Modular platform fork truck

Abstract

This utility model relates to the field of industrial vehicle technology, and more particularly to a modular platform forklift, including a frame, a battery system, and an electronic control system. The frame comprises a load-bearing frame and an outer casing detachably connected to the load-bearing frame; a battery compartment is formed within the load-bearing frame, and the battery system is housed within the battery compartment; the outer casing includes an integral casing fixedly connected to the load-bearing frame, and a detachable casing detachably connected to the integral casing; the integral casing covers the outer side of the load-bearing frame; the electronic control system is located within the load-bearing frame, and the control assembly of the electronic control system is located within the coverage area of ​​the detachable casing. This solution has the advantages of improved maintenance efficiency, optimized electrical layout, and enhanced battery system versatility.

Description

Technical Field

[0001] This utility model relates to the field of industrial vehicle technology, and in particular to a modular platform forklift. Background Technology

[0002] The current promotion of electric forklifts converted from gasoline-powered vehicles faces severe technical bottlenecks. When converting traditional forklifts to electric power, electrical components such as motor controllers and battery management systems are typically installed directly in the gaps of the existing frame, resulting in messy and unprotected wiring. More importantly, these electrical components are often fixed inside the frame or under welded metal casings, requiring the removal of multiple external components and even the use of cutting equipment during maintenance, significantly extending troubleshooting and maintenance time. This chaotic layout not only increases daily maintenance costs but can also cause operational interruptions in emergency situations due to the inability to quickly access critical controllers.

[0003] Meanwhile, the lack of functional separation between the forklift's exterior panels and load-bearing structure further exacerbates maintenance difficulties. Most frames are encased in a single welded steel plate, serving both as a mechanical load-bearing structure and a protective shell. This design leads to two problems: first, the installation location of electrical components is limited, making it difficult for maintenance personnel to access deeply embedded controllers; second, due to differences in frame structure, the shapes of the panels vary widely among forklifts from different manufacturers, making it impossible to establish universal maintenance tools and procedures. The chaotic appearance of forklifts after conversion from gasoline to electric not only affects brand image but also leads to a surge in spare parts inventory due to the non-standardized panel design.

[0004] Furthermore, the non-standardized design of battery systems has become a significant obstacle to the electrification process. Existing modification solutions fall into two extremes: one is simply placing a small-capacity battery where the engine has been removed, resulting in a waste of valuable space and severely insufficient range; the other is custom-designing irregularly shaped battery packs for each vehicle frame, increasing capacity by filling irregular spaces. While the latter alleviates the range problem, it completely eliminates battery versatility. Even more seriously, custom-designed batteries are often deeply integrated with the frame structure, requiring the simultaneous disassembly of multiple mechanical components during replacement, making what should be simple battery maintenance exceptionally complex.

[0005] These intertwined shortcomings—inefficient maintenance due to chaotic electrical layout, poor operational accessibility caused by mixed frame functions, and supply chain burdens imposed by non-standard batteries—constitute a fatal bottleneck for the large-scale application of converted electric forklifts. The industry urgently needs an innovative solution that can systematically address the three major issues of electrical layout optimization, rapid maintenance support, and battery standardization. Existing technologies urgently need improvement to address these problems. Summary of the Invention

[0006] To address the aforementioned issues, the present invention aims to provide a modular platform forklift that offers advantages such as improved maintenance efficiency, optimized electrical layout, and enhanced battery system versatility.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] This application provides a modular platform forklift, with the following technical solution: A modular platform forklift includes a frame, a battery system, and an electronic control system. The frame comprises a load frame and an outer casing detachably connected to the load frame. A battery compartment is formed within the load frame, housing the battery system. The outer casing includes an integral casing fixedly connected to the load frame and a detachable casing detachably connected to the integral casing. The integral casing covers the outer side of the load frame. The electronic control system is located within the load frame, and its control assembly is situated within the coverage area of ​​the detachable casing. This technical solution achieves functional decoupling and modular layout through structural reconfiguration. The frame is decomposed into two independent modules: the load frame and the outer casing. The load frame, as the core load-bearing structure, houses the battery compartment, ensuring both mechanical strength and integrated battery system encapsulation. The outer casing adopts a split design, combining the integral casing and the detachable casing to maintain overall protective performance while creating a quickly detachable maintenance window for the electronic control system's control assembly. The integrated cover is welded to the load-bearing frame, ensuring a smooth exterior profile. Since the exterior cover bears almost no load, a thinner cover is sufficient. Notably, the control assembly of the electronic control system is located within the area covered by the removable cover, allowing for routine maintenance without damaging the main frame structure. Simply removing a specific cover provides direct access to the core electrical components.

