model of the electric forklift. The vehicle controller can obtain the real-time cargo height, real-time cargo weight, real-time tilt angle and overturning limit according to the received height data, weight data, fork tilt angle data and vehicle tilt angle data, and calculate the maximum safe lifting height and maximum safe tilt angle through the mechanical model; the vehicle controller sets the alarm height and safety threshold height according to the maximum safe lifting height, and sets the alarm angle and safety threshold angle according to the maximum safe tilt angle; When the real-time cargo height reaches the alarm height, the vehicle controller sends a signal to make the alarm module start to sound an alarm; when the real-time cargo height reaches the safety threshold height, the vehicle controller sends a signal to make the lifting system control module stop the fork from rising; When the real-time tilt angle changes, the vehicle controller determines whether it is uphill or downhill according to the change trend of the real-time tilt angle. When the pressure data of the rear wheel is less than the safety pressure threshold when going uphill or downhill, or when the forklift is in a forward downhill state or a backward uphill state, the vehicle controller sends a signal, the drive system control module stops the throttle device from outputting power, and the drive system control module causes the brake device to perform a braking action; When the real-time tilt angle reaches the alarm angle, the vehicle controller sends a signal to cause the alarm module to start sounding an alarm; when the real-time tilt angle reaches the safety threshold angle, the vehicle controller sends a signal to cause the drive system control module to stop the throttle device from outputting power, and the drive system control module causes the brake device to perform braking action.

[0006] Preferably, the system also includes a display module, which is installed in the cab of the forklift and can display the current fork inclination angle, current lifting height, cargo weight, maximum safe lifting height and maximum safe inclination angle to the driver in real time.

[0007] According to the above technical solution, the beneficial effects of the present invention are: The present invention can monitor and calculate the real-time cargo height, real-time cargo weight, real-time tilt angle and overturning limit in real time, and calculate the maximum safe lifting height and the maximum safe tilt angle, and then set the alarm height / angle and the safety threshold height / angle which are less than the maximum height and the maximum tilt angle, and can automatically determine the uphill and downhill state of the forklift, and perform safety control when the forklift is going uphill and downhill. When a dangerous working condition is detected, the operating system can be quickly intervened, avoiding the risk of personnel misoperation or continued operation under dangerous working conditions, and the safety intervention speed of the electrical system is faster than the reaction limit of humans, avoiding the occurrence of danger in the shortest time, and can ensure the safety and stability of the cargo and the correctness of personnel operation when the driver is driving uphill and downhill, thereby providing the driver with more safety protection, greatly reducing the blindness and danger of the driver's operation, and fully ensuring the safety of personnel and cargo. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 It is a system module block diagram of the present invention. DETAILED DESCRIPTION

[0009] With reference to the accompanying drawings, the specific implementation is as follows: A safety adaptive control system for lifting and ramp operation of an electric forklift, comprising a vehicle controller installed on the forklift, a height acquisition module, a weight acquisition module, a fork tilt angle acquisition module, a vehicle tilt angle acquisition module, a rear wheel pressure acquisition module, an alarm module, a lifting system control module and a drive system control module, and also comprising a display module.

[0010] The height acquisition module includes multiple laser sensors installed on the forks. The multiple laser sensors can cooperate to monitor the height of the forks and transmit the height data to the vehicle controller.

[0011] In this embodiment, the laser sensor is installed on the fork, including a signal generator, a reflector, and a sensor fixed housing; the signal generator is installed in the sensor fixed housing, and the housing is mounted on the cylinder barrel of the lifting cylinder through a bracket; the reflector is fixedly mounted on the fork frame through a bracket; the laser emitting device is fixed and emits from bottom to top, and the reflector moves with the movement of the fork frame, and the height is calculated by the reflection time.

[0012] The weight acquisition module includes multiple pressure sensors installed on the forks. The multiple pressure sensors can cooperate to monitor the weight of the goods and transmit the weight data to the vehicle controller.

