Test system for torsion wire harness performance of electric pallet truck

Abstract

The utility model discloses a test system for torsion wire harness performance of an electric pallet truck, which comprises a first torsion wire harness connected between the output end of a controller and the input ends of a handle and an interlocking switch, and a second torsion wire harness connected between the output end of the controller and the input ends of a traction motor and an electromagnetic brake, the first torsion wire harness and the second torsion wire harness are respectively connected with a test wire harness, and the test wire harnesses are connected with a function indication box; the function indication box comprises a buzzer and a plurality of groups of detection units consisting of optical couplers and relays; in each detection unit, the optocoupler is connected with the controller, and the relay is connected with the buzzer. According to the utility model, two torsion wire harnesses with more serious rotation frequency and abrasion degree are respectively connected with a test wire harness, and are respectively connected with a controller through a function indication box; whether the twisted wire harness is good or not is judged by observing whether the light-emitting diode in the function indication box emits light or not, and meanwhile a buzzer gives an alarm for reminding.

Description

TECHNICAL FIELD

[0001] The utility model relates to electric pallet truck field, concretely is a kind of electric pallet truck torsion wire harness performance's test system. BACKGROUND

[0002] Electric pallet truck is widely used in various logistics, warehousing and transportation fields due to its small size, lightweight design and easy operation. In the design of the control system of electric pallet truck, the system architecture based on controller signal direct analog quantity and switch input is currently widely used. Compared with the design of input command and controller signal receiving using CAN communication scheme, this design has the advantages of lower cost and simpler and more intuitive fault elimination process. However, this design also faces a significant problem, which is that there are too many internal connection wires in the vehicle, resulting in increased system complexity.

[0003] In electric pallet truck, the body harness refers to a component composed of multiple wires, terminals, connectors and other elements, used to connect handle, switch, motor sensor, controller and other key components into a complete circuit system. It is an important part of the electric system of electric pallet truck, responsible for transmitting power, control signals and sensor signals, ensuring smooth communication between devices, and thus realizing the normal operation of the vehicle. During the assembly of the body harness, the signal lines and power lines of the controller need to pass through the handle connecting rod and the handle to realize connection. When the handle drives the drive unit to rotate, the body harness connected to the controller will also rotate. Especially during turning and running of the vehicle, the handle needs to be frequently pressed and rotated, which further increases the rotation frequency and wear degree of the body harness. Among them, the first torsion harness 9-1 is the connection line between the handle 2 and the interlock switch 14 mounted on the handle bracket, and the second torsion harness 9-2 is the connection line between the traction motor 3 and the electromagnetic brake 16 mounted on the traction motor drive shaft and the controller 1 (see Figure 1

[0004] Therefore, during the new product design stage, the selection of wires in the body harness and reliability testing have become important detection links before the vehicle is produced. However, due to the limitations of the current analog quantity and switch input design system commonly used in electric pallet truck, if a wire in the body harness breaks during vehicle use, the system cannot determine whether there is an analog quantity and switch operation command input, and cannot send an alarm signal in time, making it difficult to accurately judge the rationality of the selected wire specifications, manufacturing process and effective service life of the body harness. This problem poses a potential challenge to improving the overall performance and reliability of electric pallet truck. UTILITY MODEL CONTENTS ​

[0005] In order to solve the above problems, the utility model discloses a kind of test system of electric pallet truck torsion harness performance, to detect and judge the performance of vehicle body harness in real time.

[0006] The specific technical scheme of the utility model is as follows:

[0007] The utility model discloses a kind of test system of electric pallet truck torsion harness performance, including the first torsion harness between the output of controller and handle, interlock switch input end, and the second torsion harness between the output of controller and traction motor, electromagnetic brake input end;The first torsion harness, second torsion harness is connected with a test harness respectively, and the test harness is connected with function indicating box;The function indicating box includes buzzer and multiple detection units consisting of photoelectric coupler and relay;Photoelectric coupler in each detection unit is connected with controller, and relay is connected with buzzer.

[0008] Further scheme, the photoelectric coupler includes photosensitive triode and light emitting diode, the photosensitive triode is connected with the coil of relay, and the contact of relay is connected with buzzer;The relay is normally closed relay, when light emitting diode is electrified and emits light, the coil of relay is electrified and makes contact open, and buzzer circuit is disconnected;When light emitting diode is de-energized and extinguishes, the coil of relay is de-energized and makes contact connect, and buzzer circuit is connected and alarms.

[0009] Further scheme, the traction motor includes speed sensor, temperature sensor;

[0010] The second torsion harness is connected with the second function indicating box by second test harness, and the second function indicating box includes 8 groups of detection units, wherein one end of 5 groups of detection units is connected with controller, and the other end is connected with speed sensor;One end of 2 groups of detection units is connected with controller, and the other end is connected with temperature sensor;One end of 1 group of detection units is connected with controller, and the other end is connected with controller by electromagnetic brake.

