Automatic forklift truck system comprehensive performance detection device and method

Abstract

The application discloses a kind of automatic fork truck whole vehicle system comprehensive performance detection equipment and method, belong to logistics and storage machinery test technical field, equipment includes test track, prevents and integrates support assembly with guide, distributed sensor and trigger system and central control system;Test track includes horizontal section and the slope section containing uphill, downhill, and guide rail is provided with full length;Central control system is connected with fork truck control system by communication interface, realizes "driving-lifting" collaborative control and data synchronous acquisition.Method includes integrated calibration, program preset, automatic coupling test, data acquisition and correlation analysis steps, by simulating climbing uphill lifting, downhill recycling etc. Real working condition, collect multi-system operation parameters, combined with key component wear quantitative analysis, establish "working condition-wear" mapping relationship.The application realizes the integrated detection of fork truck whole system, solves the defects of traditional item test, improves test authenticity and evaluation accuracy, adapts to different models of fork truck.

Description

Technical Field

[0001] This invention relates to the field of testing logistics and warehousing machinery, and in particular to a comprehensive performance testing device and method for an automatic forklift system. Background Technology

[0002] As the mainstream material handling equipment, electric hydraulic forklifts operate under a dynamic composite working condition of "carrying a load + loading and unloading on ramps + lifting the forks". Their reliability depends on the collaborative working ability of multiple systems such as electric drive, hydraulics, structure and control under complex dynamic working conditions.

[0003] In existing technologies, the testing of electric hydraulic forklifts mostly adopts a component-based testing approach. The walking performance test is only conducted on flat ground, the hydraulic lifting test is a static lifting load test, and the electronic control system is only used for basic function verification. It cannot simulate the core complex working condition of "lifting / lowering the forks while driving on a slope". As a result, cross-system failures under complex stress (such as accelerated wear of seals caused by uneven load on the cylinder during ramp lifting) are difficult to detect. Secondly, existing testing focuses more on whether the functions are implemented and whether the short-term parameters meet the standards. It lacks the ability to simultaneously collect dynamic data of multiple systems (such as drive current, hydraulic pressure, and structural vibration) in long-term, cyclic, and variable load tests. As a result, there is a lack of data support for predicting the life and reliability of the whole vehicle, and potential failures are difficult to predict in the early stage.

[0004] Therefore, there is an urgent need for an integrated solution that can accurately adapt to the structural characteristics of electric hydraulic forklifts and achieve coordinated detection of the entire system, in order to solve many of the shortcomings of existing technologies. Summary of the Invention

[0005] The purpose of this invention is to provide a comprehensive performance testing device and method for an automated forklift system to solve the problems in the background art.

[0006] To achieve the above objectives, the present invention provides a comprehensive performance testing device for an automated forklift system, comprising a test track, a distributed sensor and triggering system, an anti-deviation guide and integrated support assembly, and a central control system; the test track includes a horizontal section and a ramp section; a guide rail is provided along the length of the test track to constrain the travel trajectory of the tested electric hydraulic forklift throughout the entire process; The anti-deviation guide and integrated bracket assembly includes an auxiliary bracket connected to the frame of the tested electric hydraulic forklift. The lower end of the auxiliary bracket is provided with a guide component that cooperates with the guide rail. A central control box is integrated and installed on the auxiliary bracket. The distributed sensing and triggering system includes a position triggering sensor located at a predetermined position on the track, as well as various types of monitoring sensors; The central control system is located inside the central control box and is electrically connected to the position trigger sensor, the monitoring sensor, and the tested electric hydraulic forklift.

[0007] Preferably, the tested electric hydraulic forklift includes a walking system, a lifting system, and a self-control system; the lifting system is driven by a hydraulic cylinder, with a load-bearing component connected to the front end of the hydraulic cylinder; the walking system includes walking wheels and a walking motor connected to the walking wheels.

[0008] Preferably, the central control system is connected to the self-control system of the tested electric hydraulic forklift via a communication interface, and indirectly controls the operation of the travel motor and the lifting action of the hydraulic cylinder by sending control commands, so as to coordinate the control of the tested electric hydraulic forklift to perform travel and lifting actions.

[0009] Preferably, the central control system is configured as follows: Based on the signal from the position-triggered sensor, the tested electric hydraulic forklift is controlled to automatically reciprocate and change speed on the test track according to a preset program. When the tested electric hydraulic forklift travels to a preset point determined based on a position trigger signal, the tested electric hydraulic forklift is automatically triggered to perform a lifting action; Data from monitoring sensors is collected synchronously and stored in association with timestamps to achieve a one-to-one correspondence between track position, driving status, lifting status and multiple system operating parameters.