[0013] The fork inclination angle acquisition module includes multiple inclination sensors installed on the fork. The multiple inclination sensors can cooperate to monitor the inclination angle of the fork and transmit the fork inclination angle data to the vehicle controller.

[0014] In this embodiment, the fork inclination sensor is installed between the tilt cylinder and the frame, including a bracket, a connecting rod mechanism and a potentiometer. One end of the connecting rod mechanism is fixed to the hinge bolt head of the cylinder, and the other end is fixedly connected to the potentiometer. The potentiometer is fixedly installed on the bracket. The telescopic movement of the tilt cylinder drives the movement of the connecting mechanism, so that the signal of the inclination angle of the fork frame is measured on the potentiometer and sent to the vehicle controller.

[0015] The vehicle tilt angle acquisition module includes multiple tilt angle sensors installed on the vehicle body. The multiple tilt angle sensors can cooperate to monitor the tilt angle of the vehicle body and transmit the vehicle tilt angle data to the vehicle controller.

[0016] The rear wheel pressure acquisition module includes multiple rear wheel pressure sensors, which can monitor and transmit the rear wheel pressure data to the vehicle controller.

[0017] The alarm module can issue an alarm according to the signal of the vehicle controller, the lifting system control module can control the lifting and lowering of the fork according to the signal of the vehicle controller, and the drive system control module can control the power output of the throttle device and the braking action of the brake device according to the signal of the vehicle controller.

[0018] The vehicle controller stores the mechanical model of the electric forklift. The vehicle controller can obtain the real-time cargo height, real-time cargo weight, real-time tilt angle and overturning limit based on the received height data, weight data, fork inclination data and vehicle inclination data, and calculate the maximum safe lifting height and maximum safe inclination angle through the mechanical model.

[0019] The mechanical model of the electric forklift belongs to the prior art and is recorded in the existing literature. For example, the overturning limit can be calculated through the invention patent CN117550518A electric forklift anti-overturning method and system, and the maximum safe lifting height and safe tilt angle can be calculated through the multivariate regression model in the invention patent CN107720625A a forklift maximum cargo lifting limit method and system. The vehicle controller further sets the alarm height and safety threshold height according to the maximum safe lifting height, and sets the alarm angle and safety threshold angle according to the maximum safe tilt angle.

[0020] When the real-time cargo height reaches the alarm height, the vehicle controller sends a signal to the alarm module to start the alarm. When the real-time cargo height reaches the safety threshold height, the vehicle controller sends a signal to the lifting system control module to stop the fork from rising.

[0021] When the real-time tilt angle changes, the vehicle controller determines whether it is uphill or downhill according to the change trend of the real-time tilt angle. When the pressure data of the rear wheel is less than the safety pressure threshold when going uphill or downhill, or when the forklift is in a forward downhill state or a backward uphill state, the vehicle controller sends a signal, the drive system control module stops the throttle device from outputting power, and the drive system control module causes the brake device to brake. If the ramp safety control system comprehensively determines that it is going uphill (forward uphill) or reverse downhill (reverse downhill), the ramp safety system determines it as a safe working condition and does not restrict power and driver operation.

[0022] When the real-time tilt angle reaches the alarm angle, the vehicle controller sends a signal to the alarm module to start the alarm. When the real-time tilt angle reaches the safety threshold angle, the vehicle controller sends a signal to the drive system control module to stop the throttle device from outputting power, and the drive system control module to make the brake device perform the braking action.

[0023] The display module is installed in the cab of the forklift and can show the driver the current fork tilt angle, current lifting height, cargo weight, maximum safe lifting height and maximum safe tilt angle in real time.

