A forklift charger charging gun dust cover state detection system and method
By using multi-parameter fusion detection of voltage divider sensors, current sensors, and Hall effect proximity sensors, the problem of real-time detection of the dust cover status of the national standard charging gun of forklift chargers has been solved, achieving high-reliability and low-cost dust cover status monitoring, and ensuring the stability and safety of the charging system.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-29
- Publication Date
- 2026-06-09
AI Technical Summary
Existing technologies are insufficient for reliable, low-cost, and adaptable real-time monitoring of the dust cover status of the national standard charging gun for forklift chargers in the industrial logistics field. Especially under conditions of frequent movement and vibration, there are problems such as false alarms, missed alarms, and the inability to track changes in the dust cover status in real time.
The main control module combines a voltage divider sensor, a current sensor, and a Hall proximity sensor. It achieves accurate determination of the dust cover status by integrating multiple parameters such as CC1/CC2 voltage, charging current, and Hall proximity switch, powered by the charger's 12V power supply.
It improves the accuracy of dust cover status judgment, reduces hardware and usage costs, and can monitor the dynamic changes of the dust cover in real time during charging, ensuring the stability and safety of the charging system.
Smart Images
Figure CN122171898A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of safety monitoring technology for charging equipment, specifically a system and method for detecting the status of the dust cover of a forklift charger's charging gun. Background Technology
[0002] In the industrial logistics sector, electric forklifts are increasingly widely used due to their environmental friendliness and high efficiency. The standard charging gun for forklift chargers, as a key interface component for replenishing the energy of electric forklifts, is crucial for stable operation. The dust cover on the charging gun is an important protective structure that ensures the performance and lifespan of the charging gun. From the perspective of forklift operating environments, they are often located in complex places such as factory workshops, logistics warehouses, and construction sites. Factory workshops may be filled with metal dust and oil particles, logistics warehouses contain a large amount of packaging debris and dust, and construction sites are even more dusty and susceptible to rain. If the dust cover of the charging gun is not properly closed, these impurities can easily enter the charging gun and adhere to the charging interface and the surface of circuit components. Metal dust can cause short circuits, oil can corrode metal contacts and reduce conductivity, and excessive accumulation of debris and dust can affect the heat dissipation of the charging gun, leading to charging failures, shortening the lifespan of the charging gun, and even threatening safety during the charging process. During the charging process, if the forklift driver fails to promptly replace the dust cover after charging due to haste or forgetfulness, the charging gun will remain exposed to harsh conditions. Although some charging guns are designed with a certain level of protection, prolonged exposure without protection will significantly reduce their protective performance. Furthermore, the current charging process lacks an effective monitoring and reminder mechanism for the dust cover's status, making it difficult to ensure that the dust cover is correctly returned to its original position after each charging cycle. From a technological perspective, while some protective measures and detection technologies exist for charging guns, devices for detecting the status of dust covers on forklift charging guns still have many shortcomings. Some detection methods rely on complex sensor arrays and precision circuits, which are costly and lack stability under conditions of frequent forklift movement and vibration, easily leading to false alarms and missed alarms. Some simple detection structures are limited by installation space and charging gun structure, making it difficult to adapt to diverse forklift charging gun models and unable to accurately obtain dust cover status information. Furthermore, some detection technologies can only perform detection when the charging gun is stationary, failing to track the dynamic changes in the dust cover status during forklift operation in real time. With the increasing trend of intelligent and unmanned development of forklifts, the requirements for automation and safety in the charging process are rising. Accurate monitoring of the charging gun dust cover status has become a necessary prerequisite for ensuring the reliable operation of the charging system and realizing intelligent charging management. Therefore, developing a highly reliable, adaptable, and cost-effective forklift charger standard charging gun dust cover status detection device is of significant practical importance and urgency. Summary of the Invention The purpose of this invention is to provide a system and method for detecting the status of the dust cover of a forklift charger charging gun, in order to solve the problems mentioned in the background art.
[0003] To achieve the above objectives, the present invention provides the following technical solution: A forklift charger charging gun dust cover status detection system includes a main control module and a voltage divider sensor, a current sensor, and a Hall proximity sensor that are connected to the main control module via a signal. The main control module is connected to a power supply circuit. The power supply circuit draws power from the low-voltage circuit inside the charger and supplies power to the main control module, as well as the voltage divider sensor, current sensor, and Hall proximity sensor. The voltage divider voltage sensor includes a CC1 voltage sensor and a CC2 voltage sensor. The CC1 voltage sensor is connected to the CC1 signal line at the charger end, and the CC2 voltage sensor is connected to the CC2 signal line at the battery end, for collecting the CC1 voltage and CC2 voltage respectively. The current sensor is connected in series in the charger output circuit to detect the charging current; The sensor body of the Hall proximity switch is located on the charging gun body and is used to detect the relative distance between the dust cover and the charging gun body.
