Rack matching comparison test method of electric forklift driving system
By acquiring the dynamic road spectrum of the whole vehicle and simulating the working conditions of the whole vehicle on the test bench, the problem of large error between the bench test results and the whole vehicle test results of the electric forklift drive system was solved, achieving more accurate system matching evaluation and reducing the risk of new product development.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- ANHUI HELI CO LTD
- Filing Date
- 2026-03-16
- Publication Date
- 2026-05-26
AI Technical Summary
Existing bench tests of electric forklift drive systems cannot accurately reflect the real-world application of the vehicle, resulting in significant discrepancies between bench test results and vehicle test results.
By acquiring the dynamic road spectrum of the benchmark vehicle, the test bench is used to simulate the operating state of the drive system under actual vehicle conditions, and performance parameters are collected. The results are then compared with the dynamic road spectrum of the vehicle to determine the matching quality of the drive system under test.
It shields the influence of factors such as personnel, environment, and prototype differences in whole vehicle testing, improves the accuracy of test results, and can verify whether the design results meet the requirements in the early stage of new product development, reduce R&D risks, and shorten the R&D cycle.
Smart Images
Figure CN122084286A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of electric forklift drive technology, and in particular to a bench matching and comparison test method for an electric forklift drive system. Background Technology
[0002] Currently, in the electric forklift industry, the compatibility of the drive motor and electronic control system is determined by calibrating the steady-state performance points on a test bench. This method uses a motor-to-load test bench as the load for the tested motor, and the tested electronic control system controls the tested motor and drives the test bench, thus forming a closed-loop drive-load test system. Theoretically, provided the load motor performance is sufficient, this system can control and test the speed and torque of the tested motor and electronic control system at any performance point. The quality of the motor-electronic control system compatibility is evaluated by judging the accuracy of the parameters at each performance point during the test and calculating the efficiency.
[0003] Existing test benches calibrate and compare the performance points of motors and electronic controls, but these tests are conducted in a steady state at a certain performance point. This fails to reflect the actual state of the vehicle application and results in a large discrepancy between bench test results and vehicle test results. Summary of the Invention
[0004] In view of the above, the present invention aims to provide a bench matching and comparison test method for an electric forklift drive system to solve the aforementioned technical problems.
[0005] The technical solution adopted in this invention is as follows:
[0006] This invention provides a bench matching and comparison test method for an electric forklift drive system, including:
[0007] Obtain the dynamic road spectrum of the benchmark vehicle model;
[0008] The vehicle dynamic road spectrum is input to the test bench, and the test bench is controlled to simulate the operating state of the test drive system under actual vehicle conditions according to the vehicle dynamic road spectrum, and the performance parameters of the test drive system are collected.
[0009] The matching quality of the tested drive system is determined by comparing the performance parameters with the dynamic road spectrum of the whole vehicle.
[0010] Optionally, obtain the whole vehicle dynamic road spectrum of the benchmark model, including:
[0011] Select a benchmark vehicle model;
[0012] Control the benchmark vehicle to conduct a vehicle energy consumption test according to a preset test route;
[0013] Simultaneously collect dynamic data from the battery voltage, battery current, motor voltage, motor current, motor speed, accelerator pedal voltage, and torque sensor of the reference vehicle model on the same time axis;
[0014] The collected data is processed to remove outliers and smooth the curves, forming a dynamic road spectrum of the benchmark model.
[0015] Optionally, the test bench is controlled to simulate the operating state of the electronic control system of the drive system under test in the actual working conditions of the vehicle, including:
[0016] The test bench adjusts the input signal of the electronic control of the test drive system according to the accelerator pedal voltage signal in the dynamic road spectrum of the whole vehicle, so as to control the motor speed of the test drive system.
[0017] The test bench controls the load torque of the dynamometer towed by the motor of the tested drive system based on the torque or speed changes in the dynamic road spectrum of the vehicle, thus simulating the resistance changes during the vehicle's driving process.
[0018] Optionally, collect performance parameters of the driver system under test, including:
[0019] The output voltage and output current of the battery simulator of the tested drive system;
[0020] The output voltage and output current of the electronic control system of the tested drive system;
[0021] The output speed and output torque of the motor of the drive system under test.
[0022] Optionally, the matching quality of the tested drive system is determined by comparing the performance parameters with the vehicle's dynamic road spectrum, including:
[0023] Based on the collected performance parameters, the energy consumption and system efficiency of the tested drive system are calculated.
[0024] The energy consumption and system efficiency are compared with the benchmark vehicle model to evaluate their matching performance.
[0025] Optionally, comparing the performance parameters with the vehicle dynamic road spectrum further includes:
[0026] The accuracy of the motor and electronic control system of the tested drive system in reproducing key operating conditions in the dynamic road spectrum of the whole vehicle is compared.
