A forklift DC / DC converter life testing system

Abstract

This utility model discloses a forklift DC / DC converter life testing system, comprising a PLC controller, a wide-range programmable DC power supply, a forklift DC / DC converter, an intermediate relay, a signal acquisition system, and an electronic load. The wide-range programmable DC power supply is connected to both the PLC controller and the forklift DC / DC converter. The signal acquisition system and the electronic load are connected to the signal input terminals of the PLC controller. The signal output terminal of the PLC controller is connected to the intermediate relay, which is connected to the control terminal of the forklift DC / DC converter. The output terminal of the forklift DC / DC converter is connected to the power supply terminal of the electronic load. This utility model enables one-button start automatic testing, significantly improving testing efficiency. The system utilizes a wide-range programmable power supply and is applicable to various types of DC / DC converters, taking into account functional and protection testing to meet diverse needs.

Description

Technical Field

[0001] This utility model relates to the field of forklift DC / DC converter life testing technology, and in particular to a forklift DC / DC converter life testing system. Background Technology

[0002] A forklift DC / DC converter is a power conversion device used in electric forklifts. Its main function is to convert the high-voltage DC power from the forklift's power battery into low-voltage DC power to meet the power supply needs of the forklift's internal low-voltage electrical equipment. Voltage conversion: Converts the high voltage (e.g., 48V, 72V) of the power battery to low voltage (e.g., 12V) to power the forklift's low-voltage electrical system. Battery charging: Charges the forklift's auxiliary battery (e.g., a 12V lead-acid battery). Stable output: Ensures stable output voltage, preventing input voltage fluctuations from affecting the normal operation of low-voltage equipment. Electric forklifts: Widely used in electric forklifts to provide stable power to their instrument panels, lights, horns, controllers, and other low-voltage equipment. Other off-highway electric vehicles: Such as AGVs (Automated Guided Vehicles) and electric tractors are also often equipped with DC / DC converters.

[0003] Wide input voltage range: It can adapt to the power battery voltage of different forklift models, such as 36-84V.

[0004] High efficiency: It adopts high-frequency conversion technology, which has high conversion efficiency and reduces energy loss.

[0005] Protection functions: It has multiple protection functions such as overcurrent, overvoltage, undervoltage, and overheating to ensure equipment safety.

[0006] Electrical isolation: Some models feature electrical isolation design to improve safety.

[0007] The DC / DC converter of a forklift is an important component of the electrical system of an electric forklift, and its performance directly affects the operational stability and reliability of the forklift.

[0008] Before leaving the factory, forklift DC / DC converters need to undergo life testing. Current technologies lack effective methods for life testing and verification of forklift DC / DC converters, making it impossible to effectively verify the product's lifespan and reliability. Existing life testing methods often involve using test vehicles to verify operating conditions, which significantly reduces testing efficiency. Utility Model Content

[0009] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a forklift DC / DC converter life testing system.

[0010] This utility model is achieved through the following technical solution:

[0011] A forklift DC / DC converter life testing system includes a PLC controller, a wide-range programmable DC power supply, a forklift DC / DC converter, an intermediate relay, a signal acquisition system, and an electronic load. The wide-range programmable DC power supply is connected to both the PLC controller and the forklift DC / DC converter. The signal acquisition system and the electronic load are connected to the signal input terminals of the PLC controller. The signal output terminal of the PLC controller is connected to the intermediate relay. The intermediate relay is connected to the control terminal of the forklift DC / DC converter. The output terminal of the forklift DC / DC converter is connected to the power supply terminal of the electronic load.

[0012] It also includes an auxiliary control power supply, which is connected to the PLC controller and the intermediate relay respectively.

[0013] The signal acquisition system includes a temperature sensor and an electrical signal counter. The temperature sensor (thermocouple) is connected to the forklift's DC / DC converter to monitor the temperature curve changes during product life testing in real time. The temperature sensor stores the temperature data curve in a U-shaped memory card. The electrical signal counter is connected in parallel to the input terminal of the electronic load to monitor the electrical signal output from the DC / DC converter to the electronic load. The electrical signal counter transmits the signal to the input terminal of the PLC controller as a logical judgment for the PLC program loop.

[0014] The electronic load is set to the required life test load as needed.

[0015] Working principle

[0016] System initialization

[0017] PLC controller: As the control core of the entire life testing system, it is responsible for coordinating the work of various components. It first performs system initialization settings, including setting control logic (such as test procedures, feedback signal judgment, test time, etc.).

[0018] Wide-range programmable DC power supply: Based on DC / DC technology information, set test parameters, output the set DC voltage to simulate the voltage of the forklift's power battery, provide input power to the forklift's DC / DC converter, and feed the input signal back to the PLC controller to determine whether the main power output is normal.

[0019] Auxiliary control power supply: Provides a stable auxiliary power supply for the PLC controller and intermediate relays to ensure the normal operation of the control system.

