Automatic dormancy control system of new energy forklift

Abstract

The automatic dormancy control system of the new energy forklift comprises a circuit formed by connecting a power supply assembly and a key switch in series, the output end of the key switch is respectively connected with a main controller, an intelligent instrument and a low-voltage load, the power supply assembly comprises a lithium battery, and the lithium battery is connected with the intelligent instrument. The lithium battery is respectively connected with a battery DC-DC converter and a battery main control switch, and the battery DC-DC converter is connected with the battery BMS; the output end of the power supply assembly is connected with a dual emergency stop switch, one end of a switch K1 in the dual emergency stop switch is connected with the battery BMS through a coil of the relay, and the other end of the switch K1 is directly connected with the battery BMS to form a dormancy detection loop; one end of a switch K2 in the double emergency stop switch is connected with the anode of the lithium battery through a normally-closed switch of the relay, and the other end is connected with the key switch. When it is monitored that the whole vehicle is in a dormant state, power supplies such as a main controller, an intelligent instrument and a low-voltage load are cut off, so that energy loss is reduced, and related parts such as a battery are protected.

Description

Technical Field

[0001] The utility model relates to the technical field of forklifts, in particular to an automatic sleep control system for new energy forklifts. Background Art

[0002] New energy forklifts use clean energy sources such as lithium-ion batteries and fuel cells as power sources, greatly reducing carbon emissions and noise pollution, and becoming an optimal solution for enterprises to pursue sustainable development goals. With its significant environmental protection advantages, intelligent operation experience, and economical and efficient operating costs, it is gradually occupying the dominant position in the market.

[0003] Currently, when using new energy forklifts, the entire vehicle is controlled to be turned on or off through a key switch. When the operator is ready to start working, it is first necessary to ensure that all electrical components, including the battery pack, motor controller, lighting system, braking system, etc., are correctly connected and in good condition according to strict operating procedures. Subsequently, the operator gently rotates the key switch to the "ON" position, and the entire vehicle is powered on and can perform normal operations such as moving, handling, and stacking. After finishing work, the driver needs to rotate the key switch to the "OFF" position to cut off the power supply of the entire vehicle, so that all electrical components in the vehicle enter the off state, effectively avoiding unnecessary energy waste, and also ensuring that the forklift will not cause safety hazards due to accidental startup when unattended, and ensuring the "safe" storage state of the vehicle. If the driver is negligent and leaves without rotating the key switch to the "OFF" position, the forklift will maintain the standby mode, and components such as the vehicle controller, instrument, and external load (lights, etc.) will always be in the working state, continuously consuming electricity. It is not until the power of the lithium battery pack is exhausted that the entire vehicle will power off. This not only increases the operating cost, but also may cause over-discharge of the battery due to long-term non-power-off, damaging the battery life. More seriously, if the forklift in the standby state is not properly fixed or placed in an unstable environment, it may be accidentally moved due to external factors, constituting a potential safety threat. Content of the Utility Model

[0004] In order to solve the above problems, the utility model specifically provides an automatic sleep control system for new energy forklifts, which judges the usage requirements by real-time monitoring of the operating state of the new energy forklift. When it is detected that the entire vehicle has not been used for a certain period of time, it automatically cuts off the power supply of components such as the controller and low-voltage load (lights, etc.), reduces energy loss, and protects the battery, etc. When the entire vehicle is started again, only the emergency stop switch needs to be reset to restore the normal use of the entire vehicle.

[0005] In order to achieve the above object, the technical solution adopted by the utility model is as follows:

[0006] An automatic sleep control system for a new energy forklift, comprising a circuit composed of a power supply component and a key switch connected in series. The output end of the key switch is respectively connected to a main controller, an intelligent meter, and a low-voltage load. The power supply component includes a lithium battery. The positive electrode of the lithium battery is respectively connected to a battery DC-DC converter and a battery main control switch. The output end of the battery DC-DC converter is connected to a battery BMS; the output end of the power supply component is connected to a double emergency stop switch. One end of switch K1 in the double emergency stop switch is connected to the battery BMS through the coil of a relay, and the other end is directly connected to the battery BMS to form a sleep detection circuit; one end of switch K2 in the double emergency stop switch is connected to the positive electrode of the lithium battery through the normally closed switch of the relay, and the other end is connected to the key switch.

[0007] In a further aspect, the output end of the battery main control switch is connected to the power supply end of the main controller through the contact of a main contactor; the coil of the main contactor is connected in series on the main controller.

[0008] In a further aspect, the output end of the key switch is respectively connected to the start signal ends of the main controller and the intelligent meter. The output end of the key switch is respectively connected to the power supply ends of the intelligent meter and the vehicle DC-DC converter. The output end of the vehicle DC-DC converter is connected to the low-voltage load.