[0011] Further scheme, the handle includes key switch connected with battery pack, the output of key switch is connected with switch circuit board, and hoisting switch, lowering switch, accelerator, reverse switch, emergency reverse switch, horn switch are installed on the switch circuit board;

[0012] The first torsion wire bundle is connected with the first test wire bundle and the first function indicating box, the first function indicating box comprises eight groups of detection units, one end of the first group of detection units is connected with the controller and the other end is connected with the key switch; one end of the second group of detection units is connected with the controller through the coil of the lifting contactor and the other end is connected with the lifting switch, the contact of the lifting contactor is connected in series between the battery group and the lifting motor; one end of the third group of detection units is connected with the controller through the descending electromagnetic valve and the other end is connected with the descending switch; one end of the fourth group of detection units is connected with the controller and the other end is connected with the accelerator; one end of the fifth group of detection units is connected with the controller and the other end is connected with the reverse switch; one end of the sixth group of detection units is connected with the controller and the other end is connected with the emergency reverse switch; one end of the seventh group of detection units is connected with the controller through the interlocking switch; one end of the eighth group of detection units is connected with the horn switch and the other end is connected with the horn.

[0013] In a further aspect, the power port of the function indicating box is connected with the vehicle control power supply for power supply.

[0014] The controller and the handle are connected in series at two ends of the battery group, a second fuse is connected between the positive electrode of the battery group and the controller; a first fuse and an emergency power-off switch are connected in series between the positive electrode of the battery group and the handle.

[0015] The test method is as follows:

[0016] S1, connect the first test wire bundle on the first torsion wire bundle connected between the output end of the controller and the handle and the input end of the interlocking switch, then connect the first test wire bundle with the first function indicating box, and connect the first function indicating box with the controller;

[0017] Connect the second test wire bundle on the second torsion wire bundle connected between the output end of the controller and the traction motor and the input end of the electromagnetic brake, then connect the second test wire bundle with the second function indicating box, and connect the second function indicating box with the traction motor;

[0018] S2, turn on the power supply, close the key switch in the handle, and the controller and the handle circuit board are powered on for self-checking, at the same time, the light coupling in the first function indicating box and the second function indicating box is provided with power supply;

[0019] S3, after closing the key switch, operate the lifting switch, the descending switch, the interlocking switch, the accelerator, the reverse switch, the emergency reverse switch and the horn switch in turn, and observe whether the light-emitting diode in each first light coupling in the first function indicating box emits light; if all emit light, it indicates that the first torsion wire bundle is in good performance; if one light-emitting diode is extinguished, the corresponding relay wire package loses power and the contact is connected, the first buzzer circuit is connected and alarms; it indicates that the first torsion wire bundle has open circuit;

[0020] In detail as follows:

[0021] S31, close the key switch, when the first torsion wire harness is good, then the first light emitting diode of the first function indicating box is powered on and emits light, the relay coil is powered on and the contact is disconnected, and the first buzzer circuit is disconnected; when the light emitting diode is powered off and extinguished, the relay coil is powered off and the contact is connected, the first buzzer circuit is connected and alarms; indicating that the first torsion wire harness connected here is open circuit;

[0022] S32, after closing the key switch, close the lifting switch again, then the coil of the first light emitting diode of the first function indicating box and the lifting contactor is powered on, the contact of the lifting contactor is connected, and the lifting motor works to drive the fork to rise; if the light emitting diode of the first light emitting diode emits light, indicating that the first torsion wire harness is good; when the light emitting diode of the first light emitting diode is extinguished, the relay coil is powered off and the contact is connected, the first buzzer circuit is connected and alarms; indicating that the first torsion wire harness connected here is open circuit;

[0023] S33, after closing the key switch in the handle, close the descending switch again, then the first light emitting diode of the first function indicating box and the descending relay is powered on, the descending oil cylinder is opened, and the fork is lowered; if the light emitting diode of the first light emitting diode emits light, indicating that the first torsion wire harness is good; when the light emitting diode of the first light emitting diode is extinguished, the relay coil is powered off and the contact is connected, the first buzzer circuit is connected and alarms; indicating that the first torsion wire harness connected here is open circuit;

[0024] S34, after closing the key switch in the handle, close the interlocking switch, then the light emitting diode of the first light emitting diode of the first function indicating box is powered on and emits light; when the light emitting diode of the first light emitting diode is extinguished, the relay coil is powered off and the contact is connected, the first buzzer circuit is connected and alarms; indicating that the first torsion wire harness connected here is open circuit;

[0025] S35, after closing the key switch and the interlocking switch, rotate the accelerator in the handle backward, close the backward switch, the light emitting diode of the first light emitting diode and the first light emitting diode are powered on and emit light, and control the vehicle to run in the backward direction; if the first light emitting diode or the first light emitting diode is extinguished, the relay coil is powered off and the contact is connected, the first buzzer circuit is connected and alarms; indicating that the first torsion wire harness connected here is open circuit;

[0026] S36, after closing the key switch and the interlocking switch, close the emergency reverse switch, the light emitting diode of the first light emitting diode is powered on and emits light, and the controller controls the traction motor to run in the reverse direction; if the light emitting diode of the first light emitting diode is extinguished, the relay coil is powered off and the contact is connected, the first buzzer circuit is connected and alarms; indicating that the first torsion wire harness connected here is open circuit;

[0027] S37, after closing the key switch in the handle, then close the horn switch, the first light coupling eight light emitting diode is powered and emits light, the horn works; if the first light coupling eight light emitting diode is extinguished, the relay coil is powered off to make the contact connected, the first buzzer circuit is connected to alarm; indicating that the first torsion wire harness connected here occurs open circuit.