[0004] As a further aspect of the present invention: the power supply circuit is connected to the 12V circuit in the charger, the power supply circuit is provided with a voltage conversion module, and the output voltage of the power supply circuit is connected to the main control module, the voltage divider voltage sensor, the current sensor, and the Hall proximity sensor through the voltage conversion module.
[0005] As a further embodiment of the present invention: the CC1 signal line includes a 12V power supply at the charger end, a first resistor R1, a second resistor R2, and a push-button switch; one end of R1 is connected to the 12V power supply, and the other end is connected to the CC1 voltage measurement point; R2 is connected in parallel with the push-button switch and then in series between the CC1 voltage measurement point and the battery end; the battery end is provided with a charger end R1, and the charger end R1 is connected to the CC1 voltage measurement point; the CC1 voltage sensor collects the voltage signal of the CC1 voltage measurement point.
[0006] As a further embodiment of the present invention: the CC2 signal line includes a 12V power supply at the battery end, a third resistor R3 and a fifth resistor R5; one end of R5 is connected to the 12V power supply at the battery end, and the other end is connected in series with R3 at the charger end through the charging gun plug, and the other end of R3 is grounded; the CC2 voltage sensor collects the voltage signal of the connection node between R3 and the plug.
[0007] As a further aspect of the present invention: the current sensor is an SC780 model, connected in series in the charger output circuit, for detecting the charging current, and the main control module is an STM32F103 chip.
[0008] As a further aspect of the present invention: the Hall proximity switch is an NPN three-wire square magnetic sensor with an operating voltage of 5V and a detection distance of 0-15mm. The Hall proximity sensor body is attached to the charging gun latch, and the matching magnet is attached to the dust cover.
[0009] A method for detecting the status of the dust cover of a forklift charger's charging gun includes the following steps: Step 1: Real-time acquisition of CC1 voltage and CC2 voltage during the charging process using CC1 voltage sensor and CC2 voltage sensor, and acquisition of charging current using current sensor; Step 2: When the charging current drops to 0A, proceed to the charging end status judgment. Step 3: When charging is complete, if CC1 voltage = 12V and CC2 voltage = 0V are detected, it is determined that the charging gun has been completely disconnected from the battery. Step 4: The main control module supplies power to the Hall proximity switch and detects the output signal of the Hall proximity switch; if a low-level signal is received, it is determined that the dust cover is closed; if no low-level signal is received, it is determined that the dust cover is not closed.
[0010] As a further aspect of the present invention: in step 1, the states of the CC1 voltage and CC2 voltage during the charging process include: In standby mode, with the dust cover closed and the nozzle not inserted: CC1=6V, CC2=12V; With the dust cover removed, the button pressed and the nozzle not inserted: CC1=12V, CC2=12V; During charging, with the charging head fully inserted and the button released: CC1=4V, CC2=6V; When charging is complete and the charger is unplugged, but the button is pressed and the charger head is not completely disconnected: CC1=6V, CC2=6V; With the nozzle completely disconnected: CC1=12V, CC2=0V.
[0011] As a further aspect of the present invention: In step 3, the logic for determining that the charging gun is completely disconnected from the battery is as follows: the Hall proximity switch is triggered to supply power only when CC1=12V, CC2=0V and current=0A are simultaneously satisfied; when the distance between the magnet and the sensor body is ≤15mm, it is determined that the dust cover is closed.
[0012] Compared with the prior art, the beneficial effects of the present invention are: 1. This application uses a voltage divider sensor to monitor the CC1 / CC2 voltage and an SC780 sensor to detect the charging current. Combined with a Hall proximity switch, it realizes the dust cover status judgment. It uses the charger's 12V power supply, which is converted to power the module, so no additional power supply equipment is required.
[0013] 2. In the charging process, the CC1 / CC2 voltage changes in a stepwise manner with the insertion and removal of the charging gun and button operation. The charging status can be determined by the voltage change, and the charging end can be determined by the current sensor. Only when the charging gun is completely disconnected will the main control start the Hall sensor to detect whether the dust cover is closed. The accuracy of the judgment is improved by multi-parameter fusion judgment, and the hardware cost and usage cost are low. Attached Figure Description
[0014] Figure 1 This is a schematic diagram of the detection system in this embodiment; Figure 2 This is the circuit diagram for the CC1 voltage measurement in this embodiment; Figure 3 This is the circuit diagram for the CC2 voltage measurement in this embodiment; Detailed Implementation 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 only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0015] Please see Figure 1 In this embodiment of the invention, a forklift charger charging gun dust cover status detection system includes a main control module and a voltage divider voltage sensor, a current sensor, and a Hall proximity sensor that are connected to the main control module via signals. The main control module is connected to a power supply circuit. The main control module uses the STM32F103C8T6 chip, which integrates a 12-bit ADC (analog-to-digital converter) module for acquiring CC1 / CC2 voltage and current sensor signals and Hall sensor signals.