[0020] Experimental process

[0021] Input power control: The wide-range programmable DC power supply can adjust the output voltage according to the product characteristics, simulating the battery voltage changes of the forklift under different operating conditions, and providing input power to the forklift DC / DC converter.

[0022] DC / DC converter operation: After receiving the input power, the forklift DC / DC converter starts working, converting the input high-voltage DC power into low-voltage DC power.

[0023] Load control: The PLC controller controls the start and stop of the forklift's DC / DC converter through intermediate relays, and simulates the load conditions in actual use through electronic loads, applying different load currents to the output of the DC / DC converter to test its performance under different load conditions.

[0024] Signal acquisition and feedback:

[0025] Temperature acquisition sensor: Monitors the operating temperature of the forklift's DC / DC converter in real time and uploads the temperature change curve data to the PLC controller.

[0026] Electrical signal counter: Collects the output electrical signals of the forklift's DC / DC converter and transmits these signals to the PLC controller for logical judgment.

[0027] Data Analysis and Adjustment: The PLC controller analyzes the operating status of the forklift's DC / DC converter in real time based on the collected temperature and electrical signal data. If any abnormality is detected (such as excessively high temperature or unstable output voltage), the PLC controller will adjust the output voltage of the wide-range programmable DC power supply or the load current of the electronic load to ensure the smooth progress of the test.

[0028] End of experiment

[0029] When the test reaches the preset time or meets other termination conditions, the PLC controller issues a command to stop the operation of the forklift's DC / DC converter via an intermediate relay and shut down the wide-range programmable DC power supply and electronic load.

[0030] The PLC controller summarizes and analyzes the data throughout the test process, generates a test report, and is used to evaluate the lifespan and performance of the forklift's DC / DC converter.

[0031] The advantages of this utility model are:

[0032] The entire life test process of this invention is automatically controlled by a PLC controller, reducing manual intervention and improving the accuracy and repeatability of the test. The PLC controller can automatically adjust the input voltage, load current, and other test conditions according to preset parameters, and monitor various signals during the test in real time to ensure the smooth progress of the test.

[0033] This utility model's wide-range programmable DC power supply can output DC voltages within different ranges, effectively simulating battery voltage variations in forklifts under various operating conditions, making test results closer to real-world usage. Simultaneously, the electronic load can simulate different load conditions, testing the performance of the forklift's DC / DC converter under various load conditions, providing more comprehensive data support for evaluating its lifespan and reliability.

[0034] This utility model provides comprehensive data acquisition and analysis.

[0035] The signal acquisition system includes a temperature sensor and an electrical signal counter, which can acquire the operating temperature and input / output electrical signals of the forklift's DC / DC converter in real time, providing rich data for the PLC controller. The PLC controller can analyze the operating status of the forklift's DC / DC converter in real time based on this data, promptly detect abnormalities and make adjustments, ensuring the accuracy and reliability of the test results.

[0036] This invention incorporates an intermediate relay, whose operation is controlled by the signal output of the PLC controller, thereby enabling start-stop control of the forklift's DC / DC converter. This control method effectively avoids potential safety hazards associated with directly operating the DC / DC converter. Simultaneously, the PLC controller can monitor various parameters during the test in real time based on collected temperature and electrical signal data. If any abnormalities are detected (such as excessively high temperature or unstable output voltage), timely measures can be taken, such as adjusting test conditions or stopping the test, ensuring the safety of the test process.

[0037] Highly expandable functionality

[0038] The system is designed with a degree of flexibility and scalability. For example, more data acquisition sensors or testing equipment can be added as needed to meet different testing requirements. Furthermore, the PLC controller program can be modified and optimized according to testing requirements to further improve the system's functionality and performance. Attached Figure Description

[0039] Figure 1 This is a block diagram illustrating the working principle of this utility model. Detailed Implementation

[0040] like Figure 1As shown, a forklift DC / DC converter life test system includes a PLC controller 1, a wide-range programmable DC power supply 2, a forklift DC / DC converter 3, an intermediate relay 4, a signal acquisition system 5, and an electronic load 6. The wide-range programmable DC power supply 2 is connected to both the PLC controller 1 and the forklift DC / DC converter 3. The signal acquisition system 5 and the electronic load 6 are connected to the signal input terminals of the PLC controller 1. The signal output terminal of the PLC controller 1 is connected to the intermediate relay 4. The intermediate relay 4 is connected to the control terminal of the forklift DC / DC converter 3. The output terminal of the forklift DC / DC converter 3 is connected to the power supply terminal of the electronic load 6.

[0041] It also includes an auxiliary control power supply 7, which is connected to the PLC controller 1 and the intermediate relay 4 respectively.

[0042] The signal acquisition system 5 includes a temperature sensor 8 and an electrical signal counter 9, both of which are connected to the signal input terminals of the PLC controller 1. The temperature sensor 8 (thermocouple) is connected to the forklift DC / DC converter 3 to monitor the temperature curve changes during product life testing in real time. The temperature sensor 8 stores the temperature data curve in a U-shaped memory card. The electrical signal counter 9 is connected in parallel to the electronic load input terminal to monitor the electrical signal output from the DC / DC converter 3 to the electronic load. The electrical signal counter 9 transmits the signal to the input terminal of the PLC controller 1 as a logical judgment for the PLC program loop.

