CN107311086B - Control unit and method for judging whether forklift load is overweight - Google Patents

Control unit and method for judging whether forklift load is overweight Download PDF

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Publication number
CN107311086B
CN107311086B CN201610264507.7A CN201610264507A CN107311086B CN 107311086 B CN107311086 B CN 107311086B CN 201610264507 A CN201610264507 A CN 201610264507A CN 107311086 B CN107311086 B CN 107311086B
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forklift
load
control unit
overweight
truck
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CN107311086A (en
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侯祥
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Bosch powertrain Co.,Ltd.
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Bosch Automotive Diesel Systems Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B66HOISTING; LIFTING; HAULING
    • B66FHOISTING, LIFTING, HAULING OR PUSHING, NOT OTHERWISE PROVIDED FOR, e.g. DEVICES WHICH APPLY A LIFTING OR PUSHING FORCE DIRECTLY TO THE SURFACE OF A LOAD
    • B66F17/00Safety devices, e.g. for limiting or indicating lifting force
    • B66F17/003Safety devices, e.g. for limiting or indicating lifting force for fork-lift trucks
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B66HOISTING; LIFTING; HAULING
    • B66FHOISTING, LIFTING, HAULING OR PUSHING, NOT OTHERWISE PROVIDED FOR, e.g. DEVICES WHICH APPLY A LIFTING OR PUSHING FORCE DIRECTLY TO THE SURFACE OF A LOAD
    • B66F9/00Devices for lifting or lowering bulky or heavy goods for loading or unloading purposes
    • B66F9/06Devices for lifting or lowering bulky or heavy goods for loading or unloading purposes movable, with their loads, on wheels or the like, e.g. fork-lift trucks
    • B66F9/075Constructional features or details

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Mechanical Engineering (AREA)
  • Transportation (AREA)
  • Civil Engineering (AREA)
  • Forklifts And Lifting Vehicles (AREA)

Abstract

The invention provides a control unit for judging whether the load of a forklift is overweight, which comprises a speed sensor and a speed sensor, wherein the speed sensor is connected with the speed sensor, and the speed sensor is connected with the speed sensorA degree sensor and a determination module in communication with an engine control unit of the forklift truck, the determination module being configured to obtain a nominal hydraulic pressure (P) of the forklift truck lifting cylinder from a nominal hydraulic pressure transfer curve at the engine speed-of the forklift truck lifting cylinder based on the obtained engine speed (S)rate) Based on the obtained voltage value (V)operating) The valve opening ratio (K) is obtained from the operating voltage-valve opening ratio transfer curve and is based on the nominal hydraulic pressure (P)rate) The valve opening ratio (K) and the sectional area (A) of the forklift lifting hydraulic cylinder obtain the load mass (M) of the forklift, then whether the forklift has a load overweight phenomenon which causes the forklift to overturn or not is judged by utilizing a lever principle, and a result prompt of whether the load is overweight or not is provided for a forklift driver based on a judgment result. The invention also provides a method for judging whether the load of the forklift is overweight.