[0009] Furthermore, this application proposes that the battery compartment be located within a load-bearing frame beneath the seat, with a cover for the battery compartment and the seat mounted on the cover. This technical solution utilizes the space beneath the seat to centrally house the battery system by arranging the battery compartment within the load-bearing frame. Simultaneously, the integrated design of the cover and seat makes the seat itself a fixed component of the cover. When maintenance or battery replacement is required, simply removing the seat directly exposes the battery compartment, avoiding the cumbersome operation of disassembling multiple peripheral components required in traditional solutions. The cover-mounted battery compartment structure ensures the protection of the battery system and, through the detachable cover and seat linkage design, minimizes the battery maintenance path.

[0010] Furthermore, this application proposes that the control assembly of the electronic control system includes an electrical panel disposed on the side of the load frame; the removable housing includes a side housing, with the electrical panel located within the coverage area of ​​the side housing. This technical solution achieves rapid maintenance through a collaborative design of spatial layout and structural layering. By placing the electrical panel on the side of the load frame, the critical controller is no longer installed deep within the traditional frame, but directly exposed to the coverage area of ​​the removable housing. As a removable component, the side housing's coverage area corresponds to the position of the electrical panel; during maintenance, only the side housing needs to be removed to directly access the electrical panel without removing other peripheral structures. This design optimizes the accessibility of electrical components through side layout and utilizes the partial disassembly and assembly characteristics of the removable housing to avoid the operational complexity of removing the entire housing, thereby significantly shortening troubleshooting time.

[0011] Furthermore, this application proposes that the control assembly of the electronic control system includes a main controller located at the rear of the load frame; the removable housing includes a rear housing, with the main controller located within the coverage area of ​​the rear housing. This solution achieves rapid maintenance of the main controller by arranging it at the rear of the load frame and placing it within the coverage area of ​​the removable rear housing. Specifically, the rear-mounted layout of the main controller separates it from other functional areas of the forklift, avoiding the difficulty of access caused by deep burial within the traditional frame; the removable design of the rear housing directly exposes the location of the main controller, eliminating the need to remove other peripheral components or damage the frame structure during maintenance. This combination of spatial separation and modular covering ensures the protection requirements of the main controller during operation, while the independent disassembly and reassembly of the rear housing allows maintenance personnel to directly access critical components, significantly improving maintenance efficiency.

[0012] Furthermore, this application also proposes that a counterweight assembly is provided on the rear side of the frame, a main controller is located inside the counterweight assembly, and the rear cover is detachably connected to the counterweight assembly.

[0013] Furthermore, this application proposes that the internal cavity of the integrated housing constitutes the hydraulic oil tank. This solution achieves integrated frame design by directly using the internal cavity of the integrated housing as the hydraulic oil tank. In this technical solution, the integrated housing, originally only an exterior covering, is given a dual function: both covering the outer frame and directly carrying hydraulic oil through its internal cavity structure. This design eliminates the additional installation space and fixing structure required by traditional independent oil tanks, resulting in a more compact overall frame layout. Since the hydraulic oil tank and housing are integrated, maintenance or replacement only requires operation on the detachable integrated housing, avoiding the cumbersome process of separately disassembling the oil tank and surrounding components in traditional solutions. In addition, the rigid structure of the integrated housing itself can meet the pressure requirements of the hydraulic oil tank without additional reinforcement, further simplifying the frame construction.