[0028] S4, see if each second light emitting diode in the second function indication box emits light, if all emit light, it indicates that the second torsion wire harness is good in performance; if one light emitting diode is extinguished, the corresponding relay coil is powered off to make the contact connected, the second buzzer circuit is connected to alarm; indicating that the second torsion wire harness occurs open circuit.

[0029] The utility model discloses a test system for torsion wire harness of electric pallet truck, which comprises a test harness, a function indication box and a controller, wherein the test harness is connected with each port of the function indication box, and the function indication box is connected with the controller.

[0030] The electric wires of each torsion part of the vehicle body wire harness are connected with the function indication box through the test harness, and the on-off state of each electric wire is detected. In the reliability test of the vehicle body wire harness, when any electric wire in the test part of the vehicle body wire harness is disconnected, the function indication box will send out the buzzer and the light emitting diode is extinguished to prompt that the vehicle body wire harness has a disconnection.

[0031] Therefore, the utility model is limited in the design system of the analog quantity and switch input commonly used in the current electric pallet truck, and when the electric wire in the vehicle body wire harness is disconnected during the use of the vehicle, whether the light emitting diode emits light and whether the buzzer alarms can be used to directly judge the rationality of the selected electric wire specification, the manufacturing process and the effective service life of the vehicle body wire harness. BRIEF DESCRIPTION OF DRAWINGS

[0032] Figure 1 It is the structure diagram of the electric pallet truck in the utility model;

[0033] Figure 2 It is the principle block diagram of the utility model.

[0034] Figure 3 It is the circuit diagram of the utility model.

[0035] In the figure: controller 1, handle 2, key switch 21, lifting switch 22, lowering switch 23, accelerator 24, reverse switch 25, emergency reverse switch 26, horn switch 27,

[0036] traction motor 3, speed sensor 31, temperature sensor 32;

[0037] first test harness 4, second test harness 5, first function indication box 6, second function indication box 7, battery pack 8, vehicle body harness 9, first torsion harness 91, second torsion harness 92, emergency power-off switch 10, lifting motor 11, lifting contactor 12, lowering solenoid valve 13, interlock switch 14, horn 15, electromagnetic brake 16, first fuse 17, second fuse 18;

[0038] In the first function indication box 6:

[0039] first optocoupler 1 611, first optocoupler 2 612, first optocoupler 3 613, first optocoupler 4 614, first optocoupler 5 615, first optocoupler 6 616, first optocoupler 7 617, first optocoupler 8 618,

[0040] first relay 1 621, first relay 2 622, first relay 3 623, first relay 4 624, first relay 5 625, first relay 6 626, first relay 7 627, first relay 8 628,

[0041] first buzzer 63;

[0042] In the second function indication box 7:

[0043] second optocoupler 1 711, second optocoupler 2 712, second optocoupler 3 713, second optocoupler 4 714, second optocoupler 5 715, second optocoupler 6 716, second optocoupler 7 717, second optocoupler 8 718,

[0044] second relay 1 721, second relay 2 722, second relay 3 723, second relay 4 724, second relay 5 725, second relay 6 726, second relay 7 727, second relay 8 728,

[0045] second buzzer 73. DETAILED DESCRIPTION

[0046] The technical solutions of the present application will be further described below in conjunction with the drawings and specific embodiments.

[0047] Example 1:

[0048] As Figure 1The electric pallet truck structure schematic diagram, including handle 2, controller 1, traction motor 3 and electromagnetic brake 16, interlock switch 14, vehicle harness 9. Wherein interlock switch 14 is installed on the bracket of handle 2, electromagnetic brake 16 is installed on the drive shaft of traction motor 3. Vehicle harness 9 connects handle 2, interlock switch 14, traction motor 3, controller 1, electromagnetic brake 16, lifting contactor 12, lowering electromagnetic valve 13, lifting motor 11 into a complete circuit system. In the process of vehicle operation, the rotation frequency and wear degree are more serious, and there are two torsion harnesses, wherein the first torsion harness 9-1 is the connecting line between handle 2, interlock switch 14 installed on the handle bracket and controller 1 respectively, and the second torsion harness 9-2 is the connecting line between traction motor 3, electromagnetic brake 16 installed on the drive shaft of traction motor and controller 1 respectively.

[0049] As shown in Figure 2 A kind of electric pallet truck torsion harness performance test system, including the first torsion harness 91 connected between the output end of controller 1 and the input end of handle 2, interlock switch 14, and the second torsion harness 92 connected between the output end of controller 1 and the input end of traction motor 3, electromagnetic brake 16;The first torsion harness 91, second torsion harness 92 are connected with a test harness respectively, and the test harness is connected with a function indicating box;The function indicating box includes buzzer and multiple groups of detection units composed of optical coupler and relay;The optical coupler in each detection unit is connected with controller 1, and the relay is connected with buzzer.

[0050] That is, by observing whether the function indicating box will emit buzzer and whether the light-emitting diode will be extinguished, the performance of vehicle harness is judged, that is, whether open circuit occurs due to wear, and then whether the selected vehicle harness is qualified is judged. And after hearing the buzzer emitting buzzer alarm, it is observed in detail which light-emitting diode of the function indicating box is extinguished, and according to this, the specific open circuit wire can be judged, and the failure time of vehicle harness 9 can also be obtained.