Description

Control unit and method for judging whether forklift load is overweight
Technical Field
The invention relates to the field of forklifts, in particular to a control system and a control method for calculating forklift load and judging whether the forklift load is overweight.
Background
The balanced forklift is used as a short-distance heavy-load carrying vehicle widely applied, a lifting fork for lifting and descending heavy objects is arranged in the front of the balanced forklift, and a balance weight block for providing stability for the forklift is arranged at the tail of the balanced forklift, so that the balanced forklift is suitable for loading, unloading, stacking and carrying finished objects and the like in ports, stations and enterprises.
The balance type forklift uses a lever principle, and the product of the mass of the front carried heavy object and the arm of force must be smaller than the product of the self mass of the forklift (mostly provided by a balance weight) and the arm of force of the forklift, so that the stable work of the forklift can be ensured. Otherwise, the forklift may run a rollover risk with immeasurable losses to personnel and property.
Currently, whether the lifting weight of the off-road forklift exceeds the allowable load capacity is generally judged by experience, and particularly under the condition that the amount of the lifting weight is not known, the situation that the estimation error occurs to cause overload and further cause danger is inevitable. However, it is costly to equip a forklift with a weighing system, and it is necessary to provide expensive measuring sensors and associated connecting lines, which undoubtedly increases the cost of the forklift considerably.
It is desirable to solve the above problems.
Disclosure of Invention
In order to accurately and reliably judge whether a forklift load is overweight without increasing huge costs, the present invention provides a control unit for judging whether a forklift load is overweight, the control unit comprising a speed sensor connected to a forklift engine itself and a judgment module communicatively connected to an engine control unit of a forklift, the judgment module being configured to obtain a rated hydraulic pressure of a forklift lifting cylinder from an engine speed-rated hydraulic pressure transfer curve of the forklift lifting cylinder stored in the control unit based on an engine speed obtained from the speed sensor, obtain a valve opening ratio from an operating voltage-valve opening ratio transfer curve stored in the control unit based on a voltage value obtained from the engine control unit, and obtain a load quality of the forklift based on the rated hydraulic pressure, the valve opening ratio and a sectional area of the forklift lifting cylinder, and then, judging whether the forklift has a load overweight phenomenon which causes the forklift to overturn or not by utilizing a lever principle, and providing result prompt of whether the load is overweight or not for a forklift driver based on a judgment result.
According to a possible embodiment, the control unit further comprises a memory communicatively connected to the determination module, wherein the memory stores at least the following forklift intrinsic characteristic parameters: the hydraulic control system comprises a load force arm, a forklift mass, a forklift force arm, an engine rotating speed-rated hydraulic pressure transfer curve of a forklift lifting hydraulic cylinder, and an operating voltage-valve opening ratio transfer curve.
According to a possible embodiment, the determination module is configured to prompt the driver of the forklift truck that the load is not overweight in case the product of the load mass and the load moment arm of the forklift truck is smaller than the product of the load mass and the load moment arm of the forklift truck, and to prompt the driver of the forklift truck that the load is overweight in case the product of the load mass and the load moment arm of the forklift truck is greater than or equal to the product of the load mass and the load moment arm of the forklift truck.
According to a possible embodiment, the control unit further comprises an alarm in communication with the determination module, and the result prompt comprises a visual prompt and/or an audio prompt.
According to a possible embodiment, the visual cue comprises at least one of: whether the light of the alarm flickers or not, the different colors displayed by the alarm and the lighting form of the alarm lamp are judged; and/or the sound information comprises a buzzer sound or voice emitted by an alarm.
According to one possible embodiment, the control unit may be provided as a separate control unit or integrated into the engine control unit of the forklift.
According to another aspect of the present invention, there is provided a method for determining whether a load of a forklift is overweight using the above control unit, the method comprising using the determining module:
s1: obtaining an engine speed output from a speed sensor of a forklift engine itself and obtaining a voltage value output from an engine control unit of the forklift;