[0027] The above-described solution of the present invention has at least the following beneficial effects:
[0028] The above-described solution of the present invention obtains the dynamic road spectrum of a benchmark vehicle model; inputs the dynamic road spectrum to a test bench, controls the test bench to simulate the operating state of the tested drive system under actual vehicle conditions based on the dynamic road spectrum, and collects the performance parameters of the tested drive system; and compares the performance parameters with the dynamic road spectrum to determine the matching quality of the tested drive system. This solution shields all factors that may affect the test results during the vehicle test, such as operator, environment, and prototype differences. Using the dynamic road spectrum of the vehicle model as the basis for bench comparison and verification of the drive system of a vehicle model improves the accuracy of the test results. Attached Figure Description
[0029] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described below with reference to the accompanying drawings, wherein:
[0030] Figure 1 A flowchart of a bench matching and comparison test method for an electric forklift drive system provided in an embodiment of the present invention.
[0031] Figure 2 This is a schematic diagram of the structure of an electric forklift drive system provided in an embodiment of the present invention.
[0032] Figure 3 This is a schematic diagram of the structure of the test bench provided in an embodiment of the present invention. Detailed Implementation
[0033] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.
[0034] This invention proposes an embodiment of a bench matching and comparison test method for an electric forklift drive system. Specifically, as follows: Figure 1 As shown, it includes:
[0035] Step 11: Obtain the overall vehicle dynamics of the benchmark model;
[0036] Step 12: Input the vehicle dynamic road spectrum to the test bench, control the test bench to simulate the operating state of the test drive system under the actual working conditions of the vehicle according to the vehicle dynamic road spectrum, and collect the performance parameters of the test drive system.
[0037] Step 13: Based on the performance parameters, compare them with the dynamic road spectrum of the whole vehicle to determine the matching quality of the tested drive system.
[0038] like Figure 2As shown, the drive system of an electric forklift mainly consists of an electronic control unit, a motor, and a reduction gearbox. The control mode of the electric forklift drive system differs from that of an electric car. To ensure smooth and slow operation and safer contact with goods, the electric forklift uses simulated drive motor speed control. The accelerator pedal on the vehicle is actually a sliding resistor. By adjusting the resistance, different voltages can be generated as control signals for different target motor speeds. Different voltages correspond to different target speeds, and each control point has a linear relationship and is used one-to-one. To ensure comprehensive and accurate testing of the vehicle's road spectrum, a torque sensor 71 must be added to the normal system.
[0039] In the vehicle's operational state, the on-board battery 11 is connected to the positive and negative terminals of the electronic control unit 3 via two cables 2. The U, V, and W cables from the electronic control unit 3 are connected to the U, V, and W cables from the motor 5, respectively. The motor 5 is connected to the gearbox axle 8 assembly via a torque sensor 71, and the gearbox axle 8 assembly is connected to the drive wheel 91. When the vehicle is moving, the on-board battery provides electrical energy to the drive system. The target speed of the motor can be controlled by adjusting the throttle pedal, and the motor 5 converts the chemical energy of the battery into mechanical energy. The rotational mechanical energy of the motor 5 is transmitted to the drive wheel through the gearbox axle assembly, thus realizing the vehicle's movement and acceleration / deceleration. Since the forklift drive motor is speed-controlled, when the throttle pedal 4 is opened to a certain degree, for a certain target speed, when the motor encounters resistance, within the motor's power range, the electronic control unit will adjust the motor's input current to overcome the resistance and maintain the speed.
[0040] The vehicle dynamic road spectrum is a sequence of dynamic parameters collected from vehicle energy consumption tests, reflecting the vehicle's operating status under actual working conditions. In this embodiment, the dynamic road spectrum of a vehicle of the same tonnage is used as a comparison benchmark. It is input into the test bench as a basis for comparing the performance of motors and electronic controls. The accuracy, energy consumption, and efficiency of different motors and electronic controls in reproducing the vehicle's dynamic road spectrum are used to determine the quality of matching between different motors and electronic controls. This is used to determine whether the design requirements are met or to make improvements and optimizations.
[0041] Specifically, in step 11, because forklift products of different tonnages have significant differences in weight and power performance, the standard whole machine energy consumption test route must be divided according to products of the same tonnage. It is not possible to reproduce and compare the whole vehicle route across tonnages. For example, when testing the drive system of a 3.5t electric forklift on a test bench, only the energy consumption route of the 3.5t electric forklift can be selected for working condition reproduction and energy consumption comparison.
