An electric fork truck integrated power system
Patent Information
- Application Number
- CN202522265054.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-27
- Publication Date
- 2026-10-20
- Estimated Expiration
- 2035-10-27
AI Technical Summary
[0003]在现有技术中，行走动力单元通常布置于车体前桥处，液压动力单元布置于车体中部或后部，电机控制单元则分散布置于车体其他区域，这种大范围分散布置导致各单元之间的连接线缆长度过长，不仅增加了整车装配的复杂性及线缆成本，还因线缆电阻造成的电能损耗而降低了使用效率，最终使得整车能耗大幅增加；此外，由于驱动及液压动力单元分散，散热系统需要为每个单元单独设计冷却装置，导致整体结构非常复杂，成本进一步上升；尽管为了简化结构，有技术方案尝试将油泵电机、行走电机及其控制器集成设置在一起，但这种集成方式会使得电机控制器上的电子元件、油泵电机和行走电机均集中发热，造成相邻区域的热叠加现象，特别是油泵电机在负责叉取物品升降时负载较大，更容易发热且对散热要求更高，而热叠加现象的发生，尤其是在油泵电机与行走电机之间的区域，给散热带来了显著困难，影响了系统的稳定性和可靠性
[0009]作为改进，PCB控制板固定设置于顶板的顶部，顶板的底部分布设有多个散热鳍片。应用该结构后，通过将PCB控制板直接固定于导流罩顶板顶部，并同时在顶板底部设置散热鳍片，使得PCB控制板上电子元件产生的热量能够迅速传导至顶板；这些热量一方面通过顶板与流经导流罩内部的冷却气流进行对流换热，另一方面由散热鳍片大幅增加其与冷却气流的接触面积，极大地强化了散热效果，从而确保了控制单元在集成环境下的工作稳定性和寿命。
Smart Images
Figure CN224869805U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of forklift technology, and more specifically, to an integrated power system for an electric forklift. Background Technology
[0002] Electric forklifts, as a common type of industrial handling vehicle, typically employ a distributed power system, with the travel power unit and hydraulic power unit located in different positions on the vehicle body. The travel power unit, consisting of a drive motor and a front axle reducer, is responsible for the vehicle's forward and reverse functions, while the hydraulic power unit, composed of an oil pump motor and an oil pump, is used to raise and lower the forklift's forks.
[0003] In existing technologies, the driving power unit is typically located at the front axle of the vehicle body, the hydraulic power unit is located in the middle or rear of the vehicle body, and the motor control unit is distributed in other areas of the vehicle body. This large-scale distributed distribution results in excessively long connecting cables between the units, which not only increases the complexity of the vehicle assembly and the cost of cables, but also reduces the efficiency of use due to power loss caused by cable resistance, ultimately leading to a significant increase in the energy consumption of the entire vehicle. In addition, because the drive and hydraulic power units are distributed, the cooling system needs to design a separate cooling device for each unit, resulting in a very complex overall structure and further increasing costs. Although some technical solutions have attempted to integrate the oil pump motor, driving motor, and their controller together to simplify the structure, this integration method causes the electronic components on the motor controller, the oil pump motor, and the driving motor to all generate concentrated heat, resulting in heat superposition in adjacent areas. In particular, the oil pump motor is under a large load when responsible for lifting and lowering goods, making it more prone to heat generation and requiring higher heat dissipation. The occurrence of heat superposition, especially in the area between the oil pump motor and the driving motor, brings significant difficulties to heat dissipation, affecting the stability and reliability of the system. Utility Model Content
[0004] The purpose of this invention is to overcome the technical defects in the prior art and provide an integrated power system for electric forklifts that is compact in structure, has good heat dissipation, and can effectively reduce energy consumption.
[0005] To address the aforementioned problems, this utility model provides an integrated power system for an electric forklift, comprising a PCB control board, a travel motor, and an oil pump motor. The travel motor and the oil pump motor are arranged side-by-side along the axial direction at the bottom of the PCB control board. A heat dissipation device is provided between the PCB control board and the travel motor and the oil pump motor. The heat dissipation device includes a shroud and a fan. The shroud is fixedly installed at the bottom of the PCB control board, the travel motor and the oil pump motor are fixedly installed at the bottom of the shroud, and the fan is fixedly installed on one side of the shroud. At least one first air outlet is provided at the bottom of the shroud, and the first air outlet is oriented towards the area between the travel motor and the oil pump motor.
[0006] Compared with the prior art, the advantages of this utility model are as follows: By integrating the PCB control board, the travel motor, and the oil pump motor axially side by side, this utility model significantly shortens the connection cables between the units. This not only simplifies the vehicle assembly and reduces cable costs, but also effectively reduces power loss caused by excessive cable length, thereby reducing the overall energy consumption of the vehicle. At the same time, the specially designed heat dissipation device, through the cooperation of the air guide and the fan, and utilizing the first air outlet located at the bottom of the air guide and facing the area between the travel motor and the oil pump motor, can accurately guide the cooling airflow to the area of heat accumulation where the heat is most concentrated and the heat dissipation demand is most urgent after integration. This effectively solves the heat dissipation problem caused by integration, ensuring the heat dissipation efficiency and operational reliability of the system in a compact structure, and avoiding performance degradation or failure due to overheating.