s2: based on the engine speed (S) and the voltage value (V), respectivelyoperating) Obtaining a rated hydraulic pressure (P) of the forklift lifting hydraulic cylinder from the engine speed-rated hydraulic pressure transfer curve and the operating voltage-valve opening ratio transfer curve of the forklift lifting hydraulic cylinder stored in the control unitrate) And a valve opening ratio (K);
s3: based on the rated hydraulic pressure (P)rate) The valve opening ratio (K) and the sectional area (A) of a lifting hydraulic cylinder of the forklift are used for obtaining the load mass of the forklift;
s4: judging whether the forklift has a load overweight phenomenon which causes the forklift to overturn or not by utilizing a lever principle;
s5: and providing a result prompt of whether the load is overweight to a forklift driver based on the judgment result.
According to the invention, only two real-time parameters are needed for calculating to judge whether the load of the forklift is overweight: the engine speed and the battery voltage of the truck are obtained from sensors and an engine control unit already provided in the truck itself. Therefore, the forklift does not need to be provided with a high-cost weighing system comprising expensive sensors and related lines, and the purpose of judging whether the forklift is overweight is achieved without greatly increasing the cost. In addition, the judgment is obtained by formula calculation for modeling, and compared with empirical judgment, the judgment accuracy and the reliability are greatly improved.
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The above and other advantages and features of the present application will be better understood from the following detailed description of preferred embodiments with reference to the accompanying drawings.
Fig. 1 shows a schematic view of a control unit for determining whether a forklift load is overweight according to the invention;
fig. 2 shows a flow chart of a method for determining whether a forklift load is overweight according to the invention.
Detailed Description
The invention aims to provide a more accurate and reliable method for judging whether a forklift load is overweight and a control unit for executing the method on the premise of not greatly increasing the cost.
Fig. 1 shows a block diagram of a control unit for determining whether a load of a forklift truck is overweight according to the invention.
The control unit, generally indicated by reference numeral 20, comprises a memory 22, a decision module 24 and an optional alarm 26.
As shown in FIG. 1, the determination module 24 is communicatively connected to the engine 'S own speed sensor 12 and the fork lift' S engine control unit 14 to obtain the current speed S of the engine and the current battery operating voltage V, respectivelyoperating
The determination module 24 is also communicatively coupled to the memory 22. The memory 22 stores parameters related to the intrinsic characteristics of the forklift, including, but not limited to: load arm L (distance between the approximate center of the fork of the forklift and the front wheel of the forklift), forklift mass M1And a force arm L of the forklift1(distance between the center of gravity of the forklift and the front wheel of the forklift), an engine rotating speed-rated hydraulic pressure transfer curve, an operating voltage-valve opening ratio transfer curve and the like.
On the one hand, the determination module 24 obtains the current speed S of the engine from the speed sensor 12 of the engine itself, and then obtains the corresponding rated hydraulic pressure P from the engine speed-rated hydraulic pressure transfer curve based on the current speed Srate
On the other hand, the determination module 24 obtains the current battery operating voltage V from the engine control unit 14 of the forkliftoperatingOperating power based on the current batteryPressure VoperatingThe current valve opening ratio K is obtained from the operating voltage-valve opening ratio transfer curve.
Thus, according to equation Pactual=Prate× K, the judgment module 24 can obtain the current actual hydraulic pressure P of the lifting hydraulic cylinder of the forkliftactual
When the radius of the hydraulic cylinder is r, the effective sectional area A of the hydraulic cylinder is pi × r2Can be calculated, from which the determination module 24 can calculate the actual required lifting force FLIs Pactual× A. considering a safety proportionality coefficient x between the weight of the load and the lifting force of the lifting cylinder and considering the acceleration g of gravity, the actual load mass M is obtained as FL/xg。
At this time, the determining module 24 extracts the load arm L and the forklift mass M from the memory 221And a force arm L of the forklift1And the like, and judging whether the forklift has a load overweight phenomenon which can cause the forklift to overturn around the front wheel according to a lever principle.
If the product of the load mass M × and the load arm L is less than the mass M of the forklift1× Forklift arm L1The judgment module 24 sends a result prompt that the load of the forklift is not overweight to the driver of the forklift, namely, the driver is informed that the forklift can work normally, namely, the load is lifted.
