Electrical control system of three-way stacking forklift

Abstract

The utility model provides an electrical control system of a three-way stacking forklift, which comprises a power supply module used for supplying power to the whole system; the executing mechanism is used for executing walking, lifting and steering actions of the vehicle; the controller group comprises a traction motor controller, a steering motor controller and a motion control module which are in communication connection through a CAN bus; the controller group further comprises an analog quantity and switching value control unit, the analog quantity and switching value control unit comprises an accelerator and a main lifting potentiometer, and the analog signal output end of the accelerator is connected to the traction motor controller; the analog signal output end of the main lifting potentiometer is connected to the motion control module; the action activation unit is configured to allow the vehicle to execute walking, lifting and steering actions at the same time when the DIN1 port to the DIN4 port of the motion control module are all high levels; and when only the DIN1 port is at a high level, the vehicle is allowed to independently execute walking or lifting or steering actions. And the vehicle control precision, the safety and the system coordination are improved.

Description

Technical Field

[0001] This utility model relates to the field of electrical control technology for three-way stacker forklifts, specifically to an electrical control system for a three-way stacker forklift. Background Technology

[0002] In recent years, three-way stacker forklifts (whose forks can perform forking actions in three directions) have been widely used in the logistics and warehousing field. The reliability and accuracy of their electrical control systems directly affect operational efficiency and safety. Currently, the electrical control solutions for three-way stacker forklifts generally suffer from the following technical bottlenecks:

[0003] The activation conditions for actions are ambiguous: existing systems lack clear combination conditions for triggering core actions such as walking, lifting, and turning. For example, the activation of operation commands relies solely on a single switch signal, without implementing hierarchical access control through multi-port state combinations. This may lead to misoperation or illegal action triggering (such as accidental activation of the lifting mechanism when safety conditions are not met), posing safety hazards and reducing operational reliability.

[0004] Disconnect between analog and digital control: In traditional solutions, the speed regulation (analog control) of lifting and lowering actions and the solenoid valve switching (digital control) are often designed independently, resulting in insufficient coordination between the two. For example, the lifting speed cannot be continuously adjusted according to the analog signal input by the potentiometer, and can only achieve coarse control through the "on / off" position, which restricts the precision of the action and the dynamic response capability, and affects the work efficiency.

[0005] Therefore, it is crucial to design a three-way stacking forklift that can improve control accuracy, safety, and system coordination. Utility Model Content

[0006] To solve the above-mentioned technical problems, this utility model provides a three-way stacker forklift electrical control system, including:

[0007] The power module is used to supply power to the entire system;

[0008] Actuators are used to perform driving, lifting, and steering actions on vehicles; and

[0009] The controller group includes a traction motor controller, a steering motor controller, and a motion control module connected via a CAN bus. The input terminal of the motion control module is connected to the output terminals of the traction motor controller and the steering motor controller, respectively. The controller group also includes:

[0010] The analog and digital control unit includes a throttle accelerator and a main lifting potentiometer. The analog signal output terminal of the throttle accelerator is connected to the AIN_1 port of the traction motor controller to output a first analog signal; the analog signal output terminal of the main lifting potentiometer is connected to the AIN_2 port of the motion control module to output a second analog signal.

[0011] The motion activation unit is configured such that when all DIN_1 to DIN_4 ports of the motion control module are high, the motion control module sends a coordinated motion command to the traction motor controller and the steering motor controller to allow the vehicle to perform walking, lifting, and steering actions simultaneously; when only the DIN_1 port is high, the motion control module sends a single action enable signal to the traction motor controller and the steering motor controller respectively through independent control lines to allow the vehicle to perform walking, lifting, or steering actions individually.

[0012] Furthermore, the range of the first analog signal is 0.5V-4.5V, wherein:

[0013] When the first analog signal value is 2.5V-4.5V, the vehicle moves forward.

[0014] When the first analog signal value is 2.5V, the vehicle is stationary;

[0015] When the value of the first analog signal is 2.5V-0.5V, the vehicle reverses.

[0016] Furthermore, the range of the second analog signal is 0.5V-4.5V, wherein:

[0017] When the value of the second analog signal is 2.5V-0.5V, the main hoisting solenoid valve opens and adjusts the oil pump motor speed according to the analog signal.

[0018] When the second analog signal value is 2.5V-4.5V, the main lowering solenoid valve opens and the opening degree of the main lowering proportional valve is adjusted according to the analog signal.

