Controller system capable of quickly positioning fault

Abstract

The utility model discloses a controller system capable of quickly positioning faults, which particularly relates to the technical field of forklift fault diagnosis and comprises a switching signal acquisition module, a master control MCU (Microprogrammed Control Unit), a driving output valve control module, a fault positioning module and a current sampling module, the output end of the switching signal acquisition module is connected with the input end of the main control MCU; the output end of the main control MCU is connected with the input end of the driving output valve control module; the output end of the driving output valve control module is in signal connection with the input end of the current sampling module; the output end of the current sampling module is in signal connection with one input end of the main control MCU; and one output end of the main control MCU is in signal connection with the input end of the fault positioning module. According to the utility model, the switch signal acquisition module, the current sampling module and the fault positioning module are utilized, so that the controller system can enable forklift maintenance personnel to quickly position the fault reason according to the indication condition of the LED indicator lamp on the controller, thereby saving the maintenance time and cost of workers, and greatly improving the working efficiency.

Description

Technical Field

[0001] The utility model relates to the technical field of forklift fault diagnosis. More specifically, the utility model relates to a controller system for quickly locating faults. Background Art

[0002] As is known, a forklift, as an important tool for mechanized handling, is an indispensable part of an enterprise's logistics system and has a very wide range of applications in places such as warehouses, distribution centers, ports, stations, airports, etc. Therefore, a forklift is an essential equipment in an enterprise's logistics system. With the popularization of forklift applications, it is necessary to maintain forklifts in order to promptly eliminate faults and ensure the safety of vehicle use.

[0003] However, in actual use, conventional forklift fault diagnosis systems do not include the diagnosis of the quality of solenoid valves. Some internal combustion forklifts do not have a CAN local area network system and also lack corresponding fault diagnosis systems. Therefore, in order to quickly locate the cause of faults, a controller system for quickly locating faults is proposed as a further improvement. Summary of the Utility Model

[0004] In order to overcome the above-mentioned defects of the prior art, an embodiment of the utility model provides a controller system for quickly locating faults to solve the problems raised in the above-mentioned background art.

[0005] To achieve the above object, the utility model provides the following technical solution: A controller system for quickly locating faults, the controller system includes: a switch signal acquisition module, a main control MCU, a drive output valve control module, a fault location module, and a current sampling module;

[0006] The output end of the switch signal acquisition module is signal-connected to an input end of the main control MCU; an output end of the main control MCU is signal-connected to the input end of the drive output valve control module; the output end of the drive output valve control module is signal-connected to the input end of the current sampling module; the output end of the current sampling module is signal-connected to an input end of the main control MCU; an output end of the main control MCU is signal-connected to the input end of the fault location module.

[0007] Further, the switch signal acquisition module acquires the valve rod switch signals of the forklift mast, including: a lift valve rod switch signal, a lower valve rod switch signal, a forward tilt valve rod switch signal, and a rear tilt valve rod switch signal.

[0008] Further, the drive output valve control module controls the solenoid valves of the forklift mast, including: a lift solenoid valve, a lower solenoid valve, a forward tilt solenoid valve, and a rear tilt solenoid valve.

[0009] Further, the output current of the solenoid valve collected by the current sampling module includes: the output current of the lifting solenoid valve, the output current of the lowering solenoid valve, the output current of the forward tilting solenoid valve, and the output current of the backward tilting solenoid valve.

[0010] Further, the output end of the fault location module is signal-connected to the LED indicator light.

[0011] Further, the fault location module displays at least five states through the LED indicator light.

[0012] The technical effects and advantages of the present utility model:

[0013] Compared with the prior art, the controller system uses the switch signal acquisition module to collect the lifting valve rod switch signal, lowering valve rod switch signal, forward tilting valve rod switch signal, and backward tilting valve rod switch signal of the forklift mast and provides them to the main control MCU. Then, according to the working states of the corresponding solenoid valves provided by the current sampling module, it is convenient for the main control MCU to judge the fault situation, and the main control MCU controls the LED indicator light to display through the fault location module. Thus, the operator can quickly locate the fault cause according to the indication of the indicator light; therefore, the controller system has the advantage that forklift maintenance personnel can quickly locate the fault cause according to the indication of the LED indicator light on the controller, saving the maintenance time and cost of workers and greatly improving the work efficiency. Description of the Drawings

[0014] Figure 1 It is a system block diagram of the present utility model.

[0015] Figure 2 It is a schematic diagram of the fault indication process of the present utility model.

[0016] The reference numerals are:

[0017] 1. Switch signal acquisition module;

[0018] 2. Main control MCU;

[0019] 3. Drive output valve control module;

[0020] 4. Fault location module;

[0021] 5. Current sampling module. Detailed Embodiments

[0022] In order to make the objectives, technical solutions and advantages of the present utility model clearer, the present utility model will be further described in detail below with reference to the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present utility model and are not used to limit the present utility model.

