Forklift controller heat dissipation system and forklift thereof

Abstract

This utility model provides a forklift controller cooling system and a forklift thereof, including a cooling fan and a vehicle controller, and a relay disposed between the cooling fan and the vehicle controller; a reference signal generation module electrically connected to the vehicle controller is configured to provide a reference signal; wherein: a load detection module is provided inside the cooling fan to generate a load feedback signal reflecting the real-time load status of the cooling fan; the vehicle controller is electrically connected to the load detection module to receive the load feedback signal, and the vehicle controller is configured to determine the working status of the cooling fan based on the comparison result of the load feedback signal and the reference signal and the relationship with the internal threshold of the vehicle controller, and when the cooling fan is determined to be in an abnormal state, output a disconnect command to cause the relay contacts to open, so that the cooling fan stops working. This effectively avoids controller overheating damage and vehicle shutdown, and improves the operational reliability and safety of the forklift under harsh working conditions.

Description

Technical Field

[0001] This utility model relates to the field of forklift technology, specifically to a forklift controller heat dissipation system and a forklift thereof. Background Technology

[0002] Forklift controllers generate a lot of heat during operation. If the heat cannot be dissipated in time, the controller temperature will become too high, leading to performance degradation, malfunctions, or even burnout, causing the entire vehicle to stop and seriously affecting operational efficiency.

[0003] Currently, forklift controllers commonly use temperature-controlled cooling fans for heat dissipation. This involves installing a temperature sensor on the controller; when the controller temperature rises to a certain set threshold, the cooling fan is activated for forced cooling; when the temperature drops to another set threshold, the fan shuts off. While this control method is simple in structure, it only focuses on the temperature of the controller itself, lacking effective monitoring and protection for the cooling fan's operating status.

[0004] In practical applications, especially in complex and dusty working environments, this existing technology has the following drawbacks: First, in the long run, dust and other contaminants will gradually penetrate and adhere to the fan blades and inside the motor, causing the fan's rotational resistance (load) to continuously increase, the speed to decrease, and the heat dissipation efficiency to decline. This is a slow and deteriorating process. Traditional temperature control cannot detect the performance degradation of the fan itself. It can only be detected when the controller's temperature rises abnormally due to insufficient heat dissipation, but by then it is too late, and cumulative thermal damage to the controller may have already been caused.

[0005] Secondly, in the short term, there is a possibility that a foreign object may suddenly become stuck in the fan, causing it to stall instantly. In this situation, the fan motor current will increase dramatically, leading to a surge in power consumption and heat generation, posing a risk of burning out the fan itself, and completely eliminating its heat dissipation function. Under such an emergency fault condition, existing temperature control systems suffer from response lag: the controller needs to wait for its own temperature to rise to a threshold before triggering an alarm or protection mechanism. During this time, the faulty fan cannot effectively dissipate heat, easily causing the controller to overheat and fail within a short period, resulting in a serious malfunction that renders the entire vehicle inoperable.

[0006] It is evident that the existing forklift controller cooling system has two main risks: firstly, it cannot effectively monitor the load status of the cooling fan in real time; secondly, it does not respond promptly when the fan performance deteriorates or stalls, ultimately leading to overheating and damage to the controller. Utility Model Content

[0007] The technical problem to be solved by this invention is how to actively detect the working status of the forklift cooling fan and take timely protective measures when it malfunctions.

[0008] In a first aspect, to solve the above-mentioned technical problems, a forklift controller cooling system is provided, including a cooling fan and a vehicle controller, and further comprising: A relay is installed between the cooling fan and the vehicle controller; The reference signal generation module, which is electrically connected to the vehicle controller, is configured to provide a reference signal; in: The cooling fan is equipped with a load detection module, which is used to generate a load feedback signal that reflects the real-time load status of the cooling fan. The vehicle controller is electrically connected to the load detection module to receive the load feedback signal. The vehicle controller is configured to determine the working state of the cooling fan based on the comparison result of the load feedback signal and the reference signal and the relationship between the comparison result and the internal threshold of the vehicle controller. When the cooling fan is determined to be in an abnormal state, the vehicle controller outputs a disconnect command to open the relay contacts, thereby stopping the cooling fan from working.

[0009] Furthermore, the load detection module is a sampling circuit installed in the cooling fan motor circuit, and the load feedback signal output by it is a voltage signal U1.

[0010] Furthermore, the reference signal generation module is a reference voltage source, and the reference signal it outputs is a constant voltage signal U2.

