Onboard weighing method and system for an industrial handling vehicle

Abstract

The application discloses a kind of industrial carrying vehicle's on-board weighing method and system, applied to vehicle controller VCU, CAN bus handle, display controller DCU, weighing pressure sensor, method includes: vehicle controller VCU obtains the operating signal of CAN bus handle in Y axis direction, and whether the portal is in vertical lifting state is judged based on this signal;When determining that the portal is in vertical lifting state, vehicle controller VCU obtains the multiple voltage signals output by weighing pressure sensor in preset time period ΔT, and calculates the pressure representative value in this time period;Vehicle controller VCU obtains the current cargo weight value based on pressure representative value by inquiry;Vehicle controller VCU sends weight value to display controller DCU to be displayed.The application directly collects CAN bus handle signal and pressure sensor signal by the existing VCU of vehicle, carries out pressure-weight conversion algorithm by VCU inside, realizes integrated on-board weighing method without independent weighing controller.

Description

Technical Field

[0001] This invention relates to the field of weighing technology for industrial handling vehicles, and particularly to an on-board weighing method and system for industrial handling vehicles. Background Technology

[0002] In the daily operation of industrial handling vehicles (such as forklifts), it is often necessary to weigh the goods stacked on the forks in real time for inventory management, overload protection, or goods information recording.

[0003] Currently, a common solution for adding weighing functionality to industrial material handling vehicles is to install a separate weighing system on the vehicle. This separate weighing system typically includes independent weighing sensors, a dedicated weighing controller (or weighing instrument), and a separate display. This installation method is more suitable for lower-spec models that do not have a built-in Vehicle Control Unit (VCU) because it does not involve coupling with the original vehicle's electronic system, and the installation process is relatively simple.

[0004] The disadvantages of existing technologies are: However, for industrial handling vehicles that are already equipped with VCUs, the above-mentioned solution of adding an independent weighing system has the following obvious technical drawbacks: High system cost: Since the independent weighing system comes with its own controller, display and other components, it creates a duplication of configuration with the vehicle's existing VCU, display controller (DCU) and other hardware resources, which directly leads to an unnecessary increase in the overall vehicle material cost.

[0005] System integration is complex and reliability is low: When advanced control functions are required, such as "limiting hydraulic lifting action when overloaded," the independent weighing system must interact with the vehicle's VCU. The current approach is to design an additional low-voltage wiring harness to hardwire the weighing system's controller to the VCU. This cross-system external wiring not only increases the complexity of the overall vehicle wiring harness design and assembly time, but the additional connectors and exposed wiring harness also reduce the system's long-term reliability under vibration conditions.

[0006] Data fusion is difficult: Since the weighing function is completed by an independent controller, while the vehicle motion control is completed by the VCU, the two are separated at the hardware level. This makes it difficult to coordinate the weighing process with the vehicle's working status (such as gantry lifting and lowering) in real time and accurately, which restricts the development of intelligent operation functions. Summary of the Invention

[0007] The purpose of this invention is to overcome the shortcomings of the existing technology. To achieve the above objective, an on-board weighing method and system for industrial handling vehicles is adopted to solve the problems mentioned in the background technology.

[0008] The first aspect provides a technical solution as follows: an on-board weighing method for industrial handling vehicles, applied to a vehicle controller (VCU), wherein the vehicle controller is connected to a CAN bus handle and a display controller (DCU) via a CAN bus, and is electrically connected to a weighing pressure sensor installed on the lifting hydraulic circuit via wires, characterized in that the method includes: The vehicle controller (VCU) acquires the operation signal of the CAN bus handle in the Y-axis direction and determines whether the gantry is in a vertical lifting state based on this signal. When the gantry is determined to be in a vertical lifting state, the vehicle controller (VCU) acquires multiple voltage signals output by the weighing pressure sensor within a preset time period ΔT, and calculates a representative pressure value within that time period based on the pre-stored voltage-pressure conversion relationship. The vehicle controller (VCU) obtains the current cargo weight value based on the pressure representative value by querying a known pressure-weight calibration curve. The vehicle controller (VCU) sends the weight value to the display controller (DCU) for display, replacing the previously displayed weight value.

[0009] As a further aspect of the present invention: the calculation of a representative pressure value within this time period further includes: Calculate the arithmetic mean of multiple pressure values ​​within the time period ΔT, and use this average value as the representative pressure value.