[0019] Furthermore, the main lifting solenoid valve and the main lowering solenoid valve are respectively connected to the motion control module via relays, and the main lowering proportional valve is connected to the motion control module.

[0020] Furthermore, the power module includes a fuse unit, which includes an emergency stop switch, a key switch, and a main contactor. The emergency stop switch and the key switch are connected in series in the main power supply circuit to cut off the power supply in an emergency.

[0021] Furthermore, the actuator includes:

[0022] A traction motor, wherein the U, V, and W three-phase output terminals of the traction motor controller are connected to the traction motor;

[0023] A steering motor is provided, and the U, V, and W three-phase output terminals of the steering motor controller are connected to the steering motor.

[0024] Furthermore, the system also includes a motor protection module, which includes:

[0025] A first temperature sensor and a second temperature sensor are respectively connected to the traction motor and the steering motor;

[0026] A direction encoder, which is communicatively connected to the steering motor controller.

[0027] Furthermore, the traction motor controller is model ACS80M23D-35P; the steering motor controller is model APS80M-35P; and the motion control module includes two controllers, model VMC80-23P and VMC80-35P.

[0028] Furthermore, the controller group also includes a lateral shift controller and a rotation controller, wherein the lateral shift controller is connected to a lateral shift motor and the rotation controller is connected to a rotation motor.

[0029] Furthermore, the lateral displacement controller is model ARES8020N-S-AC-P-M215; the rotation controller is model ARES4835-S-AC-M334.

[0030] Compared with the prior art, the present invention has the following beneficial effects:

[0031] This invention solves the problem of ambiguous activation conditions for the three major actions of walking, lifting, and turning by combining the input port status of the motion control module, thus avoiding misoperation. At the same time, it adjusts the oil pump motor speed and the opening degree of the main descent proportional valve according to the corresponding analog signal to realize real-time dynamic coordinated control of analog and digital signals, thus overcoming the shortcomings of the existing coarse control that can only achieve "on / off". Attached Figure Description

[0032] Figure 1 This is a circuit diagram of the fuse unit disclosed in an embodiment of the present utility model;

[0033] Figure 2 This is a partial circuit diagram of the motion control module disclosed in an embodiment of the present utility model, showing the ports of the VMC80-23P controller;

[0034] Figure 3 This is a partial circuit diagram of the motion control module disclosed in an embodiment of the present utility model, showing the ports of the VMC80-35P controller;

[0035] Figure 4 This is a circuit diagram of the traction motor controller disclosed in an embodiment of the present utility model;

[0036] Figure 5 This is a circuit diagram of the steering motor controller disclosed in an embodiment of the present utility model;

[0037] Figure 6 This is a circuit diagram of the lateral displacement controller and rotation controller disclosed in the embodiments of this utility model;

[0038] Figure 7 This is a circuit diagram of the low-voltage circuit section disclosed in an embodiment of the present utility model.

[0039] In the picture:

[0040] 10. Traction motor controller; 11. Traction motor; 12. Oil pump motor;

[0041] 20. Steering motor controller; 21. Steering motor; 22. Direction encoder;

[0042] 31. VMC80-35P controller; 32. VMC80-23P controller;

[0043] 41. Lateral shift controller; 42. Rotation controller. Detailed Implementation

[0044] To make the technical solutions and effects of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings in the embodiments. Obviously, the described embodiments are some embodiments of this utility model, but not all embodiments.

[0045] The present invention aims to provide an electrical control system for a three-way stacker forklift, which solves the problems of ambiguous activation conditions and disconnect between analog and digital control in existing three-way stacker forklifts.

[0046] The system mainly includes a power module, a controller group, and actuators. The power module is used to supply power to the entire system, and the actuators are used to perform walking, lifting, and steering actions of the vehicle.

[0047] The power module also includes a fuse unit, which comprises an emergency stop switch, a key switch, and a main contactor. The emergency stop switch quickly cuts off the power supply, preventing damage from overload. The key switch is used for normal power on / off control, ensuring safe system operation. The main contactor, as a key control component for circuit switching, controls the power supply to the entire system. The emergency stop switch and key switch are connected in series in the main power supply circuit for quickly cutting off the power supply in emergency situations.

[0048] The actuator includes a traction motor 11 and a steering motor 21. The U, V, and W three-phase output terminals of the traction motor controller 10 are connected to the traction motor 11, and the U, V, and W three-phase output terminals of the steering motor controller 20 are connected to the steering motor.

