Electric forklift matching test system and method

Abstract

This application provides an electric forklift matching test system and method. The system includes a power supply system, a travel system connected to the power supply system, a working hydraulic system, a control system, and a detection system, as well as a test platform for installing the above systems. The system and method can test the travel system or the working hydraulic system of an electric forklift separately, or test the travel system and the working hydraulic system working together, thereby determining the coupling between the travel system and the working hydraulic system. This facilitates more accurate calculation of product performance and more reasonable technical matching during electric forklift R&D, thereby controlling product costs while ensuring product quality.

Description

Technical Field

[0001] The present application relates to the technical field of electric forklift testing, and in particular to an electric forklift matching test system and method. Background Art

[0002] As the sole power source for electric forklifts, the power battery not only powers the travel motor to drive the wheels and move the forklift during daily operation, but also, depending on operational requirements, the power battery powers the hydraulic motor and the hydraulic system to perform operations such as raising and lowering the forks and tilting the mast forward and backward. As the forklift moves cargo, the load and power required by the hydraulic motor fluctuate with the mast's movements, causing the current in the entire system to fluctuate continuously. These significant fluctuations can affect the forklift's overall performance, such as unstable travel speed, slow response of the hydraulic system, and reduced battery life.

[0003] However, the existing test system can only test the electric forklift's travel system or working hydraulic system and single components therein, such as the drive axle, motor, mast, etc., but cannot test the joint operation of the travel system and the working hydraulic system, and cannot reflect the coupling between the travel system and the working hydraulic system. Summary of the Invention

[0004] In order to solve the technical problems existing in the prior art, the first aspect of the present application provides an electric forklift matching test system, including a power supply system, a traveling system connected to the power supply system, a working hydraulic system, a control system and a detection system, as well as a test platform for installing the above systems;

[0005] The travel system includes a travel motor, a reduction gearbox and a drive axle which are sequentially connected in transmission, and the output shafts at both ends of the drive axle are respectively connected to a load simulation unit;

[0006] The working hydraulic system includes a hydraulic motor, a hydraulic pump, a hydraulic multi-way valve and a hydraulic cylinder which are sequentially connected in a transmission manner. The hydraulic cylinder is connected to the forklift mast, and the forklift mast is connected to a load block.

[0007] The control system is electrically connected to the travel system and the working hydraulic system, respectively, and is used to control the operating conditions of the travel motor, the hydraulic motor and the hydraulic cylinder;

[0008] The detection system is connected to the traveling system and the working hydraulic system, and is used to detect performance parameters of the traveling system and / or the working hydraulic system during operation.

[0009] Furthermore, the load simulation unit includes a load motor and a reducer connected between the load motor and the drive axle. The load motor is connected to a load controller and an independent load power supply.

[0010] Furthermore, the control system includes a travel motor controller connected between the travel motor and the power supply system, and a hydraulic motor controller connected between the hydraulic motor and the power supply system.

[0011] Furthermore, the travel motor controller is connected to a travel motor operating device in communication with the travel motor controller, and the hydraulic multi-way valve is connected to a hydraulic multi-way valve operating device.

[0012] Furthermore, the detection system includes at least one first current and voltage sensor connected between the power supply system and the travel motor, a first torque and speed sensor connected between the drive axle output shaft and the load simulation unit, at least one second current and voltage sensor connected between the power supply system and the hydraulic motor, a second torque and speed sensor connected between the hydraulic motor and the hydraulic pump, and a pressure flow sensor between the hydraulic pump and the hydraulic multi-way valve, and between the hydraulic multi-way valve and the hydraulic cylinder.

[0013] Furthermore, the hydraulic cylinder includes a lifting cylinder and a tilting cylinder, and the detection system also includes a linear displacement and angular displacement sensor arranged on the forklift mast, which is used to measure the linear velocity of the forklift mast when it rises or falls and the angular velocity of the forklift mast when it tilts forward or backward.

[0014] Furthermore, the power supply system is a power battery, and the detection system further includes a temperature sensor and a discharge current sensor connected to the power battery.