If the product of the load mass M × and the load arm L is greater than or equal to the mass M of the forklift1× Forklift arm L1The load is then overweight, lifting the load may cause the truck to overturn. At this time, the judgment module 24 sends an overweight load result prompt to the driver of the forklift so that the driver can take necessary measures in time, such as reducing the engine speed, not lifting the load, and the like.
The control unit 20 may be provided with an alarm 26 in communication with the decision block 24 for indicating to the truck driver the result of whether the truck load is overweight. The result cue may be a visual cue or an audio cue or a combination thereof.
The alarm 26 may be provided in the form of an alarm lamp. The result prompt sent by the judgment module 24 may be a change in the color of a warning lamp, for example, when the forklift load is not overweight, the warning lamp displays green, and when the forklift load is overweight, the warning lamp displays red, although other colors may be preset; the resulting prompt from the determination module 24 may be a change in the illuminated state of the warning light, such as the warning light not flashing when the forklift load is not overweight and flashing when the forklift load is overweight. Of course, any other manner of visually identifying the cue could be used as would occur to one skilled in the art.
In addition to the visual cues described above, the alarm 26 may be preset with various audible forms for conveying the resulting cues to the driver. As an example, the alarm lamp may be allowed to light but not sound only when the forklift load is not overweight, and the alarm may sound when the forklift load is overweight. As an alternative embodiment, different audible cues may be provided for the overweight and non-overweight conditions of the truck, respectively.
The control unit for determining whether a load of a forklift truck is overweight according to the invention is described in detail above with reference to fig. 1. The method steps by which the control unit determines whether the forklift load is overweight will now be described with reference to figure 2.
First in step S1, the determination module 24 obtains the current speed S of the engine and the current battery operating voltage V from the engine 'S own speed sensor 12 and the forklift' S engine control unit 14, respectively, in communication therewithoperating
In step S2, the determination module 24 obtains a corresponding nominal hydraulic pressure P based on the current speed S and the engine speed-nominal hydraulic pressure transfer curve stored in the memory 22rateAnd based on the present battery operating voltage VoperatingAnd the operating voltage-valve opening ratio transfer curve stored in the memory 22 obtains the current valve opening ratio K.
In step S3, the determination module 24 bases on the rated hydraulic pressure PrateAnd calculating the load mass M by using the valve opening ratio K and the sectional area A of the hydraulic cylinder.
In step S4, it is determined whether or not the forklift is overturned by using the principle of leverageIs overweight. This step includes extracting from the memory 22, for example, the load arm L, the forklift mass M1And a force arm L of the forklift1Etc. and the product of the load mass M × load arm L and the forklift mass M1× Forklift arm L1The products of (a) and (b) are compared.
In step S5, the driver of the forklift is provided with a result prompt indicating whether the load is overweight according to the judgment result, and the step comprises that the product of the load arm L of the load mass M × is smaller than the mass M of the forklift1× Forklift arm L1The result prompt that the load is not overweight is provided for the forklift driver under the condition that the product of the front side and the rear side is larger than or equal to the product of the rear side.
The control unit as described above is used to determine whether the load of the forklift truck is overweight according to the method as described above, and the required real-time parameters include only the engine speed and the battery voltage of the forklift truck, which are obtained from the sensors and the engine control unit configured in the forklift truck. Therefore, accurate determination of whether a forklift load is overweight is achieved without the need to equip the forklift with a costly weighing system including expensive sensors and associated wiring. According to the principle of the invention, the judgment is obtained by modeling and formula calculation, and compared with the prior judgment based on experience, the judgment accuracy and the reliability are greatly improved.
Preferred embodiments of the present invention are given above with reference to the accompanying drawings. It will be appreciated by those skilled in the art that the foregoing description is only illustrative of the principles of the invention and is not intended to limit the scope of the invention. Various modifications, additions or substitutions for the features, structures, forms, etc. shown in the drawings and described above can be made by those skilled in the art without departing from the principle and spirit of the invention, and all such modifications, additions or substitutions are within the scope of the invention.