[0024] The vehicle controller, display module and alarm module are all displayed through the intelligent instrument. The intelligent instrument is fixed in front of the driver in the cab and fixed to the A-pillar on the right side of the overhead guard through a universal bracket; the intelligent instrument uses signal cables to connect the rear wheel pressure sensor, fork pressure sensor, laser sensor and angle sensor. The intelligent instrument can increase the working voltage of these sensors, and at the same time it can receive the signals sent by each sensor, amplify and process them, analyze and judge through data processing, and finally display them on the display screen on the intelligent instrument. The displayed data includes the current fork inclination angle, current lifting height, cargo weight, maximum safe lifting height and maximum fork inclination angle. The intelligent instrument also realizes functions such as color and sound alarms on the instrument through the alarm module, and issues early warning reminders on the safe range of the weight and height of the lifted cargo.

Claims

1. A safety adaptive control system for electric forklift lifting and ramp operation, characterized by: It includes a vehicle controller installed on the forklift, a height acquisition module, a weight acquisition module, a fork tilt angle acquisition module, a vehicle tilt angle acquisition module, a rear wheel pressure acquisition module, an alarm module, a lifting system control module and a drive system control module; The height acquisition module includes multiple laser sensors installed on the forks. The multiple laser sensors can cooperate to monitor the height of the forks and transmit the height data to the vehicle controller; The weight acquisition module includes multiple pressure sensors installed on the forks, which can cooperate to monitor the weight of the goods and transmit the weight data to the vehicle controller; The fork inclination angle acquisition module includes multiple inclination sensors installed on the forks. The multiple inclination sensors can cooperate to monitor the inclination angle of the forks and transmit the inclination angle data of the forks to the vehicle controller; The vehicle tilt angle acquisition module includes multiple tilt angle sensors installed on the vehicle body, which can cooperate to monitor the tilt angle of the vehicle body and transmit the vehicle tilt angle data to the vehicle controller; The rear wheel pressure acquisition module includes multiple rear wheel pressure sensors, which can monitor and transmit the rear wheel pressure data to the vehicle controller; The alarm module can send out an alarm according to the signal of the vehicle controller, the lifting system control module can control the lifting and lowering of the fork according to the signal of the vehicle controller, and the drive system control module can control the power output of the throttle device and the braking action of the brake device according to the signal of the vehicle controller; The vehicle controller stores the mechanical model of the electric forklift. The vehicle controller can obtain the real-time cargo height, real-time cargo weight, real-time tilt angle and overturning limit according to the received height data, weight data, fork tilt angle data and vehicle tilt angle data, and calculate the maximum safe lifting height and maximum safe tilt angle through the mechanical model; the vehicle controller sets the alarm height and safety threshold height according to the maximum safe lifting height, and sets the alarm angle and safety threshold angle according to the maximum safe tilt angle; When the real-time cargo height reaches the alarm height, the vehicle controller sends a signal to make the alarm module start to sound an alarm; when the real-time cargo height reaches the safety threshold height, the vehicle controller sends a signal to make the lifting system control module stop the fork from rising; When the real-time tilt angle changes, the vehicle controller determines whether it is uphill or downhill according to the change trend of the real-time tilt angle. When the pressure data of the rear wheel is less than the safety pressure threshold when going uphill or downhill, or when the forklift is in a forward downhill state or a backward uphill state, the vehicle controller sends a signal, the drive system control module stops the throttle device from outputting power, and the drive system control module causes the brake device to perform a braking action; When the real-time tilt angle reaches the alarm angle, the vehicle controller sends a signal to cause the alarm module to start sounding an alarm; when the real-time tilt angle reaches the safety threshold angle, the vehicle controller sends a signal to cause the drive system control module to stop the throttle device from outputting power, and the drive system control module causes the brake device to perform braking action.

2. A safety adaptive control system for electric forklift lifting and ramp operation according to claim 1, characterized in that: The system also includes a display module, which is installed in the cab of the forklift and can display the current fork tilt angle, current lifting height, cargo weight, maximum safe lifting height and maximum safe tilt angle to the driver in real time.

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