[0015] A second aspect of the present application provides a test method based on the above-mentioned electric forklift matching test system, comprising the following steps:

[0016] S1. Controlling the operation of the traveling system through a control system, with the working hydraulic system kept in a closed state, and obtaining a first traveling performance parameter of the traveling system through a detection system;

[0017] S2. Maintaining the running state of the traveling system, controlling the operation of the working hydraulic system through the control system, and obtaining a second traveling performance parameter of the traveling system and a first hydraulic performance parameter of the working hydraulic system through the detection system;

[0018] S3. Control the traveling system to stop running through the control system, while the working hydraulic system remains in operation, and obtain a second hydraulic performance parameter of the working hydraulic system through the detection system.

[0019] Furthermore, the operation of the travel system includes the travel motor operating according to first preset operating parameters, and the load simulation unit applying a preset load to both ends of the drive axle;

[0020] The operation of the working hydraulic system includes the hydraulic pump operating according to the second preset operating parameters, and the hydraulic cylinder driving the forklift mast with the load block to move.

[0021] Furthermore, the walking performance parameters of the walking system include the current value and voltage value of the walking system, and the torque value and speed value of the drive axle;

[0022] The hydraulic performance parameters of the working hydraulic system include the current value and voltage value of the working hydraulic system, the torque value and speed value of the hydraulic pump input end, and the hydraulic pressure value and hydraulic flow value of the hydraulic pump output end.

[0023] Compared with the prior art, the present invention has the following advantages:

[0024] The electric forklift matching test system provided in this application can independently test the travel system or hydraulic system of an electric forklift, or can test the travel system and hydraulic system working together to determine the coupling between the travel system and the hydraulic system. This facilitates more accurate performance calculation and more rational technical matching during electric forklift R&D, thereby controlling product costs while ensuring product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 is a flow chart of the electric forklift matching test method of the present application;

[0026] Figure 2 It is a structural diagram of the test platform of this application;

[0027] Figure 3 It is a schematic diagram of the electric forklift matching test system of the present application;

[0028] Figure 4 It is a structural diagram of the electric forklift matching test system of the present application;

[0029] 1. Power supply system;

[0030] 21. Travel motor; 22. Reducer; 23. Drive axle; 24. Load simulation unit; 241. Load motor; 242. Reducer;

[0031] 31. Hydraulic motor; 32. Hydraulic pump; 33. Hydraulic multi-way valve; 34. Hydraulic cylinder; 35. Forklift mast; 36. Load block;

[0032] 41. Travel motor controller; 42. Hydraulic motor controller; 43. Travel motor operating device; 44. Hydraulic multi-way valve operating device;

[0033] 51. First current and voltage sensor; 52. First torque and speed sensor; 53. Second current and voltage sensor; 54. Second torque and speed sensor; 55. Pressure and flow sensor. DETAILED DESCRIPTION

[0034] To facilitate understanding of this application, the following will clearly and completely describe the technical solutions in the embodiments of this application in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0035] refer to Figures 2 to 4 As shown, this embodiment provides an electric forklift matching test system, including a power supply system 1, a traveling system connected to the power supply system 1, a working hydraulic system, a control system and a detection system, as well as a test platform for installing the above systems;

[0036] The travel system includes a travel motor 21, a reduction gearbox 22 and a drive axle 23 which are sequentially connected in transmission. The output shafts at both ends of the drive axle 23 are respectively connected to a load simulation unit 24;

[0037] The working hydraulic system includes a hydraulic motor 31, a hydraulic pump 32, a hydraulic multi-way valve 33 and a hydraulic cylinder 34 which are sequentially connected. The hydraulic cylinder 34 is connected to a forklift mast 35, and a load block 36 is connected to the forklift mast 35.

[0038] The control system is electrically connected to the travel system and the working hydraulic system, and is used to control the operating conditions of the travel motor 21, the hydraulic motor 31 and the hydraulic cylinder 34;

[0039] The detection system is connected to the traveling system and the working hydraulic system, and is used to measure the performance parameters of the traveling system and / or the working hydraulic system during operation.

[0040] The test system of the existing technology can only test the travel system or working hydraulic system of the electric forklift and single components therein such as the drive axle, motor, mast, etc., but cannot test the joint operation of the travel system and the working hydraulic system, and cannot reflect the coupling status between the travel system and the working hydraulic system.

[0041] The electric forklift matching test system provided in this embodiment can test the travel system or hydraulic system of an electric forklift independently, or the travel system and hydraulic system working together, thereby determining the coupling between the travel system and the hydraulic system. This facilitates more accurate performance calculation and more rational technical matching during electric forklift R&D, thereby controlling product costs while ensuring product quality.