[0014] Furthermore, this application proposes a battery system comprising multiple unit battery modules, which are detachably connected in series or parallel to form an extended battery array adapted to the shape of the forklift battery compartment, thereby creating battery systems with different voltage platforms and capacities. This technical solution achieves flexible configuration and rapid maintenance of the battery system through modular battery design. The detachable connection of multiple unit battery modules frees the battery system from fixed shapes, allowing for direct replacement of individual modules during maintenance without overall disassembly. The series or parallel connection allows for adjustment of the total voltage and capacity according to actual operating conditions, overcoming the limitations of single parameters in traditional customized batteries. The extended battery array is arranged to match the shape of the battery compartment, fully utilizing the internal space of the chassis while avoiding installation interference caused by irregularly shaped battery packs. This modular combination structure allows the same batch of unit battery modules to be adapted to different forklift models, significantly improving the versatility of the battery system, while reducing supply chain management difficulties through standardized components.

[0015] Furthermore, this application proposes that the battery system also includes a high-voltage box, which is connected to multiple battery modules and the electronic control system via high-voltage resistant wiring harnesses. This technical solution, by adding a high-voltage box as the core electrical hub of the battery system, constructs a standardized connection system between the modular battery and the vehicle's electrical system. The introduction of the high-voltage box enables centralized management of the output current of multiple battery modules. It establishes physical connections with each battery module via high-voltage resistant wiring harnesses. This design ensures line stability during high-voltage, high-current transmission and eliminates contact impedance differences when different battery modules are connected in parallel through a unified interface. The high-voltage resistant wiring harnesses are specifically selected for the high-voltage environment that may arise from the modular battery array. Their insulation performance and current-carrying capacity match the expansion requirements of the battery system, ensuring the safety of electrical connections when adding or removing battery modules. The direct connection between the high-voltage box and the electronic control system forms a closed-loop control link, enabling precise regulation of the battery system's energy output and providing a hardware pathway for real-time monitoring by the battery management system.

[0016] Furthermore, this application proposes that the battery system includes a battery management system (BMS) for real-time monitoring of the voltage, temperature, and health status of the unit battery modules, and for feeding back fault information to the electronic control system via a communication protocol. This technical solution constructs a multi-dimensional battery status monitoring system by introducing a BMS. The BMS collects voltage parameters of the unit battery modules in real time, accurately identifying abnormal operating conditions such as overcharging or undercharging; it continuously monitors temperature data, providing early warning of thermal runaway risks and preventing battery pack performance degradation; and by evaluating health status parameters, it can predict battery life degradation trends and optimize charging and discharging strategies. In particular, the use of a communication protocol to directly feed fault information back to the electronic control system enables real-time interaction between battery status data and the control system, allowing fault information to be quickly analyzed and triggering corresponding protection mechanisms. This closed-loop monitoring mechanism not only enhances the active protection capabilities of the battery system but also significantly shortens fault location time through digital management, providing maintenance personnel with accurate fault diagnosis data.

[0017] As can be seen from the above, the modular platform forklift and its battery system and electronic control system provided in this application enable rapid maintenance of key components through a detachable cover design. Combined with a modular battery system, it improves versatility and effectively solves the problems of chaotic electrical layout, difficult maintenance, and non-standardized batteries in traditional forklifts. It has the advantages of improving maintenance efficiency, optimizing electrical layout, and enhancing the versatility of battery systems. Attached Figure Description

[0018] Figure 1 This is a structural schematic diagram of a modular platform forklift provided in this application.

[0019] Figure 2 This is a schematic diagram of the internal layout of a modular platform forklift provided in this application.

[0020] Figure 3 The present application provides a schematic diagram of the battery system. Detailed Implementation

[0021] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0022] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0023] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more, unless otherwise expressly defined.

[0024] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0025] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0026] In existing technologies, electric forklifts converted from gasoline-powered vehicles face three major technical challenges: chaotic layout of electrical components, mixed frame functions, and non-standardized battery systems. Traditional forklift conversions involve haphazardly installing components such as motor controllers in frame gaps, resulting in messy and unprotected wiring. The frame is encased in a single welded steel plate, serving both as a mechanical load-bearing structure and an outer shell. Battery systems suffer from the dual contradiction of low space utilization and poor versatility; customized battery packs are deeply integrated with the frame, requiring simultaneous disassembly of mechanical components for maintenance. These shortcomings collectively lead to high maintenance costs, poor operational accessibility, and a heavy burden on the supply chain.