[0051] The optical coupler and relay are existing products, the optical coupler includes photosensitive triode and light-emitting diode, the photosensitive triode is connected with the wire package of relay, and the contact of relay is connected with buzzer;The relay is normally closed relay, when the light-emitting diode is powered and emits light, the wire package of relay is powered and the contact is disconnected, and the buzzer circuit is disconnected;When the light-emitting diode is powered off and extinguished, the wire package of relay is powered off and the contact is connected, and the buzzer circuit is connected and alarms.

[0052] The traction motor 3 includes speed sensor 31 and temperature sensor 32;

[0053] The second torsion wire harness 92 is connected with the second function indicating box 7 through the second test wire harness 5, the second function indicating box 7 includes 8 groups of detection units, one end of 5 groups of detection units is connected with the controller 1, the other end is connected with the speed sensor 31; one end of 2 groups of detection units is connected with the controller 1, the other end is connected with the temperature sensor 32; one end of 1 group of detection units is connected with the controller 1, the other end is connected with the controller 1 through the electromagnetic brake 16.

[0054] The handle 2 includes a key switch 21 connected with the battery pack 8, the output end of the key switch 21 is connected with a switch circuit board, the switch circuit board is installed with a lifting switch 22, a descending switch 23, an accelerator 24, a reverse switch 25, an emergency reverse switch 26, a horn switch 27;

[0055] The first torsion wire harness 91 is connected with the first function indicating box 6 through the first test wire harness 4, the first function indicating box 6 includes 8 groups of detection units, one end of the first group of detection units is connected with the controller 1, the other end is connected with the key switch 21; one end of the second group of detection units is connected with the controller 1 through the coil of the lifting contactor 12, the other end is connected with the lifting switch 22, the contact of the lifting contactor 12 is connected in series between the battery pack 8 and the lifting motor 11; one end of the third group of detection units is connected with the controller 1 through the descending electromagnetic valve 13, the other end is connected with the descending switch 23; one end of the fourth group of detection units is connected with the controller 1, the other end is connected with the accelerator 24; one end of the fifth group of detection units is connected with the controller 1, the other end is connected with the reverse switch 25; one end of the sixth group of detection units is connected with the controller 1, the other end is connected with the emergency reverse switch 26; one end of the seventh group of detection units is connected with the controller 1 through the interlocking switch 14; one end of the eighth group of detection units is connected with the horn switch 27, the other end is connected with the horn 15.

[0056] Further scheme, the power port of the function indicating box is connected with the vehicle control power supply for power supply;

[0057] The controller 1 and the handle 2 are connected in series at both ends of the battery pack 8, the positive electrode end of the battery pack 8 is connected with the controller 1 through the second fuse 18; the positive electrode end of the battery pack 8 is connected with the handle 2 in sequence through the first fuse 17 and the emergency power-off switch 10.

[0058] The specific circuit is as follows Figure 3As shown, the first twisted wire bundle 91 is connected with the power output end J2-1, the lifting switch signal end J2-2, the lowering switch signal end J2-3, the acceleration signal end J2-4, the reverse switch signal end J2-5, the emergency reverse switch signal end J2-6, and the horn signal end J2-7 in the handle 2 as the starting end; and the corresponding terminal is connected with the control power end J1-1, the lifting signal end J1-4, the lowering signal end J1-5, the acceleration signal end J1-6, the reverse signal end J1-7, the emergency reverse signal end J1-8, the interlock signal power end J1-3, and the positive power end of the horn 15 in the controller 1.

[0059] The second twisted wire bundle 92 is connected with the positive and negative power wire bundle 9 of the speed sensor 31, the A-phase, B-phase, and C-phase of the traction motor 3, and the PT+ and PT- signal ends of the temperature sensor 32 as the starting end; and the corresponding terminal is connected with the +24V, the negative power GND1, J1-11, J1-12, J1-13, PT+, PT-, PB+, and PB- ports of the controller 1.

[0060] The first test wire bundle 5 is connected between the first twisted wire bundle 91 and the first function indication box 6, and the second test wire bundle 6 is connected between the second twisted wire bundle 92 and the second function indication box 7.

[0061] The battery 8 provides working power for the test system. The positive output terminal IB+ of the battery 8 is connected to the power output terminal J2-1 in the handle 2 through the first fuse 17 and the emergency power-off switch 10 in sequence. The power output terminal J2-1 provides power for the CMM port connection of the switch circuit board of the handle 2. The power output terminal J2-1 is output to the control power terminal 3B+ through the light-emitting diode of the first optocoupler 611 in the first function indication box 6. The control power terminal 3B+ is connected to the vehicle control battery to provide power for the light-dependent triodes in the eight first optocouplers (the first optocoupler one 611, the first optocoupler two 612, the first optocoupler three 613, the first optocoupler four 614, the first optocoupler five 615, the first optocoupler six 616, the first optocoupler seven 617, and the first optocoupler eight 618) and the eight first relays (the first relay one 621, the first relay two 622, the first relay three 623, the first relay four 624, the first relay five 625, the first relay six 626, the first relay seven 627, and the first relay eight 628) in the first function indication box 6. Similarly, the control power terminal 3B+ provides power for the eight second optocouplers (the second optocoupler one 711, the second optocoupler two 712, the second optocoupler three 713, the second optocoupler four 714, the second optocoupler five 715, the second optocoupler six 716, the second optocoupler seven 717, and the second optocoupler eight 718) and the eight second relays (the second relay one 721, the second relay two 722, the second relay three 723, the second relay four 724, the second relay five 725, the second relay six 726, the second relay seven 727, and the second relay eight 728) in the second function indication box 7.