[0042] In some embodiments, the test platform includes a traveling system installation platform, a working hydraulic system installation platform, a gantry system installation platform, and a power system and control system installation platform.

[0043] In some embodiments, the load simulation unit 24 includes a load motor 241 and a reducer 242 connected between the load motor 241 and the drive axle 23. Specifically, the number of the load motor 241 and the reducer 242 are both two, the input shaft of the reducer 242 is circumferentially fixedly connected to the output shafts at both ends of the drive axle 23 through a coupling, and the output shaft of the reducer 242 is circumferentially fixedly connected to the output shaft of the load motor 241 through a coupling. At the same time, the load motor 241 is connected to a load controller and an independent load power supply. This is to avoid the load motor 241 using the power supply system 1 to affect the test data. The load simulation unit 24 can control the load motor 241 through the load controller to apply a force to the output shafts at both ends of the drive axle 23 to simulate the load that the walking system bears when the electric forklift is unloaded, fully loaded, uphill, downhill or on flat ground.

[0044] In some embodiments, the control system includes a travel motor controller 41 connected between the travel system and the power supply system 1 , and a hydraulic motor controller 42 connected between the hydraulic motor 31 and the power supply system 1 .

[0045] In some embodiments, the travel motor controller 41 is connected to a travel motor control device 43 in communication therewith. The travel motor control device 43 is electrically connected to the travel motor controller 41 via a wired or wireless connection and is configured to send control instructions to the travel motor controller 41 to control the operation of the travel motor 21. The hydraulic multi-way valve 33 is connected to a hydraulic multi-way valve control device 44, which controls the movement of the valve core of the hydraulic multi-way valve 33, thereby enabling operations such as raising and lowering, and tilting the forklift mast 35.

[0046] In some embodiments, the detection system includes at least one first current and voltage sensor 51 connected between the power supply system 1 and the travel motor 21, a first torque and speed sensor 52 connected between the output shaft of the drive axle 23 and the load simulation unit 24, at least one second current and voltage sensor 53 connected between the power supply system 1 and the hydraulic motor 31, a second torque and speed sensor 54 connected between the hydraulic motor 31 and the hydraulic pump 32, and a pressure flow sensor 55 between the hydraulic pump 32 and the hydraulic multi-way valve 33, and between the hydraulic multi-way valve 33 and the hydraulic cylinder 34.

[0047] Specifically, two first current and voltage sensors 51 are provided, one between the power supply system 1 and the travel motor controller 41 and one between the travel motor controller 41 and the travel motor 21. These sensors are used to measure the current and voltage output from the power supply system 1 to the travel system, as well as the current and voltage input to the travel motor 21. First torque and speed sensors 52 are provided between the output shafts at both ends of the drive axle 23 and the input shaft of the reducer 242, respectively, to monitor the torque and speed of the drive axle 23 in real time. Two second current and voltage sensors 53 are provided, one between the power supply system 1 and the hydraulic motor controller 42 and one between the hydraulic motor controller 42 and the hydraulic motor 31, respectively. These sensors are used to measure the current and voltage output from the power supply system 1 to the working hydraulic system, as well as the current and voltage input to the hydraulic motor 31. A pressure and flow sensor 55 is used to detect the hydraulic pressure and flow output by the hydraulic pump 32, as well as the hydraulic pressure and flow input to the hydraulic cylinder 34.

[0048] In some embodiments, the gantry system mounting platform includes a gantry mounting base, to which the hydraulic cylinders 34 and forklift mast 35 are secured. The hydraulic cylinders 34 include lift and tilt cylinders, each with its piston rods connected to the forklift mast 35, for driving the mast 35 upward or forward or backward. The detection system also includes linear and angular displacement sensors mounted on the forklift mast 35 to measure the linear velocity of the mast 35 as it rises or descends, and the angular velocity of its forward or backward tilt.

[0049] In some embodiments, the power supply system 1 is a bidirectional power supply or a power battery. Preferably, the power supply system 1 is a power battery, and the detection system further includes a temperature sensor and a discharge current sensor connected to the power battery.