[0049] Please see Figure 1-6 The controller group in this embodiment will be described in detail below.

[0050] The controller assembly includes a traction motor controller 10, a steering motor controller 20, and a motion control module, all connected via a CAN bus. The input terminals of the motion control module are connected to the output terminals of the traction motor controller 10 and the steering motor controller 20, respectively. The controller assembly also includes an action activation unit and analog and digital quantity control units.

[0051] The action activation unit is configured as follows:

[0052] When the DIN_1, DIN_2, DIN_3, and DIN_4 ports of the motion control module are all at a high level, the motion control module sends coordinated action commands to the traction motor controller 10 and the steering motor controller 20 to allow the vehicle to perform walking, lifting, and steering actions simultaneously.

[0053] When only the DIN_1 port of the motion control module is high, the motion control module sends single-action enable signals to the traction motor controller 10 and the steering motor controller 20 through independent control lines, respectively, to allow the vehicle to perform walking, lifting or steering actions independently.

[0054] The analog and digital control unit includes the throttle accelerator and the main lift potentiometer, specifically:

[0055] The throttle accelerator controls the vehicle's movement. The analog signal output of the throttle accelerator is connected to the AIN_1 port of the traction motor controller 10 to output a first analog signal; the range of the first analog signal is 0.5V-4.5V, where:

[0056] When the first analog signal value is 2.5V-4.5V, the vehicle moves forward.

[0057] When the first analog signal value is 2.5V, the vehicle is stationary, and the controller has a built-in HPD function.

[0058] When the value of the first analog signal is 2.5V-0.5V, the vehicle reverses.

[0059] The main lifting potentiometer controls the vehicle's main lifting / lowering actions. The analog signal output of the main lifting potentiometer is connected to the AIN_2 port of the motion control module to output a second analog signal; the range of the second analog signal is 0.5V-4.5V, where:

[0060] When the second analog signal value is 2.5V-0.5V, the main hoisting solenoid valve opens and adjusts the speed of the oil pump motor 12 according to the analog signal; when DIN_6 of port 31 of the VMC80-35P controller is high, the hoisting motor stops operating.

[0061] When the second analog signal value is 2.5V-4.5V, the main lowering solenoid valve opens and the opening degree of the main lowering proportional valve is adjusted according to the analog signal.

[0062] The auxiliary hoisting / lowering switch is closed and DIN_8 on port 31 of the VMC80-35P controller is at a high level, simultaneously in conjunction with the main hoisting / lowering potentiometer (AIN_2) signal, where:

[0063] When the second analog signal value is 2.5V-0.5V, the auxiliary lifting solenoid valve (12V) opens, the lifting controller DIN_7 opens (12V), and the oil pump motor adjusts its speed according to the change of analog input.

[0064] When the second analog signal value is 2.5V-4.5V, the secondary descent solenoid valve opens, that is, port OD_10 is at a high level, and the secondary descent proportional valve OD_5 adjusts its opening degree according to the change of analog input.

[0065] When port DIN_5 of the VMC80-35P controller 31 is high, the walking speed is limited to 60% of the maximum speed.

[0066] The main lifting solenoid valve and the main lowering solenoid valve are connected to the motion control module via relays, and the main lowering proportional valve is connected to the motion control module.

[0067] In a further embodiment, the system also includes a motor protection module, which comprises a first temperature sensor, a second temperature sensor, and a direction encoder 22. The first and second temperature sensors are respectively connected to the traction motor 11 and the steering motor 21 for real-time monitoring of their temperatures. The direction encoder 22 is communicatively connected to the steering motor controller 20 to receive signals from the direction encoder 22, ensuring stable and precise operation of the steering motor.

[0068] In this embodiment, the traction motor controller 10 is model ACS80M23D-35P; the steering motor controller 20 is model APS80M-35P; the motion control module includes VMC80-35P controller 31 and VMC80-23P controller 32. VMC80-35P controller 31 and VMC80-23P controller 32 are important modules related to vehicle motion control. Each module has multiple input / output ports for receiving external signals and outputting control signals. For example, various switch signals, such as the position signal of the operating handle and limit switch signals, are received through the DIN (digital input) port to sense the vehicle's operating commands and operating status.