[0009] In a further aspect, a first fuse is connected in series between switch K2 of the double emergency stop switch and the normally closed switch of the relay. A second fuse is connected in series between the contact of the main contactor and the power supply end of the main controller.

[0010] In a further aspect, both between the power supply component and the main controller and between the power supply component and the intelligent meter are connected through a CAN bus.

[0011] In a further aspect, the positive electrode of the lithium battery is sequentially connected to the intelligent meter or the low-voltage load through the normally closed switch of the relay, switch K2 in the double emergency stop switch, and the key switch, and then returns to the negative electrode of the lithium battery to form a low-power circuit.

[0012] In a further aspect, the positive electrode of the lithium battery is sequentially connected to the main controller through the battery main control switch and the contact of the main contactor, and then returns to the negative electrode of the lithium battery to form a high-power circuit.

[0013] The beneficial effects of this system are:

[0014] 1. The system monitors the operating current magnitude and duration of a new energy forklift in real time through the battery BMS in the power supply component to determine the real-time status of the forklift. When it is detected that the output current of the whole vehicle is less than the set value within a certain period of time, it indicates that the forklift is in the dormant state without use. The power supply of components such as the main controller, intelligent instrument, and low-voltage load (lights, etc.) of the whole vehicle is cut off to reduce energy consumption and protect related components such as the battery. After the whole vehicle is restarted, only the double emergency stop switch needs to be disconnected and then closed for reset operation to restore the normal use of the whole vehicle.

[0015] 2. A double emergency stop switch is used in this system. It can connect two independent electrical circuits, and the two circuits work and are disconnected simultaneously. One switch controls the two circuits, making the operation more convenient.

[0016] 3. This system completely avoids the safety risks of storing the whole vehicle caused by the driver not using the whole vehicle for a long time or forgetting to rotate the key switch to the "OFF" position after work, resulting in the whole vehicle being in the powered-on state and no one around to supervise.

[0017] 4. The control circuit of this application forms three different electrical circuits: a low-power circuit, a high-power circuit, and a sleep detection circuit, which effectively controls the processes of starting, sleeping, restarting from sleep, and shutting down of the new energy forklift, saves the usage cost, and also improves the service life of the battery. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The accompanying drawings forming a part of this application are used to provide a further understanding of this application. The schematic embodiments of this application and their descriptions are used to explain this application and do not constitute an improper limitation to this application.

[0019] Figure 1 It is a principle block diagram of the present utility model.

[0020] In the figure: 1 power supply component, 11 battery BMS, 12 battery DC-DC converter, 13 lithium battery, 14 battery main control switch, 2 relay, 21 coil, 22 normally closed switch, 3 main contactor, 41 first fuse, 42 second fuse, 5 double emergency stop switch, 6 low-voltage load, 7 key switch, 8 main controller, 9 intelligent instrument, 10 vehicle DC-DC converter.

[0021] S1 low-power circuit, S2 high-power circuit, S3 sleep detection circuit. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0022] The following will refer to the accompanying drawings and combine with embodiments to detail this application. It should be noted that, without conflict, the embodiments in this application and the features in the embodiments can be combined with each other.

[0023] Refer toFigure 1 The present embodiment discloses an automatic dormancy control system for a new energy forklift, comprising a circuit composed of a power supply assembly 1 and a key switch 7 connected in series, wherein the output end of the key switch 7 is respectively connected to a main controller 8, an intelligent meter 9, and a low-voltage load 6, the power supply assembly 1 comprises a lithium battery 13, the positive electrode of the lithium battery 13 is respectively connected to a battery DC-DC converter 12 and a battery main control switch 14, and the output end of the battery DC-DC converter 12 is connected to a battery BMS11; the output end of the power supply assembly 1 is connected to a double emergency stop switch 5, wherein one end of a switch K1 in the double emergency stop switch 5 is connected to the battery BMS11 through a coil 21 of a relay 2, and the other end is directly connected to the battery BMS11 to form a dormancy detection circuit S3; one end of a switch K2 in the double emergency stop switch 5 is connected to the positive electrode of the lithium battery 13 through a normally closed switch 22 of a relay 2, and the other end is connected to the key switch 7.

[0024] The output end of the battery master switch 14 is connected to the power supply end of the main controller 8 through the contact of the main contactor 3; the coil of the main contactor 3 is connected in series to the main controller 8.