[0016] The power supply circuit is connected to the 12V circuit inside the charger. The power supply circuit is equipped with a voltage conversion module. The output voltage of the power supply circuit is converted from 12V to 5V / 3.3V through the voltage conversion module, which then powers the main control module, voltage divider sensor, current sensor, and Hall proximity sensor.
[0017] The voltage divider type voltage sensor includes a CC1 voltage sensor and a CC2 voltage sensor. The CC1 voltage sensor is connected to the CC1 signal line on the charger side, and the CC2 voltage sensor is connected to the CC2 signal line on the battery side, used to collect the CC1 voltage and CC2 voltage respectively. The CC1 signal line includes a 12V power supply on the charger side, a first resistor R1, a second resistor R2, and a push-button switch. One end of R1 is connected to the 12V power supply, and the other end is connected to the CC1 voltage measurement point. R2 is connected in parallel with the push-button switch and then in series between the CC1 voltage measurement point and the battery side. The battery side has a charger-side R1, which is connected to the CC1 voltage measurement point. The CC1 voltage sensor collects the voltage signal at the CC1 voltage measurement point. The CC2 signal line includes a 12V power supply on the battery side, a third resistor R3, and a fifth resistor R5. One end of R5 is connected to the 12V power supply on the battery side, and the other end is connected in series with R3 on the charger side through the charging gun plug. The other end of R3 is grounded. The CC2 voltage sensor collects the voltage signal at the connection point between R3 and the plug.
[0018] A current sensor is connected in series in the charger output circuit to detect the charging current. In this embodiment, an SC780 closed-loop Hall current sensor is used.
[0019] The sensor body of the Hall proximity switch is located on the charging gun body to detect the relative distance between the dust cover and the charging gun body. In this embodiment, the Hall proximity switch adopts a Bondos NPN three-wire square sensor with a working voltage of 5V, a detection distance of 0-15mm, and an NPN normally open output (low level when there is magnetism, high level when there is no magnetism). The sensor body of the Hall proximity switch is attached to the inside of the charging gun latch (where it contacts the dust cover) with double-sided adhesive. The neodymium iron boron magnet is attached to the corresponding position of the dust cover. When the cover is closed, the distance between the magnet and the sensor is ≤15mm.
[0020] The current sensor is model SC780, which is connected in series in the charger output circuit to detect the charging current. The main control module uses STM32F103 chip.
[0021] The Hall proximity switch is an NPN three-wire square magnetic sensor with an operating voltage of 5V and a detection distance of 0-15mm. The Hall proximity sensor body is attached to the charging gun latch, and the matching magnet is attached to the dust cover.
[0022] A method for detecting the status of the dust cover of a forklift charger's charging gun includes the following steps: Step 1: Real-time acquisition of CC1 voltage and CC2 voltage during the charging process using CC1 voltage sensor and CC2 voltage sensor, and acquisition of charging current using current sensor; The states of CC1 voltage and CC2 voltage during the charging process include: In standby mode, with the dust cover closed and the nozzle not inserted: CC1=6V, CC2=12V; With the dust cover removed, the button pressed and the nozzle not inserted: CC1=12V, CC2=12V; During charging, with the charging head fully inserted and the button released: CC1=4V, CC2=6V; When charging is complete and the charger is unplugged, but the button is pressed and the charger head is not completely disconnected: CC1=6V, CC2=6V; With the nozzle fully disconnected: CC1=12V, CC2=0V Step 2: When the charging current drops to 0A, proceed to the charging end status judgment. Step 3: When charging is finished, if CC1 voltage = 12V and CC2 voltage = 0V are detected, it is determined that the charging gun has been completely disconnected from the battery. The determination logic for the complete disconnection of the charging gun from the battery is: the Hall proximity switch is triggered to supply power only when CC1 = 12V, CC2 = 0V and current = 0A are simultaneously satisfied. Step 4: The main control module supplies power to the Hall proximity switch and detects the output signal of the Hall proximity switch; if a low-level signal is received, it is determined that the dust cover is closed; if no low-level signal is received, it is determined that the dust cover is not closed. In this embodiment, when the distance between the magnet and the sensor body is ≤15mm, it is determined that the dust cover is closed.