[0010] Preferably, the monitoring sensors include an oil pressure sensor installed on the hydraulic cylinder of the electro-hydraulic forklift under test, an electrical parameter sensor installed on the travel motor circuit of the electro-hydraulic forklift under test, an angle sensor installed on the chassis of the electro-hydraulic forklift under test, and a vibration sensor installed on the key mechanical components of the electro-hydraulic forklift under test.

[0011] Preferably, the auxiliary support is a rigid frame structure, used to stably support the central control box and cooperate with the guide assembly to achieve the anti-deviation function; the guide assembly is a guide wheel set, which rolls with the guide rail to constrain the tested electric hydraulic forklift to travel along the rail in a directional manner and avoid deviating from the trajectory.

[0012] Preferably, the test track includes an uphill section, a level section, and an downhill section.

[0013] Preferably, it also includes a load simulation module, which is a fork-type counterweight box adapted to the fork assembly of the electro-hydraulic forklift under test, and the counterweight box is provided with adjustable counterweight blocks.

[0014] Preferably, the position trigger sensor is an infrared sensor or an RFID tag reader, which is spaced apart along the length of the test track, with a positioning accuracy of ≤±5cm; the sampling frequency of the vibration sensor is ≥1kHz, and the measurement accuracy of the electrical parameter sensor is ±0.5%FS.

[0015] Based on the aforementioned comprehensive performance testing equipment for automated forklift systems, this invention proposes a testing method comprising the following steps: S1. Integration and Calibration: Place the electric hydraulic forklift under test at the starting position of the test track, install and lock the counterweight box, connect the various systems and complete the sensor calibration; S2. Program preset: Preset test parameters in the central control system, including number of cycles, track gradient, travel speed of each section, trigger position and parameters of lifting and lowering actions, alarm threshold of monitoring parameters; and collaborative control logic to trigger lifting and lowering actions at specific positions on the test track; S3. Perform automated coupling test: Control the tested electric hydraulic forklift to automatically reciprocate on the track. Its travel speed is set to the first speed in the horizontal and stable section, and the second speed in the inclined uphill and inclined downhill sections. The second speed is less than the first speed. When it travels to the preset trigger position, it is automatically controlled to perform lifting action to realize the dynamic coupling test of travel-lifting. S4. Data Synchronization Acquisition: During the test, the driving parameters (speed, position), lifting status parameters (lifting height, number of cylinder actions), and multi-system operating parameters (oil pressure, current, vibration, tilt angle) of the tested electric hydraulic forklift are synchronously collected and stored according to timestamps. S5. Correlation Analysis: After the test is completed, the key components are disassembled for wear quantification measurement. Using multiple linear regression or vibration spectrum analysis algorithms, the measurement results are correlated with the corresponding operating data stored in S4 to establish a "operating parameters-wear amount" mapping model to evaluate component life and vehicle reliability.

[0016] Preferably, in step S2, the preset trigger positions are set at the beginning end, the starting area of ​​the uphill section, the middle area of ​​the downhill section, and the end end to simulate operation, uphill lifting, and downhill recovery conditions.

[0017] Preferably, in step S5, the key components include at least the walking motor bearing and the lifting cylinder seal; the correlation analysis includes regression analysis of bearing wear and historical vibration spectrum changes, and comparison of seal condition with historical oil pressure fluctuations.

[0018] Therefore, the comprehensive performance testing equipment and method for an automated forklift system of the present invention has the following beneficial effects: (1) Through the track design of “horizontal section + uphill section + downhill section” and the dynamic coupling test of “driving-lifting”, the core working conditions in the actual operation of forklifts are accurately reproduced, which solves the defect that traditional sub-item test cannot simulate composite stress, and the test results are more valuable for reference.

[0019] (2) Integrating test track, anti-deviation guidance, sensor acquisition, load simulation and central control modules, it realizes integrated testing of the four major systems of walking, lifting, power and control, and can detect cross-system related faults, significantly improving the comprehensiveness of testing.

[0020] (3) By combining multi-sensor synchronous acquisition with quantitative measurement of wear of key components, a “working condition-wear” mapping relationship is established, upgrading the detection from the traditional “qualification judgment” to “life prediction”, providing data support for product optimization design, quality control and predictive maintenance.