[0023] As shown in the attached Figure 1and appendix Figure 2 A controller system for quickly locating faults as shown, the controller system includes: a switch signal acquisition module 1, a main control MCU 2, a drive output valve control module 3, a fault location module 4, and a current sampling module 5;

[0024] Among them, the main control MCU 2 is used as the central processing unit; the current sampling module 5 is used for the output solenoid valve circuit of the drive output valve control module 3, and the current sampling module 5 obtains a voltage signal from the sampling resistor of the drive output valve control module 3;

[0025] The output end of the switch signal acquisition module 1 is signal-connected to an input end of the main control MCU 2; an output end of the main control MCU 2 is signal-connected to the input end of the drive output valve control module 3; the output end of the drive output valve control module 3 is signal-connected to the input end of the current sampling module 5; the output end of the current sampling module 5 is signal-connected to an input end of the main control MCU 2; an output end of the main control MCU 2 is signal-connected to the input end of the fault location module 4;

[0026] Among them, the main control MCU 2 determines the switch states of the lifting, lowering, forward tilting, and backward tilting valve rods of the forklift mast collected by the switch signal acquisition module 1. Furthermore, the main control MCU 2 controls the on / off of the solenoid valves in the drive output valve control module 3. At the same time, the main control MCU 2 collects the magnitude of the current output by the solenoid valves in the drive output valve control module 3 through the current sampling module 5. Finally, the main control MCU 2 performs logical calculations and judgments and controls the LED indicator to display the situation through the fault location module 4.

[0027] In a preferred embodiment, as shown in the appendix Figure 1 and appendix Figure 2 shown, the switch signal acquisition module 1 collects the valve rod switch signals of the forklift mast, including: the lifting valve rod switch signal, the lowering valve rod switch signal, the forward tilting valve rod switch signal, and the backward tilting valve rod switch signal;

[0028] Among them, the switch signal acquisition module 1 outputs the collected lifting valve rod switch signal, lowering valve rod switch signal, forward tilting valve rod switch signal, and backward tilting valve rod switch signal of the forklift mast to the main control MCU 2.

[0029] In a preferred embodiment, as shown in the appendix Figure 1 and appendix Figure 2 shown, the drive output valve control module 3 controls the solenoid valves of the forklift mast, including: the lifting solenoid valve, the lowering solenoid valve, the forward tilting solenoid valve, and the backward tilting solenoid valve.

[0030] Among them, after the main control MCU2 collects the fork lift mast lifting, lowering, forward tilting, and rear tilting valve stem switch states provided by the switch signal acquisition module 1, the main control MCU2 will control the on / off of the lift solenoid valve, lowering solenoid valve, forward tilting solenoid valve, and rear tilting solenoid valve in the drive output valve control module 3; that is, after the drive output valve control module 3 receives the instruction from the main control MCU2, it executes the on / off of the lift solenoid valve, lowering solenoid valve, forward tilting solenoid valve, and rear tilting solenoid valve of the corresponding fork lift mast.

[0031] In a preferred embodiment, as shown in the appendix Figure 1 and the appendix Figure 2 shown, the current sampling module 5 collects the output current of the solenoid valve, including: the output current of the lift solenoid valve, the output current of the lowering solenoid valve, the output current of the forward tilting solenoid valve, and the output current of the rear tilting solenoid valve.

[0032] Among them, the current sampling module 5 detects the loop current in the lift solenoid valve, lowering solenoid valve, forward tilting solenoid valve, and rear tilting solenoid valve of the fork lift mast in real time; and then the main control MCU2 judges whether there is a short circuit or open circuit fault of the solenoid valve according to the magnitude of the current.

[0033] In a preferred embodiment, as shown in the appendix Figure 1 and the appendix Figure 2 shown, the output end of the fault location module 4 is signal-connected to the LED indicator light; so as to show whether there is a fault and the fault point through different display effects of the LED indicator light; and then play the effect of quickly locating the fault.

[0034] Among them, the switch signal acquisition module 1 collects the signals of the 4-way valve stem switch states of the lift, lowering, forward tilting, and rear tilting of the fork lift mast through 4 IO ports, and outputs to control only one LED indicator light; that is, as long as one of the valve stem switches of the lift, lowering, forward tilting, and rear tilting fails, the LED indicator light shows the fault state.

[0035] In a preferred embodiment, as shown in the appendix Figure 1 and the appendix Figure 2 shown, the fault location module 4 shows at least five states through the LED indicator light.