[0069] The controller group also includes a lateral controller 41 and a rotary controller 42, both of which are servo drives. The lateral controller 41 is connected to the lateral motor, and the rotary controller 42 is connected to the rotary motor. The model number of the lateral controller 41 is ARES8020N-S-AC-P-M215; the model number of the rotary controller 42 is ARES4835-S-AC-M334.

[0070] like Figure 7 The low-voltage circuit shown provides power from the battery to the DC-DC converter via the emergency stop switch and key switch, converting the 80V voltage to 24V voltage to power electrical components such as headlights, warning lights, buzzers, electric horns, and cooling fans.

[0071] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An electrical control system for a three-way stacker forklift, characterized in that, include: The power module is used to supply power to the entire system; Actuators are used by vehicles to perform driving, lifting, and steering actions; as well as The controller group includes a traction motor controller (10), a steering motor controller (20), and a motion control module connected via a CAN bus. The input terminal of the motion control module is connected to the output terminals of the traction motor controller (10) and the steering motor controller (20), respectively. The controller group also includes: The analog and digital control unit includes a throttle accelerator and a main lifting potentiometer. The analog signal output terminal of the throttle accelerator is connected to the AIN_1 port of the traction motor controller (10) to output a first analog signal; the analog signal output terminal of the main lifting potentiometer is connected to the AIN_2 port of the motion control module to output a second analog signal. The motion activation unit is configured such that when all DIN_1 to DIN_4 ports of the motion control module are at a high level, the motion control module sends a coordinated motion command to the traction motor controller (10) and the steering motor controller (20) to allow the vehicle to perform walking, lifting and steering actions simultaneously; when only the DIN_1 port is at a high level, the motion control module sends a single action enable signal to the traction motor controller (10) and the steering motor controller (20) respectively through independent control lines to allow the vehicle to perform walking, lifting or steering actions individually.

2. The three-way stacker forklift electrical control system according to claim 1, characterized in that, The range of the first analog signal is 0.5V-4.5V, where: When the first analog signal value is 2.5V-4.5V, the vehicle moves forward. When the first analog signal value is 2.5V, the vehicle is stationary; When the value of the first analog signal is 2.5V-0.5V, the vehicle reverses.

3. The three-way stacker forklift electrical control system according to claim 1, characterized in that, The range of the second analog signal is 0.5V-4.5V, where: When the value of the second analog signal is 2.5V-0.5V, the main lifting solenoid valve opens and the speed of the oil pump motor (12) is adjusted according to the analog signal; When the second analog signal value is 2.5V-4.5V, the main lowering solenoid valve opens and the opening degree of the main lowering proportional valve is adjusted according to the analog signal.

4. The three-way stacker forklift electrical control system according to claim 3, characterized in that, The main lifting solenoid valve and the main lowering solenoid valve are respectively connected to the motion control module via relays, and the main lowering proportional valve is connected to the motion control module.

5. The three-way stacker forklift electrical control system according to claim 1, characterized in that, The power module includes a fuse unit, which includes an emergency stop switch, a key switch, and a main contactor. The emergency stop switch and the key switch are connected in series in the main power supply circuit to cut off the power supply in an emergency.

6. The three-way stacker forklift electrical control system according to claim 3, characterized in that, The implementing mechanism includes: Traction motor (11), the U, V, W three-phase output terminals of the traction motor controller (10) are connected to the traction motor (11). Steering motor (21), the U, V, W three-phase output terminals of the steering motor controller (20) are connected to the steering motor.

7. The three-way stacker forklift electrical control system according to claim 6, characterized in that, The system also includes a motor protection module, which includes: A first temperature sensor and a second temperature sensor are respectively connected to the traction motor (11) and the steering motor (21). A direction encoder (22) is communicatively connected to the steering motor controller (20).

8. The three-way stacker forklift electrical control system according to claim 1, characterized in that, The traction motor controller (10) is model ACS80M23D-35P; the steering motor controller (20) is model APS80M-35P; the motion control module includes a VMC80-23P controller (32) and a VMC80-35P controller (31).

9. The three-way stacker forklift electrical control system according to claim 1, characterized in that, The controller group also includes a lateral controller (41) and a rotation controller (42), wherein the lateral controller (41) is connected to a lateral motor and the rotation controller (42) is connected to a rotation motor.

10. The three-way stacker forklift electrical control system according to claim 9, characterized in that, The lateral shift controller (41) is model ARES8020N-S-AC-P-M215; the rotation controller (42) is model ARES4835-S-AC-M334.

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