Modular Forklift Chassis for Interchangeable Diesel and Electric Drives
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing forklifts lack the ability to easily switch between different power train configurations without altering their structural elements or performance, making it difficult to adapt to new technologies or customer needs.
Innovation Solution
A modular chassis with tie-down plates and supports allows for interchangeable 4x2 diesel, 4x4 diesel, 4x2 electric, and 4x4 electric drive configurations by using a fabricated metal structure with tie plates and brackets that can be easily swapped without modifying the existing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional forklift design is used with fixed power train configuration, then the structural elements remain simple and stable, but the forklift cannot be easily adapted to different drive configurations (diesel/electric, 4x2/4x4)
Solution Approach 1:
The power train system is segmented into interchangeable modules (diesel engine, electric motor, transfer cases for 4x2 and 4x4) that can be independently replaced. The chassis is divided into standardized mounting zones with tie-down plates that accommodate different power train types without requiring structural modifications.
Solution Approach 2:
The fabricated metal structure with standardized tie-down plates serves multiple functions: structural support, mounting interface for different power trains, and vibration damping. This universal interface allows the same chassis to accommodate diesel and electric power trains, as well as 4x2 and 4x4 drive configurations.
2Adaptability or versatility
If the power train is modified to meet new technologies or environmental regulations, then the forklift can adapt to new requirements, but complex operations and long periods of immobilization are required
Solution Approach 1:
The chassis is pre-configured with multiple tie-down plates positioned at standardized locations before the power train replacement occurs. Bracket positions are pre-marked and prepared, allowing the new power train to be quickly mounted without requiring complex measurements or structural modifications during the replacement process.
Solution Approach 2:
The mounting system uses removable brackets and tie-down plates that can be quickly installed and removed. This dynamic mounting approach allows power train replacement to be performed rapidly compared to permanent structural attachments, minimizing immobilization time while maintaining secure connection during operation.
3Weight of moving object
If a tubular structure chassis is used, then the chassis is lighter, but the central space is obstructed making it difficult to exchange components of different geometries
Solution Approach 1:
Instead of using a traditional tubular frame that occupies central space, the invention uses a fabricated metal plate structure with tie-down plates mounted on the outer surfaces. This dimensional reorganization moves mounting interfaces from the central volume to the external surfaces, clearing the central space for component exchange while maintaining structural integrity.
4Adaptability or versatility
If the chassis structure is modified to accommodate different power trains, then different drive configurations can be achieved, but the existing components and main use of the forklift are affected
Solution Approach 1:
Only the local mounting areas where tie-down plates and brackets are installed are modified to accommodate different power trains. The rest of the chassis structure, hydraulic system, and operational components remain unchanged, ensuring that the forklift's main function and performance characteristics are preserved across different power train configurations.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to an all-terrain forklift to which a modular concept is applied in order to obtain four different power train configurations without modifying the geometry of all the structural elements of the forklift or the type of use for which it is intended. The four power configurations are 4x2 diesel drive, 4x4 diesel drive, 4x2 electric drive and 4x4 electric drive. The modular concept is based on an industrial metalwork chassis/structure (1) built from steel plate of varying thicknesses, and supports that in turn comprise a tie plate (3) welded to the inside of the side walls (2), supports for a transfer box (4) and supports for the power train (7), both of which are also formed from steel plate and fastened to the tie plate (3) using screws and washers.