[0027] To address these issues, the inventors discovered that the root cause lay in the lack of functional layering in the vehicle frame, the non-removable protective structure, and the lack of modular battery design. Analysis revealed that separating the load-bearing structure from the external protective structure could simultaneously resolve the conflict between mechanical strength and maintenance accessibility; and that standardizing the battery compartment and adopting a scalable array could balance space utilization and versatility. Based on this, the inventors proposed decomposing the vehicle frame into independent load-bearing frames and a removable cover, creating rapid maintenance access while ensuring structural strength, and simultaneously designing a modular battery system to accommodate different capacity requirements.

[0028] Therefore, as Figure 1-3 As shown, this embodiment proposes a modular platform forklift, including a frame, a battery system, and an electronic control system. The frame includes a load frame 2 and an outer casing detachably connected to the load frame 2. A battery compartment 21 is formed within the load frame 2, and the battery system is housed within the battery compartment 21. The outer casing includes an integral casing 11 fixedly connected to the load frame 2, and a detachable casing detachably connected to the integral casing 11. The integral casing 11 covers the outer side of the load frame 2. The electronic control system is disposed within the load frame 2, and the control assembly of the electronic control system is located within the coverage area of ​​the detachable casing.

[0029] The load frame 2 refers to the main load-bearing structure of the forklift, which can be constructed using high-strength steel welded into a frame structure. Its internal space is divided into at least a battery compartment 21 and an electronic control system installation area. This frame independently bears the mechanical load, eliminating the need for the exterior cover to bear stress, thus allowing for a lightweight and detachable design. The exterior cover refers to the protective component covering the outside of the load frame 2. The exterior cover enhances the uniformity and adaptability of the converted electric forklift, creating a streamlined appearance. Specifically, it can be implemented as an integrated cover 11 fixedly connected to the frame and a detachable cover (not labeled) connected by bolts. The integrated cover 11 covers the outer main outline of the frame, while the detachable cover is positioned to correspond to the locations of key components of the electronic control system, forming modular maintenance windows. The battery compartment 21 refers to the enclosed space inside the load frame 2 used to house the battery system. This can be achieved by creating cavities of various shapes with covers within the frame. The size and shape of the compartment can be adjusted based on the converted electric forklift, allowing for the installation of modular battery arrays of different capacities. The electronic control system assembly refers to the core electrical control components of a forklift, which may include components such as the motor controller and battery management system. Its installation location is limited to the area covered by a removable housing. This layout ensures that maintenance only requires removing a portion of the housing to access the control elements.

[0030] In this design, the load frame 2 serves as an independent load-bearing structure, isolating the battery system from the electronic control system through internal space division. An integrated housing 11 is fixedly connected to the frame, forming a basic protective layer and maintaining aesthetic integrity. A removable housing connects to the integrated housing 11 via standardized interfaces, covering the area containing critical components of the electronic control system. When maintenance is required, operators only need to remove a specific removable housing to directly access the control assembly without damaging the main structure. The battery system is encapsulated within a standardized battery compartment 21, which adapts to different capacity requirements through modular assembly. The compartment opening is offset from the removable housing location to avoid the risk of misoperation. Through the above technical solution, this application achieves directional accessibility to the electrical component layout. During maintenance, only a partial removable housing needs to be removed to access the control assembly, significantly shortening troubleshooting time. The layered design of the vehicle frame structure eliminates the need for the outer housing to bear weight, allowing for a lightweight and quick-disassembly structure, reducing maintenance workload. The standardized battery compartment 21, combined with a modular battery array design, enables the battery system to be scalable and versatile, reducing the types of spare parts and simplifying the replacement process.