[0007] As an improvement, the air guide includes a top plate, a bottom plate, and four side plates. The top plate, bottom plate, and side plates together form a hollow box-like structure. The first air outlet is located in the middle of the bottom plate and is distributed along the axial direction of the oil pump motor. A second air outlet is opened on one side of the bottom plate, and the second air outlet is distributed along the axial direction of the oil pump motor, and is located on both sides of the axial direction of the oil pump motor, opposite to the first air outlet. The fan is fixed on a side plate opposite to the side where the second air outlet is located. After applying this structure, by designing the air guide as a sealed box-like structure, the cooling airflow generated by the fan can be effectively guided and gathered, preventing airflow loss. The first and second air outlets at the bottom, especially the second air outlet and the first air outlet being located on both sides of the oil pump motor, allow the cooling airflow to blow simultaneously from different directions onto the high-heat superposition area between the travel motor and the oil pump motor, as well as the oil pump motor body, forming a directional and efficient heat dissipation channel for the two main heat sources, thereby significantly improving the overall heat dissipation efficiency and uniformity of the integrated system.
[0008] As an improvement, the first air outlet is angled on the base plate, tilting downwards from the fan direction towards the oil pump motor. By applying this structure, the angled design of the first air outlet allows the cooling airflow to flow out from inside the guide shroud, forming a directional airflow towards the area between the travel motor and the oil pump motor, extending along the oil pump motor's axial direction. This angled guidance not only enhances the airflow's penetration and coverage of the core heat-overlapping area, preventing ineffective diffusion of airflow on the motor surface, but also further improves the heat exchange efficiency between the airflow and the motor's heating surface, thus achieving more precise and efficient heat dissipation with a simpler structure.
[0009] As an improvement, the PCB control board is fixedly mounted on the top of the top plate, and multiple heat dissipation fins are distributed at the bottom of the top plate. With this structure, by directly fixing the PCB control board to the top of the shroud top plate and simultaneously installing heat dissipation fins at the bottom of the top plate, the heat generated by the electronic components on the PCB control board can be rapidly conducted to the top plate. This heat is transferred through convection between the top plate and the cooling airflow flowing through the shroud, and the heat dissipation fins significantly increase the contact area between the PCB control board and the cooling airflow, greatly enhancing the heat dissipation effect and ensuring the stability and lifespan of the control unit in an integrated environment. Attached Figure Description
[0010] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is the first perspective view of the heat dissipation device in this utility model; Figure 3 This is the second perspective view of the heat dissipation device in this utility model; Figure 4 This is a schematic diagram of the structure of the base plate of the air deflector in this utility model; Figure 5 This is a schematic diagram of the top plate of the air guide in this utility model.
[0011] Explanation of reference numerals in the attached figures: 1. PCB control board; 2. Walking motor; 3. Oil pump motor; 4. Heat dissipation device; 41. Air guide shroud; 411. Top plate; 412. Bottom plate; 413. Side plate; 42. Fan; 51. First air outlet; 52. Second air outlet; 6. Heat dissipation fins. Detailed Implementation
[0012] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings.
[0013] like Figure 1 and Figure 2 As shown, an integrated power system for an electric forklift includes a PCB control board 1, a travel motor 2, and an oil pump motor 3. The system is characterized in that the travel motor 2 and the oil pump motor 3 are arranged side-by-side along the axial direction at the bottom of the PCB control board 1. A heat dissipation device 4 is provided between the PCB control board 1 and the travel motor 2 and the oil pump motor 3. The heat dissipation device 4 includes a shroud 41 and a fan 42. The shroud 41 is fixedly installed at the bottom of the PCB control board 1, the travel motor 2 and the oil pump motor 3 are fixedly installed at the bottom of the shroud 41, and the fan 42 is fixedly installed on one side of the shroud 41. At least one first air outlet 51 is provided at the bottom of the shroud 41, and the first air outlet 51 is oriented towards the area between the travel motor 2 and the oil pump motor 3.
[0014] This embodiment integrates the PCB control board 1, the travel motor 2, and the oil pump motor 3 axially side-by-side, significantly shortening the connection cables between the units. This not only simplifies vehicle assembly and reduces cable costs but also effectively reduces power loss caused by excessively long cables, thereby lowering the overall vehicle energy consumption. Simultaneously, the specially designed cooling device 4, through the cooperation of the air guide 41 and the fan 42, and utilizing the first air outlet 51 located at the bottom of the air guide 41 facing the area between the travel motor 2 and the oil pump motor 3, can precisely guide the cooling airflow to the area of highest heat concentration and most urgent heat dissipation needs after integration. This effectively solves the heat dissipation problem caused by integration, ensuring the system's heat dissipation efficiency and operational reliability within a compact structure, and preventing performance degradation or malfunctions due to overheating.