[0011] Furthermore, the vehicle controller is configured to calculate the voltage difference ΔU between the voltage signal U1 and the constant voltage signal U2, wherein: When the pressure difference ΔU is less than the threshold, the cooling fan is determined to be in normal condition; When the pressure difference ΔU is greater than or equal to the threshold, the cooling fan is determined to be in an abnormal state.

[0012] Furthermore, the system also includes an instrument panel and a buzzer, both of which are electrically connected to the vehicle controller; wherein, when the cooling fan is in an abnormal state, the vehicle controller sends a command to the instrument panel to display fault information and / or to drive the buzzer to work.

[0013] Furthermore, the vehicle controller is also electrically connected to the forklift's travel motor controller and lifting motor controller. When the cooling fan is in an abnormal state, the vehicle controller sends a power limiting command to the travel motor controller and / or the lifting motor controller.

[0014] In a second aspect, this utility model provides a forklift, including a forklift body and a controller, wherein the forklift body is provided with the forklift controller heat dissipation system.

[0015] Compared with the prior art, the present invention has the following beneficial effects: This invention incorporates a load detection module within the cooling fan, which is electrically connected to the vehicle controller, and introduces a reference signal generation module. This allows the system to directly monitor the fan's load status in real time, rather than indirectly sensing the controller's temperature. Consequently, in the early stages when the fan experiences increased load or stalling due to dust accumulation or foreign object obstruction, the system can identify potential fault risks through signal comparison and immediately implement multi-level protection measures, including alarms, shutdown, and vehicle power limiting. This effectively prevents controller overheating and damage, as well as vehicle shutdown, thereby improving the reliability and safety of the forklift under harsh operating conditions. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the present invention; Figure 2 This is a schematic diagram of the load detection module in this utility model.

[0017] In the picture: 10. Vehicle controller; 20. Cooling fan; 21. Load detection module; 30. Reference signal generation module; 40. Relay; 51. Instrument panel; 52. Buzzer; 53. Travel motor controller; 54. Hoisting motor controller. Detailed Implementation

[0018] 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.

[0019] The present invention aims to provide a forklift controller cooling system that can achieve early identification and proactive protection of cooling fan failures by directly monitoring the load status of the cooling fan.

[0020] Please see Figure 1 The forklift controller cooling system mainly includes a vehicle controller 10, a cooling fan 20, a reference signal generation module 30, and a relay 40. Specifically: The cooling fan 20 is equipped with a load detection module 21, which is used to generate a load feedback signal that reflects the real-time load status of the cooling fan 20.

[0021] The reference signal generation module 30 is electrically connected to the vehicle controller 10 and is used to provide a reference signal.

[0022] Relay 40 is located between vehicle controller 10 and cooling fan 20. Specifically, the control coil of relay 40 is electrically connected to the control output terminal of vehicle controller 10, and its normally open contact is connected in series in the main power supply circuit of cooling fan 20.

[0023] In a further embodiment, the vehicle controller 10 is electrically connected to the load detection module 21 to receive load feedback signals. The vehicle controller 10 is configured to receive the load feedback signal and a reference signal, and determine the operating status of the cooling fan 20 based on the comparison result of the two and the relationship with the pre-stored threshold inside the vehicle controller 10. When the cooling fan 20 is determined to be in an abnormal state, a disconnect command is output to open the contacts of the relay 40, thereby stopping the cooling fan 20 from working.

[0024] In this scheme, the load detection module 21 is a sampling circuit installed in the motor circuit of the cooling fan 20, and its output load feedback signal is a voltage signal U1. The reference signal generation module 30 is a reference voltage source, and its output reference signal is a constant voltage signal U2.

[0025] In a further embodiment, the vehicle controller 10 is configured to calculate the voltage difference ΔU between the voltage signal U1 and the constant voltage signal U2, wherein: When the pressure difference ΔU is less than the threshold, the cooling fan 20 is determined to be in normal condition.

[0026] When the pressure difference ΔU is greater than or equal to the threshold, the cooling fan 20 is determined to be in an abnormal state.

[0027] In this solution, the forklift controller cooling system also includes an instrument panel 51 and a buzzer 52, both of which are electrically connected to the vehicle controller 10. When the cooling fan 20 is in an abnormal state, the vehicle controller 10 sends a command to the instrument panel 51 to display fault information and / or to activate the buzzer 52.