[0031] In the specific implementation scheme, the battery compartment 21 is located within the load frame 2 below the seat. The battery compartment 21 has a cover, and the seat is mounted on the cover. The battery compartment 21 being located within the load frame 2 below the seat means that the storage space for the battery system is arranged directly below the operator's seating position. This can be achieved by welding a support structure inside the frame to form a closed cavity, utilizing the unused vertical space under the seat to achieve a centralized layout of the battery system. The cover is a closed component that covers the opening of the battery compartment 21. It can be made of stamped steel plate or engineering plastic and is a detachable cover. Its edges are connected to the load frame 2 with bolts to form a sealed protection for the battery compartment 21. The seat being mounted on the cover means that the fixed base of the driver's seat is structurally integrated with the cover. This can be achieved by welding a mounting bracket onto the surface of the cover and locking the seat base to the bracket with bolts, so that the weight of the seat directly acts on the cover. In this scheme, the battery compartment 21 is integrated into the internal space of the load frame 2 directly below the seat, and the cover, as the closed component at the top of the battery compartment 21, forms a linked structure with the seat. When the battery needs to be inspected or replaced, simply loosen the bolts connecting the seat and the battery compartment cover to remove the seat and cover together, directly exposing the inside of the battery compartment 21. This design avoids the steps required by traditional solutions, which require disassembling multiple layers of peripheral components such as the side panels and top cover, while utilizing the space under the seat to achieve a compact layout of the battery system.

[0032] like Figure 1 and 2As shown, the control assembly of the electronic control system includes an electrical panel 42 located on the side of the load frame 2; the removable housing includes a side cover 12, with the electrical panel 42 located within the coverage area of ​​the side cover 12. The electrical panel 42 refers to an integrated mounting structure for multiple electrical control units, which can be installed on the side of the load frame 2 using bolts or rail clips, for centralized placement of controllers, relays, and terminals. This layout allows electrical components to be removed from their deep-buried state within the frame and directly exposed to the coverage area of ​​the removable housing. The side cover 12 refers to an independent outer shell component covering the side of the load frame 2, which can be a split structure with quick-release clips or threaded fasteners, its coverage area spatially corresponding to the installation position of the electrical panel 42. This component achieves selective exposure of electrical components through partial disassembly and assembly. In this design, the electrical panel 42 is positioned on the side of the load frame 2, forming a spatial nesting relationship with the side cover 12. When maintenance is required, the side cover 12 can be individually removed by releasing the clips or loosening the bolts, directly exposing the complete operating interface of the electrical panel 42. The wiring ports, status indicator lights, and debugging interfaces of electrical components are all located on the panel surface, allowing maintenance personnel to perform testing or replacement operations without removing other peripheral components. This layout achieves layered maintenance of the electrical system by moving key controllers from inside the chassis to an accessible side area, combined with the partial disassembly and assembly characteristics of the removable cover. Through the above technical solution, this application solves the problem of low maintenance efficiency caused by the need to remove multiple peripheral components during electrical component repair. The centralized arrangement of key controllers combined with the directional coverage of the removable cover allows for direct access to the electrical panel 42 by removing only one side of the cover 12 during fault diagnosis, reducing maintenance time to less than 30% of traditional solutions. At the same time, this design avoids the need to cut the chassis or damage the overall structure, reducing the risk of secondary damage caused by disassembly operations.

[0033] like Figure 1 and 2As shown, the control assembly of the electronic control system also includes a main controller 41 located on the rear side of the load frame 2. The removable housing includes a rear cover 13, with the main controller 41 located within the coverage area of ​​the rear cover 13. The main controller 41 is the core control unit of the electronic control system, which can be implemented using an integrated circuit board and heat dissipation components. Its placement on the rear side of the load frame 2 provides physical isolation from other functional areas of the forklift, avoiding the need to penetrate multiple layers of structure for maintenance. The rear cover 13 is a removable outer shell component covering the rear side of the load frame 2, which can be implemented using bolt fixing or snap-fit ​​connection structures. Its coverage area corresponds to the installation position of the main controller 41, ensuring direct exposure of the main controller 41 after disassembly. In this design, the main controller 41 is configured in the rear area of ​​the load frame 2, maintaining an independent spatial relationship with the main operating area of ​​the forklift. The rear cover 13, as a removable component, is fixed to the counterweight assembly 8 or the load frame 2 via a reversible connection. When maintenance is required, the independent disassembly of the rear cover 13 allows maintenance personnel to directly access the main controller 41 without removing other side or top covers. This layout moves the main controller 41 from a traditional deeply embedded position within the chassis to a separate rear area, and, combined with the modular design of the rear cover 13, achieves both physical isolation and rapid access. Through the above technical solution, this application enables rapid maintenance of the main controller 41, allowing maintenance personnel to disassemble the rear cover 13 without using special tools and directly access the main controller 41 for fault diagnosis or component replacement.