[0010] As a further aspect of the present invention: before calculating the arithmetic mean, a data validity judgment step is also included: Calculate in real time the maximum fluctuation amplitude ΔP of the pressure values ​​collected within the time period ΔT; The operation of calculating the arithmetic mean is performed only when △P is less than or equal to a preset threshold b; Otherwise, discard the data within the current time period △T, and re-collect and evaluate it within the next time period △T.

[0011] As a further aspect of the present invention: the pre-stored pressure-weight calibration curve is a static weighing curve, and the steps for generating the static weighing curve are as follows: When the vehicle is unloaded, the control gantry is vertically raised and recorded as the first average pressure value P1; With the vehicle fully loaded with a known weight x, the gantry is controlled to rise vertically and recorded as the second average pressure value P2; Based on the correspondence between the first average pressure value P1, the second average pressure value P2 and the known weight x, a pressure-weight calibration curve is established.

[0012] As a further aspect of the present invention: the pre-stored pressure-weight calibration curve is a dynamic weighing curve, which has multiple curves, and each curve corresponds to a different engine throttle percentage; Before querying the pressure-weight calibration curve, the method further includes: obtaining the current engine throttle percentage and selecting a corresponding dynamic weighing curve to query the cargo weight value.

[0013] As a further aspect of the present invention: the multiple dynamic weighing curves are generated by performing no-load and full-load x-calibration at throttle openings of 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, and 100%, respectively.

[0014] As a further aspect of the present invention: the step of acquiring the operation signal of the CAN bus handle in the Y-axis direction and determining whether the gantry is in a vertical lifting state based on this signal specifically includes: When the value of the CAN bus handle in the Y-axis direction is between 1 and 100, the gantry is determined to be in a vertical lifting state. When the value of the CAN bus handle in the Y-axis direction is between -1 and -100, it is determined that the gantry is in a descending state; When the value of the CAN bus handle in the Y-axis direction is 0, the gantry is determined to be stationary.

[0015] The second aspect provides a technical solution as follows: an on-board weighing system for industrial handling vehicles, used to implement the method described in any one of the above-mentioned methods, the system comprising: Vehicle Controller Unit (VCU) The CAN bus handle and display controller DCU are connected to the vehicle controller VCU via a CAN bus, and A weighing pressure sensor is connected to the vehicle controller (VCU) via a wire. The output voltage signal range of the weighing pressure sensor is 0.5V to 4.5V, corresponding to a pressure range of 0 bar to 500 bar.

[0016] The third aspect provides a technical solution: an industrial handling vehicle, including the aforementioned vehicle-mounted weighing system.

[0017] The fourth aspect provides a technical solution as follows: a vehicle controller whose internal memory stores executable instructions, which, when executed by a processor, cause the vehicle controller to implement the method described in any one of the above descriptions.

[0018] Compared with the prior art, the present invention has the following technical advantages: The above technical solution is applied to the vehicle's existing vehicle control unit (VCU). This VCU is connected to the CAN bus handle Js1 and the display controller DCU via a CAN bus, and directly connected to the weighing pressure sensor S1 installed on the lifting hydraulic circuit via a wire. During weighing, the VCU first acquires the operation signal of the CAN bus handle in the Y-axis direction to determine whether the gantry is in a vertical lifting state. When lifting is determined, the VCU collects multiple voltage signals from the weighing pressure sensor S1 within a preset time period ΔT and calculates a representative pressure value. Then, the VCU queries a pre-stored pressure-weight calibration curve to convert the representative pressure value into a cargo weight value. Finally, the VCU sends the weight value to the DCU for display.

[0019] First, it completely eliminates the need for a separate weighing controller and its associated display, directly utilizing the vehicle's existing VCU and DCU hardware resources, significantly reducing system material costs. Second, it eliminates the need for additional low-voltage wiring harnesses between the VCU and the weighing system, simplifying the overall vehicle wiring harness layout, reducing the number of external connectors, and improving the system's long-term reliability under vibration conditions. Third, the weighing logic is uniformly executed by the VCU, which can automatically determine the gantry lifting status and trigger weighing based on the CAN bus handle signal, achieving seamless coordination between the weighing function and vehicle actions, and providing an integrated implementation foundation for subsequent advanced control functions such as overload limits. Attached Figure Description

[0020] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings: Figure 1 This is a schematic diagram illustrating the steps of the vehicle-mounted weighing method according to an embodiment of this application; Figure 2 This is a schematic diagram of the static weighing curve of an embodiment disclosed in this application; Figure 3 This is a schematic diagram of the static empty / full load value display logic of an embodiment disclosed in this application; Figure 4 This is a schematic diagram of the dynamic weighing curve of an embodiment disclosed in this application; Figure 5 This is a schematic diagram of the dynamic empty / full load value display logic of an embodiment disclosed in this application; Figure 6 This is a schematic diagram of the connection of a weighing system according to an embodiment of this application. Detailed Implementation

[0021] 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.