[0062] The function ports J2-2, J2-3, J2-4, J2-5, J2-6, and J2-7 of the handle 2 are connected to the positive power supply of the horn 15 through the first test wire harness 4 and the light-emitting diodes of the first optocouplers (612, 613, 614, 615, 616, and 618) in the first function indication box 6 and the ports J1-4, J1-5, J1-6, J1-7, and J1-8 in the controller 1 in sequence. The light-emitting diode output end of the first optocoupler 617 is connected to J1-3 in the controller 1 through the interlocking switch 14.

[0063] The traction motor 3 is connected to the controller 1. Specifically, the signal terminals +24V, J1-11, J1-12, J1-13, and GND1 in the controller 1 are connected to the signal terminals +24V, A phase, B phase, C phase, and GND3 in the speed sensor 31 through the second optocouplers (715, 712, 713, 714, and 711) in the second function indication box 7 (the three are one-to-one correspondence, and the specific connection relationship is as shown in the following table). Figure 3The signal ports PT+ and PT- of the temperature sensor 32 are connected to the PT+ and PT- of the controller 1 through the second optical couplings 716 and 717 respectively; one end of the electromagnetic brake 16 is connected to the second optical coupling 718 through the second test wire harness 5, and the other end of the electromagnetic brake 16 is connected to the signal port PB+ of the controller 1, and the second optical coupling 718 is connected to the signal port PB- of the controller 1.

[0064] When the light-emitting diodes in the first optical couplings of the first function indication box 6 connected to the first torsion wire harness 91 emit light, the corresponding photoelectric triodes generate photoelectric current to output a conduction circuit to provide power supply for the coil of each first relay, and the first relay is a normally closed relay, and the contact of the first relay is disconnected. Therefore, the buzzer 63 electrically connected to the contact of the first relay does not work.

[0065] When the light-emitting diodes in the second optical couplings of the second function indication box 7 connected to the second torsion wire harness 92 emit light, the corresponding photoelectric triodes generate photoelectric current to output a conduction circuit to provide power supply for the coil of each second relay, and the second relay is a normally closed relay, and the contact of the second relay is disconnected. Therefore, the buzzer 73 electrically connected to the contact of the second relay does not work.

[0066] The positive output terminal 1B+ of the battery pack 8 is connected to the power positive supply 2B+ of the controller 1, and a second fuse 18 is connected in series between the positive output terminal 1B+ of the battery pack 8 and the power positive supply 2B+ of the controller 1. The power output terminal of the second fuse 18 is connected to the positive power supply terminal of the lifting motor 11 through the contact of the lifting contactor 12.

[0067] Embodiment Two:

[0068] The test device in Embodiment One is used to test the performance of the electric pallet truck torsion wire harness, and the test method is as follows:

[0069] S1, the first test wire harness 4 is connected to the first torsion wire harness 91 connected between the output terminal of the controller 1 and the input terminal of the handle 2 and the interlocking switch 14, and then the first test wire harness 4 is connected to the first function indication box 6, and the first function indication box 6 is connected to the controller 1.

[0070] The second test wire harness 5 is connected to the second torsion wire harness 92 connected between the output terminal of the controller 1 and the input terminal of the traction motor 3 and the electromagnetic brake 16, and then the second test wire harness 5 is connected to the second function indication box 7, and the second function indication box 7 is connected to the traction motor 3.

[0071] S2, the power supply is turned on, the key switch 21 in the handle 2 is closed, the controller 1 and the switch circuit board in the handle 2 are powered on for self-checking, and the optical couplings in the first function indication box 6 and the second function indication box 7 are powered on.

[0072] S3, after closing the key switch 21, then in turn operate the lifting switch 22, the lowering switch 23, the interlock switch 14, the accelerator 24, the reverse switch 25, the emergency reverse switch 26 and the horn switch 27, and check whether the light emitting diodes in the first function indicating box 6 are emitting light; if all the light emitting diodes are emitting light, it indicates that the first twisted wire harness 91 is in good condition; if one of the light emitting diodes is not emitting light, the corresponding relay's wire package loses power and the contact is connected, the first buzzer 63 circuit is connected and an alarm is given; it indicates that the first twisted wire harness 91 is open circuit;

[0073] S31, after closing the key switch 21, when the first twisted wire harness 91 is in good condition, the light emitting diode of the first optocoupler 611 in the first function indicating box 6 is powered and emits light, the relay's wire package gets power and the contact is disconnected, and the first buzzer 63 circuit is disconnected; when the light emitting diode loses power and stops emitting light, the relay's wire package loses power and the contact is connected, the first buzzer 63 circuit is connected and an alarm is given; it indicates that the first twisted wire harness connected here is open circuit;