[0021] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the structure of an embodiment of the present invention; Figure 2 This is a schematic diagram of the test track and guide rail according to an embodiment of the present invention; Figure 3 This is a schematic diagram showing the connection between the guide assembly and the guide rail according to an embodiment of the present invention; Figure 4 This is a block diagram illustrating the principle of the central control system according to an embodiment of the present invention; Figure label: 1. Test track; 2. Auxiliary support; 3. Central control box; 4. Guide assembly; 5. Guide rail; 6. Electric hydraulic forklift under test; 61. Load simulation module; 62. Hydraulic cylinder; 63. Travel motor. Detailed Implementation

[0023] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of the present invention, but not all embodiments.

[0025] Example like Figures 1-4 As shown, a comprehensive performance testing device for an automated forklift system is provided for testing an electro-hydraulic forklift 6. The electro-hydraulic forklift 6 is controlled by a hydraulic cylinder 62 for lifting and lowering. The front end of the hydraulic cylinder 62 is connected to a load-bearing component, and the walking motor 63 and the walking wheels cooperate to achieve walking. The performance testing device includes a test track 1, a distributed sensor and triggering system, an anti-deviation guide and integrated support assembly, and a central control system.

[0026] The main body of test track 1 is a high-strength steel welded frame, which includes a horizontal section and a ramp section along its length. The ramp section is set as an inclined uphill section, a horizontal stable section and an inclined downhill section. The slope can be set within the range of 5% to 15% according to the maximum climbing ability of the forklift being tested. It can fully simulate the full working conditions of forklift driving straight, climbing uphill to load goods, and going downhill to unload goods.

[0027] A grooved, T-shaped, or L-shaped guide rail 5 is fixedly installed along the entire length of the test track 1. In this embodiment, a grooved guide rail is used to constrain the travel trajectory of the tested electric hydraulic forklift 6 throughout the entire process, avoid lateral deviation or derailment, and ensure test stability.

[0028] The anti-deviation guide and integrated bracket assembly includes an auxiliary bracket 2 that is fixedly connected to the frame of the tested electric hydraulic forklift 6. The auxiliary bracket 2 is a rigid frame structure with sufficient strength to support the central control box 3 and work with the guide assembly 4 to achieve the anti-deviation function. It is fixedly installed on the rear of the frame of the tested electric hydraulic forklift 6 through detachable connectors (such as high-strength bolts or quick-locking clamps).

[0029] The lower end of the auxiliary bracket 2 is provided with a guide assembly 4 that cooperates with the guide rail 5. In some embodiments, the lower ends of the auxiliary bracket 2 are provided with several sets of guide wheels on both sides through mounting plates, mounting shafts and bearings to form a guide wheel assembly. The guide wheel assembly can be finely adjusted laterally through the oblong holes on the mounting plate or the screw adjustment mechanism to ensure that it can tightly and smoothly mesh with the guide rails 5 on both sides of the track, thereby achieving anti-deviation guidance.

[0030] The upper part of the auxiliary bracket 2 is designed with an installation platform for firmly installing the central control box 3, so as to achieve compact integration of the test equipment and the forklift under test, without occupying the forklift's operating space or affecting its original function.

[0031] The distributed sensor and triggering system includes multiple position trigger sensors, which are positioned at predetermined locations beside the track according to actual working conditions. These sensors are used to accurately detect the forklift's travel position and trigger lifting actions, ensuring coordinated "travel-lifting" control. In some embodiments, the position trigger sensors are preferably infrared through-beam sensors or RFID readers. They are installed beside the track at predetermined intervals or at key working points (such as the start and end points of a slope) and connected to the central control system via cables.

[0032] Multiple types of monitoring sensors are also installed on the tested electric hydraulic forklift 6, including oil pressure sensors (which can be installed on the oil inlet or return line of the lifting cylinder 62 through a three-way pipe connector to monitor changes in hydraulic system pressure), electrical parameter sensors (which use clamp-on current transformers to be fitted onto the main power supply cable of the travel motor 63 to collect electrical parameters such as current and voltage), tilt sensors (which are fixed to the center of the forklift chassis with base bolts to monitor the driving posture on slopes), and vibration sensors (which use magnetic bases or threads to be installed on key parts such as the bearing housing of the travel motor 63 and the drive axle housing to capture vibration signals during equipment operation). The signal lines of all monitoring sensors are connected to the central control system to achieve comprehensive acquisition of operating parameters of multiple systems.