[0015] like Figure 1 , Figure 2 and Figure 4 As shown, the air guide shroud 41 includes a top plate 411, a bottom plate 412, and four side plates 413. The top plate 411, bottom plate 412, and side plates 413 together form a hollow box-shaped structure. The first air outlet 51 is located in the middle of the bottom plate 412 and is distributed along the axial direction of the oil pump motor 3. A second air outlet 52 is opened on one side of the bottom plate 412. The second air outlet 52 is distributed along the axial direction of the oil pump motor 3 and is located on both sides of the axial direction of the oil pump motor 3, along with the first air outlet 51. The fan 42 is fixed on a side plate 413 opposite to the side where the second air outlet 52 is located. After applying this structure, by designing the air guide shroud 41 as a sealed box structure, the cooling airflow generated by the fan 42 can be effectively guided and gathered, preventing airflow loss. The first air outlet 51 and the second air outlet 52 at its bottom, especially the second air outlet 52 and the first air outlet 51 are respectively located on both sides of the oil pump motor 3, so that the cooling airflow can blow from different directions to the high heat superposition area between the travel motor 2 and the oil pump motor 3 and the oil pump motor 3 body at the same time, forming a directional and efficient heat dissipation channel for the two main heat sources, thereby significantly improving the overall heat dissipation efficiency and uniformity of the integrated system.
[0016] Furthermore, the first air outlet 51 is an angled opening on the base plate 412, sloping downwards from the direction of the fan 42 towards the direction of the oil pump motor 3. By applying this structure, and designing the first air outlet 51 with a specific angled structure, the cooling airflow flowing out from inside the guide shroud 41 forms a directional airflow towards the area between the travel motor 2 and the oil pump motor 3, extending along the axial direction of the oil pump motor 3. This angled guidance not only enhances the penetration and coverage of the airflow into the core heat-overlapping area, avoiding ineffective diffusion of airflow on the motor surface, but also further improves the heat exchange efficiency between the airflow and the motor's heating surface, thus achieving more precise and efficient heat dissipation with a simpler structure. Similarly, the second air outlet 52 can also be designed as an angled opening, sloping downwards from the outside of the oil pump motor 3 towards the inside of the oil pump motor 3. This guides the cooling air flowing out through the second air outlet 52 to concentrate on the outer wall of the oil pump motor 3, further improving the heat dissipation effect of the oil pump motor 3.
[0017] like Figure 2 , Figure 3 and Figure 5 As shown, the PCB control board 1 is fixedly mounted on the top of the top plate 411, and multiple heat dissipation fins 6 are distributed on the bottom of the top plate 411. By applying this structure, the heat generated by the electronic components on the PCB control board 1 can be quickly conducted to the top plate 411 through direct fixation to the top of the top plate 411 of the airflow guide 41, while heat dissipation fins 6 are simultaneously installed on the bottom of the top plate 411. This heat is transferred through convective heat exchange between the top plate 411 and the cooling airflow flowing through the airflow guide 41, and the heat dissipation fins 6 significantly increase the contact area between the heat dissipation fins and the cooling airflow, greatly enhancing the heat dissipation effect and ensuring the stability and lifespan of the control unit in an integrated environment.
[0018] Although the disclosure is as stated above, the scope of protection of this disclosure is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of this disclosure, and all such changes and modifications will fall within the protection scope of this utility model.
Claims
1. An integrated power system for an electric forklift, comprising a PCB control board (1), a travel motor (2), and an oil pump motor (3), characterized in that: The walking motor (2) and the oil pump motor (3) are arranged side by side along the axial direction at the bottom of the PCB control board (1). A heat dissipation device (4) is provided between the PCB control board (1) and the walking motor (2) and the oil pump motor (3). The heat dissipation device (4) includes a guide shroud (41) and a fan (42). The guide shroud (41) is fixedly arranged at the bottom of the PCB control board (1). The walking motor (2) and the oil pump motor (3) are fixedly arranged at the bottom of the guide shroud (41). The fan (42) is fixedly arranged on one side of the guide shroud (41). At least one first air outlet (51) is provided at the bottom of the guide shroud (41). The first air outlet (51) is arranged facing the area between the walking motor (2) and the oil pump motor (3).
2. The integrated power system for electric forklifts according to claim 1, characterized in that: The air guide shroud (41) includes a top plate (411), a bottom plate (412), and four side plates (413). The top plate (411), the bottom plate (412), and the side plates (413) together form a hollow box-shaped structure. The first air outlet (51) is located in the middle of the bottom plate (412) and is distributed along the axial direction of the oil pump motor (3). A second air outlet (52) is provided on one side of the bottom plate (412). The second air outlet (52) is distributed along the axial direction of the oil pump motor (3) and is located on both sides of the axial direction of the oil pump motor (3) along with the first air outlet (51). The fan (42) is fixed on a side plate (413) opposite to the side where the second air outlet (52) is located.
3. The integrated power system for electric forklifts according to claim 2, characterized in that: The first air outlet (51) is an oblique opening on the base plate (412), which is inclined downward from the direction of the fan (42) towards the direction of the oil pump motor (3).
4. The integrated power system for electric forklifts according to claim 2, characterized in that: The PCB control board (1) is fixedly mounted on the top of the top plate (411), and a plurality of heat dissipation fins (6) are distributed on the bottom of the top plate (411).