[0043] The electronic load 6 can be set to the required life test load as needed.

[0044] This utility model is equipped with a wide-range programmable DC power supply 2 (main input), an auxiliary control power supply 7, an electronic load 6, a PLC controller 1, an intermediate relay 4, a temperature sensor 8, an electrical signal counter 9, and a forklift DC / DC converter 3 (the object under test). The system connections are as follows: 1. Main test circuit: The wide-range programmable DC power supply 2 provides input to the DUTInput terminal of the forklift DC / DC converter 3, and the DUTOutput terminal is connected to the electronic load 6. 2. Control circuit: The PLC controller 1 controls the start signal terminal of the forklift DC / DC converter 3 through the intermediate relay 4 to connect and disconnect the main circuit. 3. Acquisition circuit: The temperature sensor 8, electrical signal counter 9, electronic load 6, and wide-range programmable DC power supply 2 transmit signals to the PLC controller 1 for logical judgment. 4. All electrical components are connected via wires.

[0045] This invention provides the main input to the forklift DC / DC converter via a wide-range programmable DC power supply 2, and the auxiliary control power supply controls the DC / DC start signal. The output terminal is connected to the electronic load terminal, and the required life test load can be set. The PLC controller performs logic control, setting the required test steps, cycles, time, counting, protection and other functions.

[0046] This invention is mainly used for life testing of forklift DC / DC converters (unattended mode), and can perform multiple tests simultaneously. This invention allows manual testing of DC / DC input characteristics, output characteristics, overload protection, over-temperature protection, and reverse polarity. It also features an external oscilloscope for acquiring DC / DC output response, rising / falling edge signals, and other electrical signals.

[0047] Features of this utility model:

[0048] 1. Highly simulates dynamic load changes

[0049] It can reproduce dynamic load changes such as forklift start-stop, lifting, and steering, and supports sudden increase / decrease / overload load testing (e.g., output 0%~120% transient response). After the program starts, parameters can be set to adjust the DC / DC output power. The wide input / output range covers the typical voltage range of forklift battery packs (e.g., 24V / 48V / 80V input, 12V / 24V output), and supports input voltage fluctuation simulation (15%±5%), closely resembling actual forklift operating conditions.

[0050] 2. Multi-dimensional lifespan aging test

[0051] For example, it supports overvoltage, undervoltage, and reverse connection protection tests, and frequent DC / DC switching on and off (e.g., 50,000 on / off cycles). It can be integrated into high and low temperature environmental chambers (-40℃~+85℃) and vibration test benches (frequency sweep, random vibration, etc.) to conduct life tests in multiple dimensions, accelerate product aging, and improve test efficiency.

[0052] 3. Safety and Reliability Design

[0053] It features three levels of protection against short circuit, overcurrent, and overtemperature, and its isolated testing method prevents damage to the device under test. It meets the test requirements of standards such as GB / T 2423 (Environmental Testing for Electrical and Electronic Products) and GB / T 43027.

[0054] 4. Scalability

[0055] It allows for easy addition or removal of load modules, suitable for testing different DC / DC converters (0-3kW), and can expand the monitoring parameters by adding equipment such as oscilloscopes and power meters. It can simultaneously perform life aging tests on multiple DC / DC converters, enabling comparative verification of different designs under the same conditions.

Claims

1. A forklift DC / DC converter life test system, characterized by: The system includes a PLC controller, a wide-range programmable DC power supply, a forklift DC / DC converter, an intermediate relay, a signal acquisition system, and an electronic load. The wide-range programmable DC power supply is connected to both the PLC controller and the forklift DC / DC converter. The signal acquisition system and the electronic load are connected to the signal input terminals of the PLC controller. The signal output terminal of the PLC controller is connected to the intermediate relay. The intermediate relay is connected to the control terminal of the forklift DC / DC converter. The output terminal of the forklift DC / DC converter is connected to the power supply terminal of the electronic load.

2. The forklift DC / DC converter life test system of claim 1, wherein: It also includes an auxiliary control power supply, which is connected to the PLC controller and the intermediate relay respectively.

3. The forklift DC / DC converter life test system of claim 1, wherein: The signal acquisition system includes a temperature sensor and an electrical signal counter. The temperature sensor is installed on the forklift DC / DC converter to monitor the temperature curve changes of the forklift DC / DC converter in real time. The electrical signal counter is connected in parallel to the input terminal of the electronic load to monitor the electrical signal output from the forklift DC / DC converter to the electronic load. The electrical signal counter transmits the signal to the input terminal of the PLC controller as a logical judgment for the PLC program loop.

4. The forklift DC / DC converter life test system of claim 1, wherein: The electronic load is set to the required life test load as needed.

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