[0034] Furthermore, a counterweight assembly 8 is located at the rear of the frame, with a main controller 41 housed within it. A rear cover 13 is detachably connected to the counterweight assembly 8. The counterweight assembly 8 is a structural module located at the rear of the frame to balance the weight of the forklift. It can be implemented using a cast iron or steel box structure, with its internal cavity configured to accommodate the main controller 41, thus fulfilling the counterweight requirements while providing independent installation space. The main controller 41 being housed within the counterweight assembly 8 means that the core electronic unit controlling the forklift's operation is integrated within the enclosed space of the counterweight assembly 8. It can be installed using bolts or rail clips, physically isolating it from the frame body. The detachable connection of the rear cover 13 to the counterweight assembly 8 means that the protective components covering the outside of the counterweight assembly 8 are connected to it using a non-welded method, specifically through a snap-fit ​​structure or quick-release bolts, allowing for independent removal of the rear cover 13 without affecting other components. In this design, the counterweight assembly 8 is designed as an independent module, with its internal space separated from the main frame. The main controller 41 is mounted inside the counterweight assembly 8 via a fixed bracket. The rear cover 13 is connected to the outer surface of the counterweight assembly 8 by clips, completely covering the area where the main controller 41 is located. When maintenance is required, the main controller 41 can be directly exposed simply by releasing the clips or bolts of the rear cover 13, without removing the seat, battery compartment 21, or other external components. The box structure of the counterweight assembly 8, while supporting the main controller 41, maintains the forklift's balance through its own weight distribution, preventing the center of gravity from shifting due to changes in the controller's installation position.

[0035] In a further preferred embodiment, the internal cavity of the integrated housing 11 constitutes the hydraulic oil tank 14. The integrated housing 11 refers to an integral cover piece fixedly connected to the load frame 2, which can be manufactured using injection molding or metal stamping processes, forming a sealed cavity while maintaining aesthetic integrity. This feature achieves frame functional integration through structural reuse, eliminating the need for a mounting base for traditional independent oil tanks. The internal cavity constituting the hydraulic oil tank 14 means that hydraulic oil is directly stored within the sealed space formed by the housing itself. This can be achieved by applying an anti-permeability coating to the inner wall of the housing and providing an oil inlet at the top and an oil outlet at the bottom. This feature reduces the number of parts through space reuse, making the frame layout more compact. In this embodiment, the integrated housing 11 fixed to the outside of the load frame 2 is designed as a hollow shell with sealing properties. During assembly, the housing forms a closed space through welding or bolting, and its interior is treated with anti-corrosion technology to form a hydraulic oil storage cavity. The hydraulic system's oil supply lines are directly connected to a pre-set interface at the bottom of the housing. Compared to existing technologies, traditional forklifts use a separate metal oil tank welded inside the frame, which occupies space for the fork lifting mechanism and requires a dedicated shock-absorbing bracket. This solution integrates the hydraulic oil storage function into the exterior body panel, thereby simplifying the vehicle structure and optimizing the space layout.

[0036] like Figure 3 As shown, the battery system includes multiple unit battery modules 32, which are connected in series or parallel in a detachable manner to form an expanded battery array adapted to the volume and shape of the forklift battery compartment 21, thus creating battery systems with different voltage platforms and capacities. Each unit battery module 32 refers to a standardized battery cell with an independent packaging structure. Specifically, it can be implemented using a cuboid shape and a uniform interface of replaceable battery packs. Each module contains a fixed number of cells and connection terminals. The standardized design of the unit battery module 32 allows it to serve as a basic unit in different combinations, solving the supply chain management challenges caused by non-standard batteries. The detachable method refers to the connection between modules via plug-in electrical interfaces and mechanical latches. Specifically, it can be achieved using metal contact interfaces with anti-misinsertion guide structures combined with quick-release clips. This connection method allows for replacement by simply removing the fixing device of a single module during maintenance, avoiding the operational complexity of overall disassembly. The expanded battery array refers to a combination structure that dynamically adjusts the arrangement of modules according to the spatial form of the battery compartment 21. Specifically, it can be implemented using a layout combining horizontal stacking and vertical stacking. The scalability of the array is reflected in the ability of the battery system to match battery compartments 21 of different volumes by increasing or decreasing the number of modules or changing the connection topology, while simultaneously meeting the dual regulation of voltage and capacity requirements.