[0042] The vehicle energy consumption test route spectrum is derived from a benchmark model. For each tonnage, the benchmark model should be selected based on positive market feedback or high sales volume, providing a basis for comparison. The vehicle test route should be a standardized route as defined by industry or company standards, ensuring a relatively accurate assessment of vehicle energy consumption. Drivers must be experienced enough to effectively control the vehicle's operating rhythm and guarantee consistency across each test cycle. All vehicle parameters used for route spectrum collection must meet factory requirements. An electric power tester mounted on the vehicle will be used to collect dynamic data on battery output voltage, electronic control voltage, electronic control current, motor voltage, motor current, motor speed, and motor torque via various sensors and the CAN bus. All collected data must correspond one-to-one on the same timeline, with a sampling frequency of at least 20Hz. The road spectrum needs to be collected continuously multiple times. Three to five test cycles with good repeatability and consistency are selected as road spectrum units. Abnormal and abrupt points in the road spectrum are removed or smoothed. Finally, the standard whole vehicle energy consumption test road spectrum is formed by splicing multiple unit cycles. It is poured into the test bench for judging the matching performance of different motors and electronic controls.
[0043] When the vehicle is tested for energy consumption along a certain route, the electric power tester and the vehicle's CAN bus simultaneously collect data on battery voltage, battery current, motor voltage, motor current, motor speed, accelerator pedal voltage, and dynamic data from the torque sensor under a certain cycle condition in the same time domain at a sampling frequency of not less than 20Hz. After anomaly point processing, this data is used as the standard energy consumption test route spectrum for the entire vehicle.
[0044] In step 12, the dynamic road spectrum of the entire vehicle is input to the test bench. The test bench is controlled to simulate the operating state of the tested drive system under actual vehicle conditions based on the dynamic road spectrum, and the performance parameters of the tested drive system are collected. Different tested motors and electronic controls reproduce the energy consumption test road spectrum of the entire vehicle on the test bench. Essentially, this is to simulate the same road spectrum on the same test bench, thereby eliminating the influence of personnel, prototypes, and environment on the test results in the whole vehicle test, so as to achieve an accurate judgment of the test results. Therefore, there are two main objectives for conducting tests on the test bench: first, to see whether the tested motor and electronic control can achieve the performance of the benchmark vehicle; and second, based on achieving this performance, to evaluate whether the tested component is more energy-efficient.
[0045] like Figure 3As shown, when the test bench is working, the battery simulator 12 simulates the vehicle battery and supplies power to the electronic control unit 3 via cable 2. The electronic control unit controls the motor 5 via the connector of cable 2. The motor 5 is connected to the dynamometer 72 via a speed and torque meter 6. The dynamometer 72 is torque-controlled by a frequency converter 92, which is connected to the dynamometer 72 via cable 2. The industrial electrical component 102 provides power to the entire test system. The test bench control system 112 can control the battery simulator voltage, the controller's throttle pedal voltage, the motor speed, and the dynamometer torque in real time according to the road spectrum. At the same time, it also collects the output current of the battery simulator and the output voltage and current of the electronic control unit. The test bench control system controls the motor speed by adjusting the throttle pedal voltage of the electronic control unit, and at the same time, the test bench control system can control the torque of the dynamometer via the frequency converter.
[0046] For example Figure 3 As shown, during the test, the battery simulator, electronic control, and motor were tested in three independent test cycles, and the three test cycles did not interfere with each other.
[0047] The battery simulator test cycle includes the battery simulator, electronic control, motor, and test bench control system, and independently detects the output current of the battery simulator; the electronic control test cycle includes the electronic control and test bench control system, and independently detects the output voltage and current of the electronic control; the motor test cycle includes the motor, speed and torque meter, dynamometer, and test bench control system, and independently detects the speed and torque of the motor.
[0048] In step 13, if the tested motor and electronic control system can reproduce the entire vehicle road spectrum within a certain accuracy range on the test bench, the performance of the tested system compared to the benchmark vehicle model can be proven. The test bench dynamically simulates changes in battery voltage, the output speed of the tested motor, and the load torque. Through parameter acquisition from various sensors, it calculates the output power of the battery simulator, the output power of the electronic control system, and the output energy of the motor during the test, as well as the efficiency of the electronic control system, motor, and system. This allows for a comparison of the energy consumption of the tested system and the entire vehicle road spectrum, thereby determining the superiority and detailed differences between the tested system and the standard vehicle system.
[0049] The bench matching and comparison test method for the electric forklift drive system in this embodiment shields all factors that may affect the test results during the whole vehicle test, such as operator, environment, and prototype differences. Using the whole vehicle dynamic spectrum as the basis for bench comparison and verification of a vehicle's drive system can improve the accuracy of the test results. It can verify whether the design results meet the requirements in the early stages of new product development, thereby reducing the risk of new product development and shortening the development cycle.
[0050] An embodiment of the present invention also provides a computing device, including: a processor and a memory storing a computer program, wherein the computer program, when executed by the processor, performs the method described in the above embodiments. All implementations in the above method embodiments are applicable to this embodiment and can achieve the same technical effect.