[0025] The double emergency stop switch in this embodiment is also called a two-position emergency stop switch. It is a safety switch for emergency power cut-off, usually composed of two switch buttons. Only by pressing the two switch buttons at the same time can the power be cut off to ensure the safe stop of the equipment. That is, it is ensured that only when an emergency stop is really needed, it can be triggered through a double confirmation action, reducing the possibility of misoperation.

[0026] In this embodiment, the main controller 8, the intelligent instrument 9, etc. are all components built into the new energy forklift, and this application does not involve any improvement thereto.

[0027] In this embodiment, the low-voltage load 6 includes lighting lamps, warning lights, USB power supplies, electric fans, etc. The high-voltage electricity of the lithium battery 13 is further converted and stepped down by the vehicle DC-DC converter 10 and then supplied to the low-voltage load for use.

[0028] In a further solution, the output end of the key switch 7 is respectively connected to the start signal end of the main controller 8 and the smart meter 9, and the output end of the key switch 7 is respectively connected to the power supply end of the smart meter 9 and the whole vehicle DC-DC converter 10, and the output end of the whole vehicle DC-DC converter 10 is connected to the low-voltage load 6.

[0029] In order to protect the line safety, a first fuse 41 is connected in series between the switch K2 of the double emergency stop switch 5 and the normally closed switch 22 of the relay 2 , and a second fuse 42 is connected in series between the contact of the main contactor 3 and the power supply end of the main controller 8 .

[0030] In a further solution, both the power supply assembly 1 and the main controller 8, and the power supply assembly 1 and the intelligent meter 9 are connected through a CAN bus for signal transmission.

[0031] Therefore, the control circuit of this application forms three different electrical loops to effectively control the starting, sleeping, sleep restarting, shutting down, etc. processes of the new energy forklift:

[0032] Low-power loop S1: The positive pole of the lithium battery 13 is sequentially connected to the intelligent meter 9 or the low-voltage load 6 through the normally closed switch 22 of the relay 2, the switch K2 in the double emergency stop switch 5, and the key switch 7, and then returns to the negative pole of the lithium battery 13, forming the low-power loop S1.

[0033] High-power loop S2: The positive pole of the lithium battery 13 is sequentially connected to the main controller 8 through the battery main control switch 14 and the contact of the main contactor 3, and then returns to the negative pole of the lithium battery 13, forming the high-power loop S2.

[0034] Sleep detection loop S3: The output terminal of the battery BMS 11 is sequentially connected to the battery BMS 11 through the switch K1 in the double emergency stop switch 5 and the coil 21 of the relay 2, forming the sleep detection loop S3.

[0035] The working process of this embodiment is as follows:

[0036] 1. The whole vehicle starts normally

[0037] The driver closes the double emergency stop switch 5 and rotates the key switch 7 to the "ON" gear. The start signals are transmitted to the main controller 8, the intelligent meter 9, and the power supply assembly 1 respectively. After receiving the wake-up signal of the key switch 7, the power supply assembly 1 immediately controls the battery main control switch 14 to close and output high-voltage power outward; at the same time, after receiving the wake-up signal of the key switch 7, the main controller 8 sends a "close" command to the main contactor 3, that is, the coil of the main contactor 3 is energized and the contacts are connected, connecting the high-voltage line between the power supply assembly 1 and the main controller 8, and the main controller 8 is energized to work; in addition, after receiving the wake-up signal of the key switch 7, the intelligent meter 9 is energized to work, and the vehicle-mounted DC-DC converter 10 and the low-voltage load 6 are also normally energized to work. That is, all the low-power and high-power loops of the whole vehicle are closed, and the normal start is successful, and the new energy forklift can be operated for related moving, handling, stacking, etc.

[0038] 2. The whole vehicle sleeps

[0039] When the vehicle stops working after a normal start, if the battery BMS11 in the power supply component 1 detects that its output current I is less than I0 (I0 needs to be set according to different vehicle models) and the duration T > T0 (tentatively 30 minutes), the battery BMS11 sends a signal to the relay 2. The relay 2 is a normally closed relay. When the coil 21 is powered on, the normally closed switch 22 is disconnected. At this time, the main controller 8 and the intelligent instrument 9 detect the disconnection signal of the low-power circuit S1. The main controller 8 sends a power-off signal, and the coil of the main contactor 3 loses power and the contacts are disconnected, that is, the high-power circuit S2 is disconnected. At this time, the main controller 8, the intelligent instrument 9, the vehicle-mounted DC-DC converter 10, and the low-voltage load 6 (including lighting lamps, warning lamps, USB power supply, electric fans, etc.) and other related components are all powered off. Then only the coil 21 of the relay 2 in the sleep detection circuit S3 of the vehicle is powered on, and the energy consumed is extremely small, which completely avoids the vehicle failure caused by the over-discharge of the power supply component 1 due to the driver not using the device for a long time or forgetting to rotate the key switch to the "OFF" position to shut down the vehicle after work; at the same time, it also fully improves the safety of the vehicle during storage.