[0036] Example:

[0037] If the lift, lowering, forward tilting, and rear tilting valve stem switches of the fork lift mast are disconnected and the LED indicator light is always off, it means that the disconnection state of the valve stem switch of the fork lift mast is normal;

[0038] If the lift, lowering, forward tilting, and rear tilting valve stem switches of the fork lift mast are closed and the LED indicator light is always off, it means that there is a fault in the valve stem switch of the fork lift mast;

[0039] If the lift, lower, tilt forward, and tilt backward valve stem switches of the forklift mast are closed and the corresponding electromagnetic valves of the forklift mast are normal, the LED indicator light will be constantly on, indicating that the controller system has not detected a fault;

[0040] If the lift, lower, tilt forward, and tilt backward valve stem switches of the forklift mast are closed and the corresponding electromagnetic valves of the forklift mast are short-circuited, the LED indicator light will repeatedly turn on for 200 ms and turn off for 200 ms, forming a flash;

[0041] If the lift, lower, tilt forward, and tilt backward valve stem switches of the forklift mast are closed and the corresponding electromagnetic valves of the forklift mast are open-circuited, the LED indicator light will flash on for 1 s and off for 1 s;

[0042] Finally, through logical calculation and judgment by the main control MCU2, the LED indicator light is controlled by the fault location module 4 for display. Thus, the operator can quickly locate the cause of the fault according to the indication of the indicator light.

[0043] The working principle of the present utility model: During use, the controller system, through the main control MCU2, collects the states of the lift, lower, tilt forward, and tilt backward valve stem switches of the forklift mast provided by the switch signal acquisition module 1, and then judges the fault situation according to the working states of the corresponding electromagnetic valves provided by the current sampling module 5, which specifically includes the following:

[0044] If the lift, lower, tilt forward, and tilt backward valve stem switches of the forklift mast are disconnected and the LED indicator light is constantly off, it indicates that the disconnection state of the valve stem switch of the forklift mast is normal;

[0045] If the lift, lower, tilt forward, and tilt backward valve stem switches of the forklift mast are closed and the LED indicator light is constantly off, the operator can quickly determine that the valve stem switch has a fault;

[0046] If the lift, lower, tilt forward, and tilt backward valve stem switches of the forklift mast are closed and the corresponding electromagnetic valves of the forklift mast are normal, and the LED indicator light is constantly on, the operator can thus determine that the system is operating normally;

[0047] If the lift, lower, tilt forward, and tilt backward valve stem switches of the forklift mast are closed and the corresponding electromagnetic valves of the forklift mast are short-circuited, and the LED indicator light repeatedly turns on for 200 ms and turns off for 200 ms, forming a flash; then the operator can quickly determine that the electromagnetic valve has a short-circuit fault;

[0048] If the lift, lower, tilt forward, and tilt backward valve stem switches of the forklift mast are closed and the corresponding electromagnetic valves of the forklift mast are open-circuited, and the LED indicator light flashes on for 1 s and off for 1 s; then the operator can quickly determine that the electromagnetic valve has an open-circuit fault.

[0049] It should be noted that in this text, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprising", "including" or any other variant thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements not only includes those elements, but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device.

[0050] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principle and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A controller system for quickly locating faults, characterized in that: The controller system includes: a switch signal acquisition module (1), a main control MCU (2), a drive output valve control module (3), a fault location module (4), and a current sampling module (5); The output end of the switch signal acquisition module (1) is signal-connected to an input end of the main control MCU (2); an output end of the main control MCU (2) is signal-connected to the input end of the drive output valve control module (3); the output end of the drive output valve control module (3) is signal-connected to the input end of the current sampling module (5); the output end of the current sampling module (5) is signal-connected to an input end of the main control MCU (2); an output end of the main control MCU (2) is signal-connected to the input end of the fault location module (4).

2. The controller system for quickly locating faults according to claim 1, wherein: The switch signal acquisition module (1) acquires the valve rod switch signals of the forklift mast, including: the lift valve rod switch signal, the lower valve rod switch signal, the forward tilt valve rod switch signal, and the rear tilt valve rod switch signal.

3. A controller system for quickly locating faults according to claim 1, characterized in that: The drive output valve control module (3) controls the electromagnetic valves of the forklift mast, including: the lift electromagnetic valve, the lower electromagnetic valve, the forward tilt electromagnetic valve, and the rear tilt electromagnetic valve.

4. A controller system for quickly locating faults according to claim 1, characterized in that: The current sampling module (5) acquires the output currents of the electromagnetic valves, including: the output current of the lift electromagnetic valve, the output current of the lower electromagnetic valve, the output current of the forward tilt electromagnetic valve, and the output current of the rear tilt electromagnetic valve.

5. A controller system for quickly locating faults according to claim 1, characterized in that: The output end of the fault location module (4) is signal-connected to the LED indicator light.

6. The controller system for quickly locating faults according to claim 5, wherein: The fault location module (4) displays at least five states through the LED indicator light.

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