[0051] In this embodiment of the invention, a computer-readable storage medium is also provided, storing instructions that, when executed on a computer, cause the computer to perform the method described in the above embodiments. All implementations of the methods described in the above embodiments are applicable to this embodiment and can achieve the same technical effect.
[0052] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.
[0053] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.
[0054] In the embodiments provided by this invention, it should be understood that the disclosed apparatus and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative. For instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between devices or units may be electrical, mechanical, or other forms.
[0055] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.
[0056] In addition, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.
[0057] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, essentially, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, ROM, RAM, magnetic disks, or optical disks.
[0058] Furthermore, it should be noted that in the apparatus and method of the present invention, it is obvious that the components or steps can be decomposed and / or recombined. These decompositions and / or recombinations should be considered equivalent solutions of the present invention. Moreover, the steps performing the above series of processes can naturally be executed in the order described, but are not necessarily required to be executed in chronological order; some steps can be executed in parallel or independently of each other. Those skilled in the art will understand that all or any step or component of the method and apparatus of the present invention can be implemented in any computing device (including processors, storage media, etc.) or network of computing devices, in hardware, firmware, software, or a combination thereof. This is something that those skilled in the art can achieve by using their basic programming skills after reading the description of the present invention.
[0059] Therefore, the object of the present invention can also be achieved by running a program or a set of programs on any computing device. The computing device can be a known general-purpose device. Therefore, the object of the present invention can also be achieved simply by providing a program product containing program code implementing the method or apparatus. That is, such a program product also constitutes the present invention, and the storage medium storing such a program product also constitutes the present invention. Obviously, the storage medium can be any known storage medium or any storage medium developed in the future. It should also be noted that in the apparatus and method of the present invention, it is obvious that the components or steps can be decomposed and / or recombined. These decompositions and / or recombinations should be considered equivalent to the present invention. Furthermore, the steps performing the above series of processes can naturally be performed in the order described, but are not necessarily required to be performed in chronological order. Some steps can be performed in parallel or independently of each other.
[0060] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.
Claims
1. A bench matching and comparison test method for an electric forklift drive system, characterized in that, include: Obtain the dynamic road spectrum of the benchmark vehicle model; The vehicle dynamic road spectrum is input to the test bench, and the test bench is controlled to simulate the operating state of the test drive system under actual vehicle conditions according to the vehicle dynamic road spectrum, and the performance parameters of the test drive system are collected. The matching quality of the tested drive system is determined by comparing the performance parameters with the dynamic road spectrum of the whole vehicle.
2. The bench matching and comparison test method for the electric forklift drive system according to claim 1, characterized in that, Obtain the whole vehicle dynamic road spectrum of the benchmark model, including: Select a benchmark vehicle model; Control the benchmark vehicle to conduct a vehicle energy consumption test according to a preset test route; Simultaneously collect dynamic data from the battery voltage, battery current, motor voltage, motor current, motor speed, accelerator pedal voltage, and torque sensor of the reference vehicle model on the same time axis; The collected data is processed to remove outliers and smooth the curves, forming a dynamic road spectrum of the benchmark model.
3. The bench matching and comparison test method for the electric forklift drive system according to claim 1, characterized in that, Controlling the test bench to simulate the operating state of the electronic control system of the drive system under test in the actual working conditions of the vehicle includes: The test bench adjusts the input signal of the electronic control of the test drive system according to the accelerator pedal voltage signal in the dynamic road spectrum of the whole vehicle, so as to control the motor speed of the test drive system. The test bench controls the load torque of the dynamometer towed by the motor of the tested drive system based on the torque or speed changes in the dynamic road spectrum of the vehicle, thus simulating the resistance changes during the vehicle's driving process.
4. The bench matching and comparison test method for the electric forklift drive system according to claim 1, characterized in that, Collect performance parameters of the driver system under test, including: The output voltage and output current of the battery simulator of the tested drive system; The output voltage and output current of the electronic control system of the tested drive system; The output speed and output torque of the motor of the drive system under test.
5. The bench matching and comparison test method for the electric forklift drive system according to claim 1, characterized in that, Based on the comparison between the performance parameters and the dynamic road spectrum of the whole vehicle, the matching quality of the tested drive system is determined, including: Based on the collected performance parameters, the energy consumption and system efficiency of the tested drive system are calculated. The energy consumption and system efficiency are compared with the benchmark vehicle model to evaluate their matching performance.
6. The bench matching and comparison test method for the electric forklift drive system according to claim 1, characterized in that, Based on the comparison between the performance parameters and the vehicle dynamic road spectrum, the method further includes: The accuracy of the motor and electronic control system of the tested drive system in reproducing key operating points in the dynamic road spectrum of the whole vehicle is compared.