[0033] The load simulation module 61 is configured as a fork-sleeve type counterweight box adapted to the fork assembly of the tested electric hydraulic forklift. The counterweight box contains adjustable counterweight blocks, and the total load weight can be adjusted within the range of 50% to 100% of the rated load by adding or removing counterweight blocks. The bottom of the box is equipped with anti-slip rubber pads, and the sides are equipped with adjustable nylon fastening straps for securing it to the forks.

[0034] The central control system is located within the central control box 3. In some embodiments, the hardware of the central control system is based on a programmable logic controller (PLC) or an industrial computer (IPC). It receives signals from position trigger sensors via digital input modules and receives and processes analog signals from each monitoring sensor via input signal processing modules (such as analog input modules or dedicated acquisition cards). The central control system is equipped with a communication module (such as a CAN bus module or an Ethernet module). This communication module establishes a data connection with the control system of the tested electric hydraulic forklift 6.

[0035] The central control system employs conventional methods in this field for program configuration. It can determine the vehicle's status based on position signals and send formatted control command frames (e.g., commands containing target speed and target lifting height) to the forklift control system. Upon receiving the commands, the forklift control system automatically controls its travel motor 63 and hydraulic cylinder 62, thereby achieving automated coordinated testing of "travel-lifting"; specifically: a) The central control system controls the tested electric hydraulic forklift 6 to automatically reciprocate and change speed on the test track 1 according to the signal from the position trigger sensor. b) When the tested electric hydraulic forklift 6 travels to the preset point determined based on the position trigger signal, the tested electric hydraulic forklift 6 is automatically triggered to perform a lifting action; c) Synchronously collect and store data from monitoring sensors according to timestamps (data storage module in the central control system) to provide complete data support for subsequent analysis.

[0036] This embodiment uses a 2-ton electric hydraulic forklift with a track gradient of 12% as an example to illustrate the testing process of the present invention, as follows: S1. Integration and Calibration: Drive the electric hydraulic forklift 6 under test to the starting position of test track 1, put the fork sleeve counterweight box on the fork assembly, add counterweight blocks to 1.4 tons, and lock them with fastening straps; install auxiliary bracket 2 and adjust guide wheel group; connect the central control system with the forklift control system and each sensor, complete zero-point calibration and communication test, and ensure normal system operation.

[0037] S2. Program Preset: Edit the test program through the human-machine interface of the central control system and set the parameters as follows: 3000 cycles; set the speed curve (3km / h for horizontal section and 1.5km / h for slope section); the cooperative control logic is "trigger lift at the beginning of the uphill section - hold for 3 seconds - descend, trigger a second lift in the middle of the downhill section - hold for 2 seconds - descend".

[0038] S3. Automated Coupling Test: After the test is started, the forklift automatically travels back and forth along the track. It travels at a constant speed of 3 km / h on horizontal sections and at 1.5 km / h on ramp sections. When it reaches the preset trigger position, it automatically executes the fork lifting action to achieve dynamic coupling of "travel-lifting". The test is completed in 3000 cycles.

[0039] S4. Data Synchronization Acquisition: During the test, the system synchronously collects and stores driving parameters (speed, position), lifting status parameters (lifting height, number of actions) and multi-system operating parameters (cylinder oil pressure, motor current, vehicle body tilt angle, vibration spectrum) according to timestamps, forming a complete test database.

[0040] S5. Correlation Analysis and Evaluation: After the test, the travel motor bearing and the main lifting cylinder seal were disassembled. The wear was quantified using precision measuring tools (bearing wear was 0.0018mm, and the seal showed no obvious aging). The wear data was correlated with the vibration spectrum of the corresponding working condition (the characteristic frequency amplitude of the vibration signal at the bearing during each ramp lift) and the hydraulic pressure fluctuation data (the pressure impact peak of cylinder 62 during each action) extracted from the database to establish a "working condition-wear" mapping relationship. The remaining component life and overall vehicle reliability of the forklift under the same working conditions were predicted. The evaluation results met the industry standard requirements.

[0041] Therefore, the present invention provides an automatic forklift system comprehensive performance testing equipment and method. Through the track design of "horizontal section + uphill section + downhill section" and "driving-lifting" dynamic coupling test, it accurately reproduces the core working conditions of the forklift in actual operation, and solves the defect of traditional sub-item test that cannot simulate composite stress. The fully automated testing process greatly reduces manual intervention, improves testing efficiency, and ensures the objectivity and consistency of test data, meeting the needs of batch testing by manufacturing enterprises and standardized testing by third-party certification bodies in multiple scenarios.