Claims (8)

1. A control unit for determining whether a load of a forklift truck is overweight, the control unit comprising a determination module communicatively connected to a speed sensor of the forklift truck engine itself and to an engine control unit of the forklift truck, the determination module configured to:
obtaining a nominal hydraulic pressure (P) of the forklift lifting cylinder from an engine speed-nominal hydraulic pressure transfer curve of the forklift lifting cylinder stored in the control unit based on the engine speed (S) obtained from the speed sensorrate),
Based on a voltage value (V) obtained from the engine control unitoperating) Obtaining a valve opening ratio (K) from an operating voltage-valve opening ratio transfer curve stored in the control unit,
based on the rated hydraulic pressure (P)rate) The valve opening ratio (K) and the cross-sectional area (A) of the lifting cylinder of the fork-lift truck obtain the load mass (M) of the fork-lift truck, and
the product of the load mass (M) and the load arm (L) of the forklift and the forklift mass (M) are realized by utilizing the lever principle1) With arm of force of fork truck (L)1) The products of the two steps are compared to judge whether the forklift has the phenomenon of overweight load causing the forklift to overturn or not, and a result prompt of whether the load is overweight or not is provided for a forklift driver based on the judgment result.
2. The control unit according to claim 1, further comprising a memory communicatively connected to the determination module, the memory having stored therein at least the following forklift intrinsic characteristic parameters: the load arm (L), the fork truck mass (M)1) Said fork truck arm of force (L)1) The transmission curve of the engine speed to the rated hydraulic pressure of the forklift lifting hydraulic cylinder and the transmission curve of the operating voltage to the valve opening ratio.
3. The control unit of claim 2, wherein the determination module is configured to determine that the product of the load mass (M) and the load moment arm (L) of the forklift is less than the forklift mass (M)1) With arm of force of fork truck (L)1) The driver of the truck is prompted that the load is not overweight, and the product of the load mass (M) and the load moment arm (L) of the truck is greater than or equal to the truck mass (M)1) With arm of force of fork truck (L)1) In the case of the product ofPrompting the forklift driver that the load is overweight.
4. The control unit of any of claims 1-3, further comprising an alarm communicatively coupled to the determination module, the result prompt comprising a visual prompt and/or an audible prompt.
5. The control unit of claim 4,
the visual cue comprises at least one of: flashing light of the alarm, the color displayed by the alarm and the on-off state of the alarm light; and/or the presence of a gas in the gas,
the sound prompt comprises a buzzer or voice sent by an alarm.
6. The control unit of any one of claims 1-3 and 5, wherein the control unit may be provided as a separate control unit or integrated into the engine control unit of a forklift.
7. The control unit of claim 4, wherein the control unit may be provided as a separate control unit or integrated into the engine control unit of a forklift truck.
8. A method for determining whether a load of a forklift truck is overweight using a control unit according to any of claims 1-7, comprising using the determination module:
s1: obtaining an engine speed (S) output from a speed sensor of the forklift engine itself and obtaining a voltage value (V) output from an engine control unit of the forkliftoperating);
S2: based on the engine speed (S) and the voltage value (V), respectivelyoperating) Obtaining a rated hydraulic pressure (P) of the forklift lifting hydraulic cylinder from the engine speed-rated hydraulic pressure transfer curve and the operating voltage-valve opening ratio transfer curve of the forklift lifting hydraulic cylinder stored in the control unitrate) And a valve opening ratio (K);
s3: based on the rated hydraulic pressure (P)rate) Obtaining the load mass (M) of the forklift by the valve opening ratio (K) and the sectional area (A) of the forklift lifting hydraulic cylinder;
s4: the product of the load mass (M) and the load arm (L) of the forklift and the forklift mass (M) are realized by utilizing the lever principle1) With arm of force of fork truck (L)1) The products are compared to judge whether the forklift has the phenomenon of overweight load which causes the forklift to overturn;
s5: and providing a result prompt of whether the load is overweight to a forklift driver based on the judgment result.
CN201610264507.7A 2016-04-26 2016-04-26 Control unit and method for judging whether forklift load is overweight Active CN107311086B (en)

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Address after: 214028 No.17 Xinhua Road, national high tech Industrial Development Zone, Wuxi City, Jiangsu Province

Patentee after: Bosch powertrain Co.,Ltd.

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