[0074] S32, after closing the key switch 21 in the handle 2, then close the lifting switch 22, the wire package of the first optocoupler 612 and the lifting contactor 12 in the first function indicating box 6 is powered, and the contact of the lifting contactor 12 is connected, the lifting motor 11 works and drives the forks to rise; if the light emitting diode of the first optocoupler 612 emits light, it indicates that the first twisted wire harness 91 is in good condition; when the light emitting diode of the first optocoupler 612 stops emitting light, the relay's wire package loses power and the contact is connected, the first buzzer 63 circuit is connected and an alarm is given; it indicates that the first twisted wire harness connected here is open circuit;

[0075] S33, after closing the key switch 21 in the handle 2, then close the lowering switch 23, the wire package of the first optocoupler 613 and the lowering relay 13 in the first function indicating box 6 is powered, and the lowering relay 13 opens the oil return circuit of the lowering oil cylinder, and the forks are lowered; if the light emitting diode of the first optocoupler 613 emits light, it indicates that the first twisted wire harness 91 is in good condition; when the light emitting diode of the first optocoupler 613 stops emitting light, the relay's wire package loses power and the contact is connected, the first buzzer 63 circuit is connected and an alarm is given; it indicates that the first twisted wire harness connected here is open circuit;

[0076] S34, after closing the key switch 21 in the handle 2, then close the interlock switch 14, the light emitting diode of the first optocoupler 617 in the first function indicating box 6 is powered and emits light; when the light emitting diode of the first optocoupler 617 stops emitting light, the relay's wire package loses power and the contact is connected, the first buzzer 63 circuit is connected and an alarm is given; it indicates that the first twisted wire harness connected here is open circuit;

[0077] S35, after closing the key switch 21 and the interlock switch 14, accelerate the accelerator 24 in the handle 2, close the reverse switch 25, the light emitting diodes in the first optocoupler four 614 and the first optocoupler five 615 are powered and emit light, and control the vehicle to run in the reverse direction; if the first optocoupler four 614 or the first optocoupler five 615 is extinguished, the coil of the relay loses power and the contact is connected, the first buzzer 63 circuit is connected and alarms; indicating that the first twisted wire harness 91 connected here is open circuit;

[0078] S36, after closing the key switch 21 and the interlock switch 14, close the emergency reverse switch 26, the light emitting diodes in the first optocoupler six 616 are powered and emit light, and the controller 1 controls the traction motor 4 to run in reverse; if the light emitting diode in the first optocoupler six 616 is extinguished, the coil of the relay loses power and the contact is connected, the first buzzer 63 circuit is connected and alarms; indicating that the first twisted wire harness 91 connected here is open circuit;

[0079] S37, after closing the key switch 21 in the handle 2, close the horn switch 27, the light emitting diodes in the first optocoupler eight 618 are powered and emit light, and the horn 15 works; if the light emitting diode in the first optocoupler eight 618 is extinguished, the coil of the relay loses power and the contact is connected, the first buzzer 63 circuit is connected and alarms; indicating that the first twisted wire harness 91 connected here is open circuit.

[0080] S4, check whether the light emitting diodes in each second optocoupler in the second function indicating box 7 emit light, if they all emit light, it indicates that the second twisted wire harness 92 is in good condition; if one of the light emitting diodes is extinguished, the coil of the corresponding relay loses power and the contact is connected, the second buzzer 73 circuit is connected and alarms; indicating that the second twisted wire harness 92 is open circuit.

[0081] The specific process is as follows:

[0082] When the key switch 21 in the handle 2 is turned on, the power output port J2-1 in the handle 2 provides power for the CMM port on the switch circuit board of the handle 2, and the power output port J2-1 outputs to the control power port 3B+ of the vehicle via the light emitting diode of the first optocoupler one 611 in the first function indication box 6. One of the power in the control power port 3B+ of the vehicle is input to the control power port J1-1 in the controller 1, and the controller 1 is powered on for self-checking; the other power is input to the first function indication box 6 to provide power for the photosensitive triode in the eight first optocouplers. When the circuit is connected, the light emitting diode in the first optocoupler one 611 emits light, the photosensitive triode generates photoelectric current and outputs, the coil of the first relay one 621 generates a pressure difference, the contacts of the first relay one 621 are disconnected, and the first buzzer 63 does not work. At the same time, the switch circuit board in the handle 2 is powered on, and the handle 2 completes self-checking. When the lifting switch 22 in the handle 2 is pressed, the 24V high voltage signal passes through the lifting switch 22, is connected in series to the positive electrode of the coil of the lifting contactor 12 via the first test wire harness 4 and the light emitting diode of the second optocoupler two 612 in the function indication box 6, and the negative electrode of the coil of the lifting contactor 12 is connected to the lifting control port J1-4 of the controller 1. The coil of the lifting contactor 12 generates a pressure difference, the lifting contactor 12 is normally open, the contacts of the lifting contactor 12 are connected, the lifting motor 11 works, and then drives the oil cylinder to lift the vehicle fork. If the line between the handle 2 and the control power port J1-1 of the controller 1 is open, the light emitting diode in the first optocoupler one 611 is extinguished, the photosensitive triode is disconnected, the coil of the first relay one 621 has no pressure difference, the contacts of the first relay one 621 are connected, and the circuit of the first buzzer 63 is connected and works to produce a buzzing alarm.