[0022] Please refer to Figure 1 In this embodiment of the invention, an on-board weighing method for an industrial handling vehicle is applied to a vehicle controller (VCU). The vehicle controller is connected to a CAN bus handle and a display controller (DCU) via a CAN bus, and is electrically connected to a weighing pressure sensor installed on the lifting hydraulic circuit via a wire. Specifically, the weighing pressure sensor S1 is a voltage output type pressure sensor of model SP500, with an output voltage range of 0.5V to 4.5V, linearly corresponding to a pressure range of 0 bar to 500 bar.

[0023] The vehicle-mounted weighing method in this embodiment is executed by the vehicle controller (VCU) and specifically includes the following steps: Step S1: Determine the lifting status of the gantry.

[0024] The vehicle controller (VCU) acquires the operation signal of the CAN bus handle in the Y-axis direction and determines whether the gantry is in a vertical lifting state based on this signal.

[0025] In this embodiment, the step of acquiring the operation signal of the CAN bus handle in the Y-axis direction and determining whether the gantry is in a vertical lifting state based on this signal specifically includes: When the value of the CAN bus handle in the Y-axis direction is between 1 and 100, the gantry is determined to be in a vertical lifting state. When the value of the CAN bus handle in the Y-axis direction is between -1 and -100, it is determined that the gantry is in a descending state; When the value of the CAN bus handle in the Y-axis direction is 0, the gantry is determined to be stationary.

[0026] The vehicle control unit (VCU) obtains the operation signal value of the CAN bus handle Js1 in the Y-axis direction via the CAN bus. When the value of Js1 in the Y-axis direction is 0, it indicates that the gantry is in a stationary state; when the value of Js1 in the Y-axis direction is any value between 1 and 100, it indicates that the gantry is in a vertical lifting state; when the value of Js1 in the Y-axis direction is any value between -1 and -100, it indicates that the gantry is in a lowering state. The VCU only proceeds to the subsequent weighing process when it determines that the gantry is in a vertical lifting state (i.e., the Y-axis value is 1~100).

[0027] Step S2: Collect pressure data and calculate representative pressure values.

[0028] When the gantry is determined to be in a vertical lifting state, the vehicle controller (VCU) acquires multiple voltage signals output by the weighing pressure sensor within a preset time period ΔT, and calculates a representative pressure value within that time period based on the pre-stored voltage-pressure conversion relationship.

[0029] In this embodiment, calculating a representative pressure value within the time period further includes: Calculate the arithmetic mean of multiple pressure values ​​within the time period ΔT, and use this average value as the representative pressure value.

[0030] In this embodiment, a data validity judgment step is included before calculating the arithmetic mean: Calculate in real time the maximum fluctuation amplitude ΔP of the pressure values ​​collected within the time period ΔT; The operation of calculating the arithmetic mean is performed only when △P is less than or equal to a preset threshold b; Otherwise, discard the data within the current time period △T, and re-collect and evaluate it within the next time period △T.

[0031] Step S3: Query the calibration curve to obtain the weight value.

[0032] The vehicle controller (VCU) obtains the current cargo weight value based on the pressure representative value by querying a known pressure-weight calibration curve.

[0033] In this embodiment, as Figure 2 As shown, the diagram illustrates a static weighing curve. The pre-stored pressure-weight calibration curve is a static weighing curve. The steps for generating this static weighing curve are as follows: When the vehicle is unloaded, the control gantry is vertically raised and recorded as the first average pressure value P1; With the vehicle fully loaded with a known weight x, the gantry is controlled to rise vertically and recorded as the second average pressure value P2; Based on the correspondence between the first average pressure value P1, the second average pressure value P2 and the known weight x, a pressure-weight calibration curve is established.

[0034] Specifically, the steps for implementing the static weighing method are as follows: like Figure 3 The diagram shown is a schematic diagram of the static empty / full load value display logic. ①S1 signal value conversion: Set the correspondence between the output voltage value and pressure value of sensor S1. The minimum output voltage value of S1 corresponds to the pressure value "0", and the maximum output current value of S1 corresponds to the pressure value Pmax. The correspondence is determined by the sensor's own parameters.

