Electric Truck-Mounted Forklift Wheel Drive for Wider Loads
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Solution Overview
Problem
Electric truck mounted forklifts face challenges in increasing their load capacity and stability due to weight constraints, limited frame openings, and overhang regulations, which restrict their ability to handle wider loads and navigate obstacles effectively.
Innovation Solution
The integration of compact interior permanent magnet (IPM) motor and planetary gearbox assemblies in the front and rear wheels, which maintains the forklift's width and ground clearance, allows for efficient power transfer and includes a spring-applied electromagnetic brake for safety, enabling wider load handling and reduced overhang.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the frame opening between the side bars is increased to handle wider loads, then the forklift's load handling capability is improved, but the overall width of the forklift increases beyond the carrying vehicle's dimensions
Solution Approach 1:
The electric motor is nested within the side bar structure, with the motor housing integrated into the side bar's internal cavity. This allows the motor to be contained within the existing width constraints while still providing sufficient power for the forklift's operations.
Solution Approach 2:
The motor and gearing components are arranged in an axial configuration along the length of the side bar rather than extending outward in width. This dimensional reorganization allows the components to fit within the width constraints while maintaining the necessary mechanical function.
2Power
If the side bar dimensions are increased to accommodate the electric motor and gearing, then the power transmission capability is improved, but the ground clearance is reduced
Solution Approach 1:
The planetary gearbox is nested within the motor housing, with the gear components contained inside the motor's internal cavity. This nested arrangement consolidates the power transmission components into a compact package that fits within the existing side bar dimensions without encroaching on ground clearance.
Solution Approach 2:
The motor housing and gearbox housing are merged into a single integrated component structure. This consolidation eliminates the need for separate housings and reduces the overall dimensional footprint of the power transmission system.
3Force
If the rear wheel assembly dimensions are increased to improve load capacity, then the forklift's lifting capability is improved, but the overhang from the carrying vehicle increases beyond legal limits
Solution Approach 1:
The rear wheel motor assembly is nested within the existing wheel structure, with the motor and gearing components contained inside the wheel hub and rim. This allows the power transmission system to be integrated into the wheel assembly without increasing the outer dimensions that would affect overhang measurements.
4Weight of moving object
If the forklift is made lightweight to maintain carrying capacity, then the carrying vehicle's payload capacity is preserved, but the structural strength and robustness are reduced
Solution Approach 1:
The side bars are constructed using composite materials that provide high strength-to-weight ratio. The aluminum alloy construction maintains structural integrity while significantly reducing the overall weight of the forklift compared to traditional steel constructions.
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 configuration enhances the forklift's ability to lift heavier loads, maintain stability, and reduce power consumption while ensuring safety through efficient power transfer and compact design, addressing the limitations of weight distribution and overhang.
Implementation Method 1
each of the front wheels is provided with a dedicated electric wheel motor assembly, each of the electric wheel motor assemblies comprising an interior permanent magnet (IPM) motor
Implementation Method 2
a planetary gear box coupled to the IPM motor, the planetary gear box being mounted axially in-line with and driven by the drive shaft
Implementation Method 3
includes a spring-applied electromagnetic brake for safety
Data Source
AI summary
This invention relates to a truck mounted forklift (TMFL), more specifically an electrically powered TMFL. The TMFL comprises a U-shaped chassis having a pair of side bars bridged by a rear cross bar, a pair of front wheels, and a rear wheel. The TMFL further comprises a lifting assembly, a driver's station, and a battery pack mounted on the chassis. Each of the front wheels is provided with a dedicated electric wheel motor assembly. The electric wheel motor assemblies each comprise an interior permanent magnet (IPM) motor having a drive shaft, and a planetary gear box coupled to the IPM motor. The planetary gear box is mounted axially in-line with and is driven by the drive shaft. The IPM motor is mounted substantially internal the side bar and the planetary gear box is mounted substantially internal the bounds of the wheel rim. In this way, a very compact configuration of drive assembly for the front wheels is provided.