[0050] refer to Figure 1 As shown, the present application also discloses a test method based on the above-mentioned electric forklift matching test system, comprising the following steps:

[0051] S1. Controlling the operation of the traveling system through a control system, with the working hydraulic system kept in a closed state, and obtaining a first traveling performance parameter of the traveling system through a detection system;

[0052] S2. Maintaining the running state of the traveling system, controlling the operation of the working hydraulic system through the control system, and obtaining a second traveling performance parameter of the traveling system and a first hydraulic performance parameter of the working hydraulic system through the detection system;

[0053] S3. The travel system is stopped by the control system, while the working hydraulic system remains in operation. The second hydraulic performance parameter of the working hydraulic system is obtained by the detection system.

[0054] Among them, the operation of the walking system includes the walking motor 21 operating according to the first preset operating parameters, and the load simulation unit 24 applying a preset load to both ends of the drive axle 23; the operation of the working hydraulic system includes the hydraulic pump 32 operating according to the second preset operating parameters, and the hydraulic cylinder 34 driving the forklift mast 35 with the load block 36 to move.

[0055] The travel performance parameters of the travel system include the current and voltage values ​​of the travel system, and the torque and speed values ​​of the drive axle 23. Specifically, the current and voltage values ​​of the travel system include the current and voltage values ​​output by the power supply system 1 to the travel system, and the current and voltage values ​​input to the travel motor 21.

[0056] The hydraulic performance parameters of the working hydraulic system include the current and voltage values ​​of the working hydraulic system, the torque and speed values ​​at the input of the hydraulic pump 32, and the hydraulic pressure and hydraulic flow values ​​at the output of the hydraulic pump 32. Specifically, the current and voltage values ​​of the working hydraulic system include the current and voltage values ​​output by the power supply system 1 to the working hydraulic system, as well as the current and voltage values ​​input to the hydraulic motor 31. The hydraulic pressure and hydraulic flow values ​​at the output of the hydraulic pump 32 include the hydraulic pressure and hydraulic flow values ​​output by the hydraulic pump 32, as well as the hydraulic pressure and hydraulic flow values ​​input to the hydraulic cylinder 34.

[0057] In some embodiments, step S1 further includes obtaining a first battery performance parameter of the power system 1 through a temperature sensor and a discharge current sensor, step S2 further includes obtaining a second battery performance parameter of the power system 1 through the temperature sensor and the discharge current sensor, and step S3 further includes obtaining a third battery performance parameter of the power system 1 through the temperature sensor and the discharge current sensor. The battery performance parameters include the temperature value and the discharge current value of the power battery.

[0058] After the test, the collected and recorded performance parameters were analyzed. Specifically, the first travel performance parameter of the electric forklift's travel system operating alone was analyzed with the second travel performance parameter when the travel system and the working hydraulic system operated together. The second hydraulic performance parameter of the working hydraulic system operating alone was analyzed with the first hydraulic performance parameter when the travel system and the working hydraulic system operated together. This was to determine the coupling between the travel system and the working hydraulic system. The first, second, and third battery performance parameters of the power system 1 were compared to analyze the impact of the combined operation of the travel system and the working hydraulic system on the performance of the power battery.

[0059] The technical solution described in this test system and method can simulate the loads borne by the travel system of an electric forklift under different operating conditions, such as when the vehicle is unloaded, fully loaded, traveling uphill, downhill, or on flat ground. It can also simulate the rise and fall, forward and backward tilt of the forklift mast 35, and operating conditions with different weights and loads. It can test the travel system or the hydraulic system alone, or the combined travel and hydraulic systems. This facilitates more accurate performance calculation and more rational technical matching during electric forklift R&D.

[0060] The above shows and describes the basic principles, main features, and advantages of the present application. Those skilled in the art should understand that the present application is not limited to the above embodiments. The above embodiments and descriptions are merely illustrative of the principles of the present application. Various changes and improvements may be made to the present application without departing from the spirit and scope of the present application. These changes and improvements are intended to fall within the scope of the present application. The scope of protection claimed in this application is defined by the appended claims and their equivalents.