[0023] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims. Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.
Claims
1. A forklift charger charging gun dust cover status detection system, characterized in that, It includes a main control module and a voltage divider voltage sensor, a current sensor, and a Hall proximity sensor that are connected to the main control module via signals. The main control module is connected to a power supply circuit. The power supply circuit draws power from the low-voltage circuit inside the charger and supplies power to the main control module, as well as the voltage divider sensor, current sensor, and Hall proximity sensor. The voltage divider voltage sensor includes a CC1 voltage sensor and a CC2 voltage sensor. The CC1 voltage sensor is connected to the CC1 signal line at the charger end, and the CC2 voltage sensor is connected to the CC2 signal line at the battery end, for collecting the CC1 voltage and CC2 voltage respectively. The current sensor is connected in series in the charger output circuit to detect the charging current; The sensor body of the Hall proximity switch is located on the charging gun body and is used to detect the relative distance between the dust cover and the charging gun body.
2. The forklift charger charging gun dust cover status detection system according to claim 1, characterized in that, The power supply circuit is connected to the 12V circuit in the charger. The power supply circuit is equipped with a voltage conversion module. The output voltage of the power supply circuit is connected to the main control module, voltage divider voltage sensor, current sensor, and Hall proximity sensor through the voltage conversion module.
3. The forklift charger charging gun dust cover status detection system according to claim 1, characterized in that, The CC1 signal line includes a 12V power supply at the charger end, a first resistor R1, a second resistor R2, and a push-button switch; one end of R1 is connected to the 12V power supply, and the other end is connected to the CC1 voltage measurement point; R2 is connected in parallel with the push-button switch and then in series between the CC1 voltage measurement point and the battery end; the battery end has a charger end R1, which is connected to the CC1 voltage measurement point; the CC1 voltage sensor collects the voltage signal of the CC1 voltage measurement point.
4. The forklift charger charging gun dust cover status detection system according to claim 1, characterized in that, The CC2 signal line includes a 12V power supply for the battery, a third resistor R3, and a fifth resistor R5. One end of R5 is connected to the 12V power supply for the battery, and the other end is connected in series with R3 at the charger end through the charging gun plug. The other end of R3 is grounded. The CC2 voltage sensor collects the voltage signal between R3 and the plug connection node.
5. The forklift charger charging gun dust cover status detection system according to claim 1, characterized in that, The current sensor is an SC780 model, connected in series in the charger output circuit to detect the charging current. The main control module uses an STM32F103 chip.
6. The forklift charger charging gun dust cover status detection system according to claim 1, characterized in that, The Hall proximity switch is an NPN three-wire square magnetic sensor with a working voltage of 5V and a detection distance of 0-15mm. The Hall proximity sensor body is attached to the charging gun latch, and the matching magnet is attached to the dust cover.
7. A method for detecting the status of a forklift charger charging gun dust cover using the forklift charger dust cover status detection system according to any one of claims 1-6, characterized in that, Includes the following steps: Step 1: Real-time acquisition of CC1 voltage and CC2 voltage during the charging process using CC1 voltage sensor and CC2 voltage sensor, and acquisition of charging current using current sensor; Step 2: When the charging current drops to 0A, proceed to the charging end status judgment. Step 3: When charging is complete, if CC1 voltage = 12V and CC2 voltage = 0V are detected, it is determined that the charging gun has been completely disconnected from the battery. Step 4: The main control module supplies power to the Hall proximity switch and detects the output signal of the Hall proximity switch; if a low-level signal is received, it is determined that the dust cover is closed; if no low-level signal is received, it is determined that the dust cover is not closed.
8. The method for detecting the status of the dust cover of a forklift charger charging gun according to claim 7, characterized in that, In step 1, the states of the CC1 voltage and CC2 voltage during the charging process include: In standby mode, with the dust cover closed and the nozzle not inserted: CC1=6V, CC2=12V; With the dust cover removed, the button pressed and the nozzle not inserted: CC1=12V, CC2=12V; During charging, with the charging head fully inserted and the button released: CC1=4V, CC2=6V; When charging is complete and the charger is unplugged, but the button is pressed and the charger head is not completely disconnected: CC1=6V, CC2=6V; With the nozzle completely disconnected: CC1=12V, CC2=0V.
9. A method for detecting the status of the dust cover of a forklift charger charging gun according to claim 7, characterized in that, In step 3, the logic for determining that the charging gun is completely disconnected from the battery is as follows: the Hall proximity switch is triggered to supply power only when CC1=12V, CC2=0V and current=0A are simultaneously satisfied. In step 2, if the distance between the magnet and the sensor body is ≤15mm, it is determined that the dust cover is closed.