[0083] Similarly, when the other wires of the first and second torsion wire harnesses 91, 92 in the vehicle body wire harness 9 are open, the light emitting diodes in the first and second function indication boxes 6, 7 are extinguished, the photosensitive triodes are disconnected, and the circuits of the first buzzer 63 or the second buzzer 73 are connected and work.

[0084] When the key switch 21 in the handle 2 is turned on and the control power port 3B+ of the vehicle is normally powered, the controller 1 and the handle 2 complete self-checking, and when the lower switch 23 in the handle 2 is pressed, the 24V high voltage signal passes through the lower switch 23, is connected in series to the lower electromagnetic valve 13 via the test wire harness 4 and the light emitting diode of the first optocoupler three 613 in the first function indication box 6, the lower electromagnetic valve 13 is powered on to open the oil circuit, and the fork is lowered. When the related connection line is open, the light emitting diode in the first optocoupler three 613 is extinguished, the photosensitive triode is disconnected, the coil of the first relay three 623 has no pressure difference, the contacts of the first relay three 623 are connected, and the first buzzer 63 works.

[0085] When the key switch 21 in the handle 2 is turned on, the control power port 3B+ of the vehicle is normally supplied with 24V power. When the handle is pressed to the area allowing the vehicle to run, the interlock switch 14 is closed, and the 24V power is connected to the interlock signal port J1-3 of the controller 1 through the tested wiring harness 4 and the light emitting diode in the first photo-coupler seven 617 in the first function indicating box 6 in series, and the controller 1 allows the vehicle to run. When the relevant connection line is open, the light emitting diode in the first photo-coupler seven 617 is extinguished, the photo-sensitive triode is open, the line pack of the first relay seven 627 has no voltage difference, the contact is closed, and the first buzzer 63 works.

[0086] When the key switch 21 in the handle 2 is turned on, the control power port 3B+ of the vehicle is normally supplied with 24V power. After the controller 1 and the handle 2 complete self-checking, the interlock switch 14 is turned on. When the accelerator 24 in the handle 2 is rotated forward, the speed signal is connected to the speed control port J1-6 of the controller 1 through the tested wiring harness 4 and the light emitting diode in the first photo-coupler four 614 in the first function indicating box 6 in series, and the controller 1 controls the traction motor 3 to run at a speed according to the forward acceleration command signal, and the vehicle runs at a speed in the forward direction. When the relevant connection line is open, the light emitting diode in the first photo-coupler four 614 is extinguished, the photo-sensitive triode is open, the line pack of the first relay four 624 has no voltage difference, the contact is closed, and the first buzzer 63 works.

[0087] When the key switch 21 in the handle 2 is turned on, the control power port 3B+ of the vehicle is normally supplied with 24V power. After the controller 1 and the handle 2 complete self-checking, the interlock switch 14 is turned on. When the accelerator 24 in the handle 2 is rotated backward, and the reverse switch 25 is turned on, the reverse signal is connected to the reverse control port J1-7 of the controller 1 through the tested wiring harness 4 and the light emitting diode in the first photo-coupler five 615 in the first function indicating box 6 in series, and the speed signal is connected to the speed control port J1-6 of the controller 1 through the tested wiring harness 4 and the light emitting diode in the first photo-coupler five 615 in the first function indicating box 6 in series, and the controller 1 controls the traction motor 3 to run at a speed according to the reverse command and the acceleration command signal, and the vehicle runs at a speed in the reverse direction. When the relevant connection line is open, the light emitting diode in the first photo-coupler four 614 or the first photo-coupler five 615 is extinguished, the corresponding photo-sensitive triode is open, the line pack of the first relay four 624 or the first relay five 625 has no voltage difference, the contact is closed, and the first buzzer 63 works.

[0088] When the key switch 21 in the handle 2 is turned on, the control power port 3B+ of the vehicle is normally powered, the controller 1 and the handle 2 complete self-checking, and the interlocking switch 14 is turned on, the emergency reverse switch 26 in the handle 2 is triggered to turn on the emergency reverse switch 26, the emergency reverse signal is transmitted through the tested wiring harness 4 and the light-emitting diode in the first optical coupling six 616 in the first function indicating box 6 to the emergency reverse signal port J1-8 of the controller 1, and the controller 1 controls the traction motor 3 to operate in reverse according to the emergency reverse signal. When the relevant connection line is open, the light-emitting diode in the first optical coupling six 616 is extinguished, the photosensitive triode is disconnected, the wire package of the first relay six 626 has no voltage difference, the contact is turned on, and the first buzzer 63 works.

[0089] When the key switch 21 in the handle 2 is turned on, the control power port 3B+ of the vehicle is normally powered, the handle 2 completes self-checking, and the horn switch 27 in the handle 2 is pressed, the horn signal is transmitted through the tested wiring harness 4 and the light-emitting diode in the first optical coupling eight 618 in the first function indicating box 6 to turn on the positive power supply of the horn switch 27, and the horn sounds. When the relevant connection line is open, the light-emitting diode in the first optical coupling eight 618 is extinguished, the photosensitive triode is disconnected, the wire package of the first relay eight 628 has no voltage difference, the contact is turned on, and the first buzzer 63 works.