Claims

1. An electric forklift matching test system, characterized in that: It comprises a power supply system (1), a traveling system connected to the power supply system (1), a working hydraulic system, a control system and a detection system, and a test platform for installing the above systems; The travel system comprises a travel motor (21), a reduction gearbox (22) and a drive axle (23) which are sequentially connected in transmission, and the output shafts at both ends of the drive axle (23) are respectively connected to load simulation units (24); The working hydraulic system comprises a hydraulic motor (31), a hydraulic pump (32), a hydraulic multi-way valve (33) and a hydraulic cylinder (34) which are sequentially connected in a transmission manner, the hydraulic cylinder (34) being connected to a forklift mast (35), and a load block (36) being connected to the forklift mast (35); The control system is electrically connected to the travel system and the working hydraulic system, respectively, and is used to control the operating conditions of the travel motor (21), the hydraulic motor (31) and the hydraulic cylinder (34); The detection system is connected to the traveling system and the working hydraulic system, and is used to detect performance parameters of the traveling system and / or the working hydraulic system during operation.

2. The electric forklift matching test system according to claim 1, characterized in that: The load simulation unit (24) comprises a load motor (241) and a reducer (242) connected between the load motor (241) and the drive axle (23); the load motor (241) is connected to a load controller and an independent load power supply.

3. The electric forklift matching test system according to claim 2, characterized in that: The control system includes a travel motor controller (41) connected between the travel motor (21) and the power supply system (1), and a hydraulic motor controller (42) connected between the hydraulic motor (31) and the power supply system (1).

4. The electric forklift matching test system according to claim 3, characterized in that: The travel motor controller (41) is connected to a travel motor operating device (43) in communication therewith, and the hydraulic multi-way valve (33) is connected to a hydraulic multi-way valve operating device (44).

5. The electric forklift matching test system according to claim 1, characterized in that: The detection system comprises at least one first current and voltage sensor (51) connected between the power supply system (1) and the travel motor (21), a first torque and speed sensor (52) connected between the output shaft of the drive axle (23) and the load simulation unit (24), at least one second current and voltage sensor (53) connected between the power supply system (1) and the hydraulic motor (31), a second torque and speed sensor (54) connected between the hydraulic motor (31) and the hydraulic pump (32), and pressure and flow sensors (55) between the hydraulic pump (32) and the hydraulic multi-way valve (33), and between the hydraulic multi-way valve (33) and the hydraulic cylinder (34).

6. The electric forklift matching test system according to claim 1, characterized in that: The hydraulic cylinder (34) includes a lifting cylinder and a tilting cylinder, and the detection system further includes a linear displacement and angular displacement sensor provided on the forklift mast (35) for measuring the linear velocity of the forklift mast (35) when it rises or falls and the angular velocity of the forklift mast (35) when it tilts forward or backward.

7. The electric forklift matching test system according to claim 1, characterized in that: The power supply system (1) is a power battery, and the detection system further comprises a temperature sensor and a discharge current sensor connected to the power battery.

8. A test method based on the electric forklift matching test system according to any one of claims 1 to 6, characterized in that: The following steps are involved: S1. Controlling the operation of the traveling system through a control system, with the working hydraulic system kept in a closed state, and obtaining a first traveling performance parameter of the traveling system through a detection system; S2. Maintaining the running state of the traveling system, controlling the operation of the working hydraulic system through the control system, and obtaining a second traveling performance parameter of the traveling system and a first hydraulic performance parameter of the working hydraulic system through the detection system; S3. Control the traveling system to stop running through the control system, while the working hydraulic system remains in operation, and obtain a second hydraulic performance parameter of the working hydraulic system through the detection system.

9. The electric forklift matching test method according to claim 8, characterized in that: The operation of the walking system includes the walking motor (21) operating according to a first preset operating parameter, and the load simulation unit (24) applying a preset load to both ends of the drive axle (23); The operation of the working hydraulic system includes the hydraulic pump (32) operating according to a second preset operating parameter, and the hydraulic cylinder (34) driving the forklift mast (35) with the load block (36) to move.

10. The electric forklift matching test method according to claim 8, characterized in that: The walking performance parameters of the walking system include the current value and voltage value output by the power supply system 1 to the walking system, the current value and voltage value input to the walking motor 21, and the torque value and speed value of the drive axle (23); the hydraulic performance parameters of the working hydraulic system include the current value and voltage value output by the power supply system 1 to the working hydraulic system, the current value and voltage value input to the hydraulic motor 31, and the torque value and speed value of the input end of the hydraulic pump (32), as well as the hydraulic pressure value and hydraulic flow value of the output end of the hydraulic pump (32).

Images