[0037] In this solution, when battery system parameters need to be adjusted, functional reconfiguration can be achieved by changing the electrical connection method of the unit battery module 32. For example, the output voltage can be increased in series mode, or the total capacity can be increased in parallel mode. The physical connection between modules adopts a standardized interface, making the position of any module interchangeable, thereby maximizing space utilization within the battery compartment 21. The arrangement of the battery array dynamically adapts to the internal contour of the compartment. This modular combination structure allows the same batch of unit battery modules 32 to be used to configure battery systems for different models of forklifts, and only the number and arrangement of modules need to be adjusted to adapt to the different battery compartment 21 structures. Compared with the prior art, this solution retains the space adaptability of irregularly shaped battery packs through the free combination of unit battery modules 32, and achieves rapid disassembly and assembly through standardized module design. Through the above technical solution, this application can quickly adjust the output voltage and capacity of the battery system by increasing or decreasing the number of modules or changing the connection method without changing the frame structure, to meet the needs of different working conditions. In maintenance scenarios, partial replacement can be achieved by disassembling the faulty module individually, avoiding the scrapping of the entire battery system due to partial damage. The standardized modular design allows different forklift models to share the same specification of unit battery module 32, reducing the variety of spare parts in stock, while the interchangeability between modules simplifies the installation and commissioning process.

[0038] Furthermore, the battery system also includes a high-voltage box 31, which is connected to multiple unit battery modules 32 and the electronic control system via high-voltage resistant wiring harnesses. The high-voltage box 31 is an electrical integrated device for centralized management of the battery system's power output. Specifically, it can be implemented using a modular component with copper busbar connectors encapsulated in a metal housing, and internally equipped with multiple standardized interfaces to accommodate different numbers of unit battery modules 32. This device serves as the core hub of the battery system, eliminating contact impedance differences when modules are connected in parallel through a unified interface. The high-voltage resistant wiring harness refers to a cable assembly with high insulation level and current carrying capacity. Specifically, it can be implemented using copper core wires wrapped with double-layer silicone insulation, with its cross-sectional area and insulation layer thickness determined according to the maximum operating voltage and current of the battery system. This wiring harness provides a stable physical connection during modular expansion, ensuring the safety of current transmission under high-voltage environments. In this solution, the high-voltage box 31 is configured to receive power output from multiple unit battery modules 32 and integrate the current through internal copper busbars. The positive and negative terminals of each unit battery module 32 are connected to the standardized interfaces of the high-voltage box 31 via independent high-voltage resistant wiring harnesses, forming parallel or series circuit topologies. The electronic control system establishes signal interaction with the control unit inside the high-voltage box 31 via communication cables to obtain the voltage and current parameters of the battery system in real time. When it is necessary to expand the battery capacity, the newly added unit battery module 32 is connected to the reserved interface of the high-voltage box 31 through a high-voltage resistant wiring harness of the same specification, and its electrical parameters are automatically included in the system control range. The direct connection between the high-voltage box 31 and the electronic control system forms a closed-loop control, ensuring the output stability under different module combinations.