[0040] 3. Starting after the vehicle goes to sleep

[0041] After the vehicle goes to sleep, after the double emergency stop switch 5 performs the action of disconnecting and then closing again, the coil 21 in the relay 2 loses power, and the normally closed switch 22 closes. At this time, the sleep detection circuit S3 is disconnected, and the low-power circuit S1 is re-closed and powered on. Turn the start key switch 7 to the "ON" position, and the power supply component 1 immediately controls the battery main control switch 14 to close and output high-voltage power outward. The main controller 8 controls the contacts of the main contactor 3 to close, and the main controller 8 works after being powered on; the intelligent instrument 9, the vehicle-mounted DC-DC converter 10, and the low-voltage load 8 are normally powered on and work, that is, the vehicle starts successfully after going to sleep.

[0042] 4. Normal shutdown of the vehicle

[0043] The driver rotates the key switch 7 to the "OFF" position, and the start signal is transmitted to the main controller 8, the intelligent instrument 9, and the power supply component 1 respectively. After receiving the closing signal of the key switch, the power supply component 1 immediately controls the battery main control switch 14 to disconnect, that is, externally cuts off the high-voltage power output. After receiving the closing signal of the key switch 8, the main controller 8 sends a "disconnect" command to the main contactor 3, and the main controller 8 loses power and does not work; at the same time, the intelligent instrument 9, the vehicle-mounted DC-DC converter 10, and the low-voltage load 6 are all powered off and do not work, and the vehicle shuts down successfully.

[0044] The above are only the preferred embodiments of the present application and are not intended to limit the present application. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present application are within the scope of protection of the pending claims of the present application.

Claims

1. An automatic sleep control system for a new energy forklift, comprising a circuit composed of a power supply component (1) and a key switch (7) connected in series, wherein the output end of the key switch (7) is respectively connected to a main controller (8), an intelligent meter (9), and a low-voltage load (6), and is characterized in that: The power supply component (1) includes a lithium battery (13). The positive electrode of the lithium battery (13) is respectively connected to a battery DC-DC converter (12) and a battery main control switch (14). The output end of the battery DC-DC converter (12) is connected to a battery BMS (11); the output end of the power supply component (1) is connected to a double emergency stop switch (5). One end of switch K1 in the double emergency stop switch (5) is connected to the battery BMS (11) through the coil (21) of a relay (2), and the other end is directly connected to the battery BMS (11) to form a sleep detection circuit (S3); one end of switch K2 in the double emergency stop switch (5) is connected to the positive electrode of the lithium battery (13) through the normally closed switch (22) of the relay (2), and the other end is connected to a key switch (7).

2. The automatic sleep control system according to claim 1, wherein: The output end of the battery main control switch (14) is connected to the power supply end of the main controller (8) through the contact of a main contactor (3); the coil of the main contactor (3) is connected in series on the main controller (8).

3. The automatic sleep control system according to claim 1, characterized in that: The output end of the key switch (7) is respectively connected to the start signal ends of the main controller (8) and an intelligent meter (9). The output end of the key switch (7) is respectively connected to the power supply ends of the intelligent meter (9) and a vehicle-mounted DC-DC converter (10). The output end of the vehicle-mounted DC-DC converter (10) is connected to a low-voltage load (6).

4. The automatic sleep control system according to claim 2, wherein: A first fuse (41) is connected in series between the switch K2 of the double emergency stop switch (5) and the normally closed switch (22) of the relay (2). A second fuse (42) is connected in series between the contact of the main contactor (3) and the power supply end of the main controller (8).

5. The automatic sleep control system according to claim 1, wherein: Both between the power supply component (1) and the main controller (8) and between the power supply component (1) and the intelligent meter (9) are connected through a CAN bus.

6. The automatic sleep control system according to claim 1, characterized in that: The positive electrode of the lithium battery (13) is sequentially connected to the intelligent meter (9) or to the low-voltage load (6) through the normally closed switch (22) of the relay (2), switch K2 in the double emergency stop switch (5), and the key switch (7), and then returns to the negative electrode of the lithium battery (13) to form a low-power circuit (S1).

7. The automatic sleep control system according to claim 2, wherein: The positive electrode of the lithium battery (13) is sequentially connected to the main controller (8) through the battery main control switch (14) and the contact of the main contactor (3), and then returns to the negative electrode of the lithium battery (13) to form a high-power circuit (S2).

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