Electric Lifter Efficiency via Mechanical Transmission
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Solution Overview
Problem
The existing hydraulic systems in forklifts are inefficient, with a total efficiency of only 52% due to low performance across various components, leading to suboptimal energy use in lifting operations.
Innovation Solution
A non-hydraulic lifting system utilizing a transmission mechanism driven by an electric motor and gearbox, which allows for distinct stages of lifting by moving the load carrier and mast structure independently, enhancing energy efficiency through a positive drive belt or chain system and epicycloidal gearbox configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a hydraulic system is used for lifting operations, then the lifting function is achieved, but the energy efficiency is low (52%)
Solution Approach 1:
The patent replaces the hydraulic system with an electric motor-driven mechanical transmission system. The electric motor (140) drives a gearbox (215) which in turn drives transmission means (110) such as chains or belts to lift the load carrier (120). This substitution eliminates the energy losses inherent in hydraulic systems and achieves approximately 76% energy efficiency through direct mechanical power transmission.
2Power
If a hydraulic pump and electro pump motor are used, then lifting power is achieved, but total efficiency drops to 52%
Solution Approach 1:
The patent replaces the two-stage power conversion system (electro pump motor + hydraulic pump) with a direct electric motor driving a mechanical transmission system. The electric motor (140) directly drives the gearbox (215) and transmission means (110), eliminating the intermediate hydraulic fluid power conversion stage and recovering approximately 24% energy efficiency that was lost in the hydraulic system.
3Reliability
If hydraulic components are used, then lifting function is achieved, but energy is lost at each component stage
Solution Approach 1:
The patent replaces the series of hydraulic components (electro pump motor, hydraulic pump, hydraulic valve, hoses, hydraulic piston) with a simplified electric motor-driven transmission system. This eliminates the cumulative energy losses at each hydraulic component interface and achieves approximately 76% overall efficiency through direct mechanical power transmission with fewer energy conversion stages.
4Use of energy by moving object
If the transmission means is driven by electric motor and gearbox, then energy efficiency increases to 76%, but device complexity increases
Solution Approach 1:
The patent divides the lifting system into distinct functional stages: the electric motor (140) provides power, the gearbox (215) provides mechanical advantage and speed reduction, and the transmission means (110) transfers power to the load carrier (120). This segmentation allows each component to be optimized for its specific function while maintaining overall system efficiency of approximately 76%.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution achieves a significantly higher efficiency of approximately 76% by optimizing energy use during lifting and regenerating energy during lowering, reducing the overall energy consumption and improving lifting capacity.
Implementation Method 1
epicycloidal gearbox configuration
Data Source
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AI summary
The invention provides an electric lifter, comprising a fixed mast structure, a movable mast structure that is movable relative to the fixed mast structure at least one transmission means (chain or cog drive belt or rack or similar), and a load carrier, in particular a fork load carrier, being connected to the at least one transmission means and configured to carry a load, wherein the at least one transmission means is movably connected to the movable mast structure while being configured to move along a closed loop path, the closed loop path being stationary relative to the movable mast structure.