[0039] Furthermore, the battery system includes a battery management system (BMS real-time monitoring system), which monitors the voltage, temperature, and health status of the unit battery modules 32 in real time and feeds back fault information to the electronic control system via a communication protocol. The battery management system is a monitoring unit composed of an embedded controller and a sensor network. Specifically, it can be implemented using a microprocessor with voltage sampling circuitry, temperature sensors, and state estimation algorithms to continuously collect battery operating parameters and perform state analysis. The unit battery module 32 is a replaceable energy storage unit composed of several cells, specifically implemented using a standard-sized lithium-ion battery pack, facilitating the formation of battery arrays of different capacities through series or parallel connections. The communication protocol refers to the standardized transmission specification for data interaction, specifically implemented using a CAN bus or RS485 protocol to ensure bidirectional data communication between the battery management system and the electronic control system. In this solution, the battery management system collects the terminal voltage of each unit battery module 32 at a fixed frequency through a voltage sampling circuit. When the detected voltage exceeds a preset threshold, it immediately triggers overcharge or undervoltage protection commands. Temperature sensors are distributed on the surface and at key internal nodes of the unit battery module 32 to monitor local temperature rise changes in real time. When an abnormal temperature gradient is detected, the heat dissipation device is activated or the charging / discharging circuit is cut off. Health status assessment is based on historical charging / discharging data and a capacity decay model, predicting remaining service life through cycle counting and internal resistance change trends. Fault information is transmitted to the electronic control system via a communication protocol, where the central controller parses the information and generates corresponding alarm codes. Simultaneously, the specific fault location and handling suggestions are displayed on the user interface. Through the above technical solution, this application achieves real-time visual monitoring of the operating status of the unit battery module 32, shortening fault diagnosis time and reducing the risk of system downtime due to battery abnormalities. At the same time, the health status assessment function provides data support for battery replacement cycles, avoiding resource waste caused by premature replacement or safety hazards caused by exceeding the battery's service life.

[0040] Based on the above solution, this application provides a modular platform forklift and its battery and electronic control systems. Through the design of a detachable cover, it enables rapid maintenance of key components. Combined with the modular battery system, it improves versatility and effectively solves the problems of chaotic electrical layout, difficult maintenance, and non-standardized batteries in traditional forklifts. It has the advantages of improving maintenance efficiency, optimizing electrical layout, and enhancing the versatility of battery systems.

[0041] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0042] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention.

Claims

1. A modular platform forklift, comprising a frame, a battery system, and an electronic control system, characterized in that: The frame includes a load frame (2) and an exterior cover detachably connected to the load frame (2); A battery compartment (21) is formed within the load frame (2), and the battery system is housed within the battery compartment (21); The outer casing includes an integral casing (11) fixedly connected to the load frame (2), and a detachable casing detachably connected to the integral casing (11); the integral casing (11) covers the outside of the load frame (2). The electronic control system is housed within the load frame (2), and the control assembly of the electronic control system is located within the coverage area of ​​the removable housing.

2. The modular platform fork truck of claim 1, wherein: The battery compartment (21) is located in the load frame (2) under the seat, and the battery compartment (21) is provided with a cover, and the seat is installed on the cover.

3. The modular platform fork truck of claim 1 or 2, wherein: The control assembly of the electronic control system includes an electrical panel (42) disposed on the side of the load frame (2); the removable cover includes a side cover (12), and the electrical panel (42) is located within the coverage area of ​​the side cover (12).

4. The modular platform fork truck of claim 1 or 2, wherein: The control assembly of the electronic control system includes a main controller (41) located on the rear side of the load frame (2); the removable cover includes a rear cover (13), and the main controller (41) is located within the coverage area of ​​the rear cover (13).

5. The modular platform fork truck of claim 4, wherein: A counterweight assembly (8) is provided on the rear side of the frame, and the main controller (41) is located inside the counterweight assembly (8). The rear cover (13) is detachably connected to the counterweight assembly (8).

6. The modular platform fork truck of claim 1, wherein: The internal cavity of the integrated housing (11) forms a hydraulic oil tank (14).

7. The modular platform fork truck of claim 1, wherein: The battery system includes multiple unit battery modules (32), which are connected in series or in parallel in a detachable manner to form an extended battery array adapted to the volume shape of the forklift battery compartment (21) to form battery systems with different voltage platforms and capacities.

8. The modular platform fork truck of claim 7, wherein: The battery system also includes a high-voltage box (31), which is connected to multiple unit battery modules (32) and an electronic control system via a high-voltage resistant wiring harness.

9. The modular platform fork truck of claim 7 or 8, wherein: The battery system includes a battery management system (BMS) for real-time monitoring of the voltage, temperature and health status of the unit battery module (32), and for feeding back fault information to the electronic control system via a communication protocol.

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