[0035] ② When unloaded, the gantry is vertically raised to a certain height. Within a set time period △T, several pressure values ​​P1-1, P1-2, P1-3, P1-4... are recorded in real time, and their average value is calculated as P1. ③ When fully loaded x, the gantry is vertically lifted to a certain height. Within a set time period △T, several pressure values ​​P2-1, P2-2, P2-3, P2-4... are recorded in real time, and their average value is calculated as P2. ④ Based on the relationship between weight and pressure, a static weighing curve is obtained. By referring to the curve using the recorded real-time pressure value P, the weight of the object can be determined. ⑤ Weighing display: Taking static full load as an example, the VCU records the pressure change value △P2 of sensor S1 within the time interval △T. If △P2 is less than or equal to b, the pressure value P2 at this time is recorded. According to the static weighing curve, the weight value x of the object is obtained and displayed on the DCU. The previous recorded value is replaced when the weighing value appears in the next time interval △T.

[0036] In this embodiment, the pre-stored pressure-weight calibration curve is a dynamic weighing curve. There are multiple dynamic weighing curves, and each curve corresponds to a different engine throttle percentage. Before querying the pressure-weight calibration curve, the method further includes: obtaining the current engine throttle percentage and selecting a corresponding dynamic weighing curve to query the cargo weight value.

[0037] In this embodiment, as Figure 4 As shown, the diagram illustrates a dynamic weighing curve. Many of the dynamic weighing curves were generated by calibrating under no-load and full-load conditions at throttle openings of 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, and 100%.

[0038] Specifically, such as Figure 5 The diagram shown is a schematic diagram of the dynamic empty and full load value display logic. The dynamic weighing process is as follows: ①S1 signal value conversion: Set the correspondence between the output voltage value and pressure value of sensor S1. The minimum output voltage value of S1 corresponds to the pressure value "0", and the maximum output current value of S1 corresponds to the pressure value Pmax. The correspondence is determined by the sensor's own parameters.

[0039] ② When unloaded, the mast is vertically raised to a certain height at throttle positions of 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, and 100%. Within a set time period △T, several pressure values ​​(P120%-1, P120%-2, P120%-3, P120%-4...) are recorded in real time, and their average values ​​are calculated as P120%, P130%,...P1100%. Testing shows that under different throttle percentages, the pressure values ​​measured when the vehicle is unloaded change very little compared to the static pressure values. The average static value P1 can be used as a reference.

[0040] ③ When fully loaded (x), the mast is vertically raised to a certain height at 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, and 100% throttle. Within a set time period △T, several pressure values ​​P220%-1, P220%-2, P220%-3, P220%-4, ... are recorded in real time, and their average values ​​are calculated as P220%, P230%, ..., P2100%. ④ At throttle octane ratings of 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, and 100%, dynamic weighing curves are obtained based on the relationship between weight and pressure. During weighing, at different rotational speeds, the weight of the object can be obtained by finding the corresponding or similar curve based on the recorded pressure value P. ⑤ Weighing display: Taking dynamic full load as an example, the VCU records the pressure change value △P2 of sensor S1 within the time interval △T. If △P2 is less than or equal to b, the pressure value P2 at this time is recorded. According to the dynamic weighing curve, the weight value x of the object is obtained and displayed on the DCU. This continues until the weighing value appears in the next time interval △T, at which point the previous recorded value is replaced.

[0041] Step S4: Send the weight value to the display.

[0042] The vehicle controller (VCU) sends the weight value to the display controller (DCU) for display, replacing the previously displayed weight value.

[0043] This embodiment provides an on-board weighing system for industrial handling vehicles, used to implement the method described in any one of the above embodiments. The system includes: Vehicle Controller Unit (VCU) The CAN bus handle and display controller DCU are connected to the vehicle controller VCU via a CAN bus, and A weighing pressure sensor is connected to the vehicle controller (VCU) via a wire. The output voltage signal range of the weighing pressure sensor is 0.5V to 4.5V, corresponding to a pressure range of 0 bar to 500 bar.

[0044] like Figure 6 The diagram illustrates the connection of an on-board weighing system. This embodiment provides an on-board weighing system for an industrial material handling vehicle. The system includes a vehicle controller (VCU), a CAN bus handle (Js1), a display controller (DCU), and a weighing pressure sensor (S1). The CAN bus handle (Js1) and the display controller (DCU) are both connected to the VCU via a CAN bus; the weighing pressure sensor (S1) is connected to the VCU via a wire. The sensor is exemplarily an SP500 type, outputting a 0.5V-4.5V voltage signal, corresponding to a pressure of 0-500 bar. The VCU internally includes a processor, memory, a CAN transceiver, and an analog-to-digital converter (ADC). The memory stores executable instructions; when these instructions are executed by the processor, the VCU implements the on-board weighing method described above.