[0028] In this solution, the vehicle controller 10 is also electrically connected to the forklift's travel motor controller 53 and lifting motor controller 54. Specifically, when the cooling fan 20 is in an abnormal state, the vehicle controller 10 sends a power limiting command to the travel motor controller 53 and / or the lifting motor controller 54. This method aims to compensate for the zero cooling capacity caused by the cooling fan 20 stopping by actively reducing the heat generated by the load, creating safe cooling conditions for the core controller and preventing overheating damage.

[0029] The technical principle of this solution is: The load on the cooling fan 20 is directly related to its operating current. When the load increases due to dirt accumulation or obstruction, the motor's operating current rises. The load detection module 21 converts the operating current into a proportionally varying voltage signal U1 using components such as a sampling resistor or a Hall sensor. This signal U1 is the load feedback signal that directly reflects the fan's health status. In a specific example, such as... Figure 2 As shown, the fan's normal operation is determined by monitoring the collector-emitter voltage Vce of the transistor or the voltage drop across resistor R: when the fan is normal, the transistor is saturated and conducting, Vce≈0, VR≈U1; when the fan is abnormal, the transistor is cut off, Vce≈U1, VR≈0. The vehicle controller 10 can identify the fan's operating status by collecting the voltage values ​​of Vce or VR, thus realizing the load detection function.

[0030] The system introduces a stable reference voltage signal U2 as a reference. The vehicle controller 10 calculates the voltage difference ΔU between U1 and U2 in real time. When the cooling fan 20 is working normally, U1 is within an expected range, and ΔU is small. When the load on the cooling fan 20 increases abnormally, U1 rises accordingly, causing ΔU to increase. Once ΔU exceeds a preset threshold voltage, the vehicle controller 10 determines that the cooling fan 20 is in an abnormal state (overload or stall). This voltage difference-based comparison method is simple, reliable, and has strong anti-interference capabilities.

[0031] This utility model also protects a forklift, which includes a forklift body and a controller, wherein the forklift body is provided with the aforementioned forklift controller heat dissipation system.

[0032] 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. A forklift controller cooling system, comprising a vehicle controller (10) and a cooling fan (20), characterized in that, Also includes: A relay (40) is installed between the vehicle controller (10) and the cooling fan (20). The reference signal generation module (30), which is electrically connected to the vehicle controller (10), is configured to provide a reference signal; in: The cooling fan (20) is equipped with a load detection module (21) to generate a load feedback signal that reflects the real-time load status of the cooling fan (20). The vehicle controller (10) is electrically connected to the load detection module (21) to receive the load feedback signal. The vehicle controller (10) is configured to determine the working state of the cooling fan (20) based on the comparison result of the load feedback signal and the reference signal and the relationship between the internal threshold of the vehicle controller (10). When the cooling fan (20) is determined to be in an abnormal state, a disconnect command is output to cause the relay (40) contacts to open, so that the cooling fan (20) stops working.

2. The forklift controller cooling system according to claim 1, characterized in that, The load detection module (21) is a sampling circuit set in the motor circuit of the cooling fan (20), and the load feedback signal output by it is a voltage signal U1.

3. The forklift controller cooling system according to claim 2, characterized in that, The reference signal generation module (30) is a reference voltage source, and the reference signal it outputs is a constant voltage signal U2.

4. The forklift controller cooling system according to claim 3, characterized in that, The vehicle controller (10) is configured to calculate the voltage difference ΔU between the voltage signal U1 and the constant voltage signal U2, wherein: When the pressure difference ΔU is less than the threshold, the cooling fan (20) is determined to be in normal condition; When the pressure difference ΔU is greater than or equal to the threshold, the cooling fan (20) is determined to be in an abnormal state.

5. The forklift controller cooling system according to claim 1 or 4, characterized in that, The system also includes an instrument panel (51) and a buzzer (52), both of which are electrically connected to the vehicle controller (10). When the cooling fan (20) is in an abnormal state, the vehicle controller (10) sends a command to the instrument panel (51) to display fault information and / or drive the buzzer (52) to work.

6. The forklift controller cooling system according to claim 1 or 4, characterized in that, The vehicle controller (10) is also electrically connected to the forklift’s travel motor controller (53) and lifting motor controller (54). When the cooling fan (20) is in an abnormal state, the vehicle controller (10) sends a power limiting command to the travel motor controller (53) and / or the lifting motor controller (54).

7. A forklift, comprising a forklift body and a controller, characterized in that, The forklift body is equipped with a forklift controller cooling system as described in any one of claims 1-6.

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