[0042] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. A comprehensive performance testing device for an automatic forklift system, used for testing an electro-hydraulic forklift under test, characterized in that: It includes a test track, a distributed sensor and triggering system, an anti-deviation guide and integrated support assembly, and a central control system; the test track includes a horizontal section and a ramp section; guide rails are provided along the length of the test track; The anti-deviation guide and integrated bracket assembly includes an auxiliary bracket connected to the frame of the tested electric hydraulic forklift. The lower end of the auxiliary bracket is provided with a guide component that cooperates with the guide rail. A central control box is integrated and installed on the auxiliary bracket. The distributed sensing and triggering system includes a position triggering sensor located at a predetermined position on the track, as well as various types of monitoring sensors; The central control system is located inside the central control box and is electrically connected to the position trigger sensor, the monitoring sensor, and the tested electric hydraulic forklift.

2. The comprehensive performance testing equipment for an automatic forklift system according to claim 1, characterized in that: The central control system is connected to the control system of the tested electric hydraulic forklift via a communication interface.

3. The comprehensive performance testing equipment for an automatic forklift system according to claim 1, characterized in that: The central control system is configured as follows: Based on the signal from the position-triggered sensor, the tested electric hydraulic forklift is controlled to automatically reciprocate and change speed on the test track according to a preset program. When the tested electric hydraulic forklift travels to a preset point determined based on a position trigger signal, the tested electric hydraulic forklift is automatically triggered to perform a lifting action; Data from monitoring sensors is collected synchronously and stored in conjunction with other data.

4. The comprehensive performance testing equipment for an automated forklift system according to claim 1, characterized in that: The monitoring sensors include a hydraulic pressure sensor installed on the hydraulic cylinder of the electric hydraulic forklift under test, an electrical parameter sensor installed on the travel motor circuit of the electric hydraulic forklift under test, a tilt sensor installed on the chassis of the electric hydraulic forklift under test, and a vibration sensor installed on the key mechanical components of the electric hydraulic forklift under test.

5. The comprehensive performance testing equipment for an automatic forklift system according to claim 1, characterized in that: The auxiliary support is a rigid frame structure.

6. The comprehensive performance testing equipment for an automated forklift system according to claim 1, characterized in that: The test track includes an uphill section, a level and stable section, and an downhill section.

7. The comprehensive performance testing equipment for an automatic forklift system according to claim 1, characterized in that: It also includes a load simulation module, which is a fork-type counterweight box adapted to the fork assembly of the electro-hydraulic forklift under test. The counterweight box is equipped with counterweight blocks that can be added or removed.

8. A testing method based on the comprehensive performance testing equipment for an automated forklift system according to any one of claims 1-7, characterized in that, Includes the following steps: S1. Integration and Calibration: Place the electric hydraulic forklift under test at the starting position of the test track, install and lock the counterweight box, connect the various systems and complete the sensor calibration; S2, Program Preset: Preset test parameters in the central control system, as well as the collaborative control logic that triggers lifting and lowering actions at specific positions on the test track; S3. Perform automated coupling test: Control the tested electric hydraulic forklift to automatically reciprocate on the track, and when it reaches the preset trigger position, automatically control it to perform fork lifting action to realize dynamic coupling test of driving-lifting. S4. Data Synchronous Acquisition: During the test, the driving parameters, lifting status parameters, and multi-system operating parameters from the monitoring sensors of the tested electric hydraulic forklift are synchronously acquired, associated, and stored. S5. Correlation Analysis and Evaluation: After the test is completed, the key components are disassembled for wear quantification measurement, and the measurement results are correlated with the corresponding operating data stored in S4 to evaluate the component life and vehicle reliability.

9. The detection method according to claim 8, characterized in that: In S2, the preset trigger position is set in the starting area of ​​the inclined uphill section and the middle area of ​​the inclined downhill section to simulate the climbing lifting and downhill recovery conditions.

10. The detection method according to claim 8, characterized in that: In S5, the key components include at least the travel motor bearing and the lifting cylinder seal; the correlation analysis includes correlating the bearing wear with the historical vibration spectrum change and comparing the seal status with the historical oil pressure fluctuation.

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