[0090] The second torsion wiring harness 92 in the vehicle body wiring harness 9 is the connection line between the traction motor 3 and the electromagnetic brake 16 on the traction motor drive shaft and the controller 1. When the speed sensor 3-1 positive power supply +24V, negative power supply GND3, A phase, B phase, C phase on the traction motor 3, PT+ and PT- in the temperature sensor 3-2, and the wire package lead-out line of the electromagnetic brake 16 are reliably connected with +24V, GND1, J1-11, J1-12, J1-13, PT+, PT-, PB+, and PB- ports in the controller 1, the light-emitting diodes in the respective second optical couplings (711, 712, 713, 714, 715, 716, 717, 718) in the second function indicating box 7 connected therewith are turned on, and the vehicle can normally work. When the above-mentioned relevant connection line is open, the light-emitting diodes in the respective second optical couplings are extinguished, the corresponding photosensitive triodes are disconnected, the wire packages of the second relays (721, 722, 723, 724, 725, 726, 727, 728) connected therewith have no voltage difference, the contacts are turned on, and the second buzzer 73 works to emit a buzzer alarm.

[0091] When the test tester hears the buzzer alarm of the first buzzer 63 or the second buzzer 73, it is observed whether the respective light-emitting diodes in the first and second function indicating boxes 6 and 7 are extinguished, thereby judging the specific open circuit of the wire and obtaining the exact time of failure of the vehicle body wiring harness 9.

[0092] The above only describes preferred embodiments of the present application and is not used to limit the present application, and any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application is within the protection scope of the claims of the present application.

Claims

1. A test system for the torsion harness performance of an electric pallet truck, comprising a first torsion harness (91) connected between the output of a controller (1) and the input of a handle (2), an interlock switch (14), and a second torsion harness (92) connected between the output of the controller (1) and the input of a traction motor (3), an electromagnetic brake (16); characterized in that: The first torsion wire bundle (91) and the second torsion wire bundle (92) are respectively connected with a test wire bundle, and the test wire bundle is connected with a function indicating box; the function indicating box comprises a buzzer and multiple groups of detection units composed of an optical coupler and a relay; the optical coupler in each detection unit is connected with the controller (1), and the relay is connected with the buzzer.

2. The test system of claim 1, wherein: The optical coupler comprises a photosensitive triode and a light-emitting diode, the photosensitive triode is connected with the coil of the relay, and the contact of the relay is connected with the buzzer; the relay is a normally closed relay, when the light-emitting diode is powered and emits light, the coil of the relay is powered and the contact is disconnected, and the buzzer circuit is disconnected; when the light-emitting diode is powered off and extinguished, the coil of the relay is powered off and the contact is connected, and the buzzer circuit is connected and alarms.

3. The test system of claim 1, wherein: The traction motor (3) comprises a speed sensor (31) and a temperature sensor (32); The second torsion wire bundle (92) is connected with the second function indicating box (7) through the second test wire bundle (5), and the second function indicating box (7) comprises eight groups of detection units, one end of five groups of detection units is connected with the controller (1), and the other end is connected with the speed sensor (31); one end of two groups of detection units is connected with the controller (1), and the other end is connected with the temperature sensor (32); one end of one group of detection units is connected with the controller (1), and the other end is connected with the controller (1) through the electromagnetic brake (16).

4. The test system of claim 1, wherein: The handle (2) comprises a key switch (21) connected with a battery pack (8), an output end of the key switch (21) is connected with a switch circuit board, and the switch circuit board is provided with a lifting switch (22), a descending switch (23), an accelerator (24), a backward switch (25), an emergency reverse switch (26) and a horn switch (27); The first torsion wire bundle (91) is connected with the first function indicating box (6) through the first test wire bundle (4), and the first function indicating box (6) comprises eight groups of detection units, one end of the first group of detection units is connected with the controller (1), and the other end is connected with the key switch (21); one end of the second group of detection units is connected with the controller (1) through the coil of the lifting contactor (12), and the other end is connected with the lifting switch (22), the contact of the lifting contactor (12) is connected in series between the battery pack (8) and the lifting motor (11); one end of the third group of detection units is connected with the controller (1) through the descending electromagnetic valve (13), and the other end is connected with the descending switch (23); one end of the fourth group of detection units is connected with the controller (1), and the other end is connected with the accelerator (24); one end of the fifth group of detection units is connected with the controller (1), and the other end is connected with the backward switch (25); one end of the sixth group of detection units is connected with the controller (1), and the other end is connected with the emergency reverse switch (26); one end of the seventh group of detection units is connected with the controller (1) through the interlocking switch (14); one end of the eighth group of detection units is connected with the horn switch (27), and the other end is connected with the horn (15).

5. The test system of claim 1, wherein: The power port of the function indicating box is connected with the vehicle control power supply for power supply.

6. The test system of claim 1, wherein: The controller (1) and the handle (2) are connected in series at two ends of the battery pack (8), a second fuse (18) is connected between the positive terminal of the battery pack (8) and the controller (1); a first fuse (17) and an emergency power-off switch (10) are connected in sequence between the positive terminal of the battery pack (8) and the handle (2).

Images