[0045] This embodiment also provides an industrial handling vehicle that includes the above-mentioned on-board weighing system, which can realize real-time weighing of goods during operation without adding an additional weighing controller.

[0046] A vehicle controller has internal memory storing executable instructions that, when executed by a processor, cause the vehicle controller to perform the method as described in any one of the above descriptions.

[0047] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention. The scope of the invention is defined by the appended claims and their equivalents, all of which should be included within the scope of protection of the invention.

Claims

1. An on-board weighing method for industrial handling vehicles, applied to a vehicle controller (VCU), wherein the vehicle controller is connected to a CAN bus handle and a display controller (DCU) via a CAN bus, and is electrically connected to a weighing pressure sensor installed on the lifting hydraulic circuit via a wire, characterized in that, The method includes: The vehicle controller (VCU) acquires the operation signal of the CAN bus handle in the Y-axis direction and determines whether the gantry is in a vertical lifting state based on this signal. When the gantry is determined to be in a vertical lifting state, the vehicle controller (VCU) acquires multiple voltage signals output by the weighing pressure sensor within a preset time period ΔT, and calculates a representative pressure value within that time period based on the pre-stored voltage-pressure conversion relationship. The vehicle controller (VCU) obtains the current cargo weight value based on the pressure representative value by querying a known pressure-weight calibration curve. The vehicle controller (VCU) sends the weight value to the display controller (DCU) for display, replacing the previously displayed weight value.

2. The method according to claim 1, characterized in that, The calculation of a representative pressure value for this time period further includes: Calculate the arithmetic mean of multiple pressure values ​​within the time period ΔT, and use this average value as the representative pressure value.

3. The method according to claim 2, characterized in that, Before calculating the arithmetic mean, a data validity determination step is also included: Calculate in real time the maximum fluctuation amplitude ΔP of the pressure values ​​collected within the time period ΔT; The operation of calculating the arithmetic mean is performed only when △P is less than or equal to a preset threshold b; Otherwise, discard the data within the current time period △T, and re-collect and evaluate it within the next time period △T.

4. The method according to claim 1, characterized in that, The pre-stored pressure-weight calibration curve is a static weighing curve, and the steps for generating this static weighing curve are as follows: When the vehicle is unloaded, the control gantry is vertically raised and recorded as the first average pressure value P1; With the vehicle fully loaded with a known weight x, the gantry is controlled to rise vertically and recorded as the second average pressure value P2; Based on the correspondence between the first average pressure value P1, the second average pressure value P2 and the known weight x, a pressure-weight calibration curve is established.

5. The method according to claim 1, characterized in that, The pre-stored pressure-weight calibration curve is a dynamic weighing curve. There are multiple dynamic weighing curves, and each curve corresponds to a different engine throttle percentage. Before querying the pressure-weight calibration curve, the method further includes: obtaining the current engine throttle percentage and selecting a corresponding dynamic weighing curve to query the cargo weight value.

6. The method according to claim 5, characterized in that, The multiple dynamic weighing curves were generated by performing no-load and full-load x-calibration at throttle openings of 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, and 100%.

7. The method according to claim 1, characterized in that, The step of acquiring the operation signal of the CAN bus handle in the Y-axis direction and determining whether the gantry is in a vertical lifting state based on this signal is as follows: When the value of the CAN bus handle in the Y-axis direction is between 1 and 100, the gantry is determined to be in a vertical lifting state. When the value of the CAN bus handle in the Y-axis direction is between -1 and -100, it is determined that the gantry is in a descending state; When the value of the CAN bus handle in the Y-axis direction is 0, the gantry is determined to be stationary.

8. An on-board weighing system for an industrial handling vehicle, used to implement the method according to any one of claims 1 to 7, characterized in that, The system includes: Vehicle Controller Unit (VCU) The CAN bus handle and display controller DCU are connected to the vehicle controller VCU via a CAN bus, and A weighing pressure sensor is connected to the vehicle controller (VCU) via a wire. The output voltage signal range of the weighing pressure sensor is 0.5V to 4.5V, corresponding to a pressure range of 0 bar to 500 bar.

9. An industrial handling vehicle, characterized in that, Including the vehicle-mounted weighing system as described in claim 8.

10. A vehicle controller having internal memory storing executable instructions that, when executed by a processor, cause the vehicle controller to perform the method as described in any one of claims 1 to 7.

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