CN114105056B - High-cargo-space forklift safety operation control system and method - Google Patents
High-cargo-space forklift safety operation control system and method Download PDFInfo
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- CN114105056B CN114105056B CN202111288078.4A CN202111288078A CN114105056B CN 114105056 B CN114105056 B CN 114105056B CN 202111288078 A CN202111288078 A CN 202111288078A CN 114105056 B CN114105056 B CN 114105056B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66F—HOISTING, 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
- B66F17/00—Safety devices, e.g. for limiting or indicating lifting force
- B66F17/003—Safety devices, e.g. for limiting or indicating lifting force for fork-lift trucks
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Forklifts And Lifting Vehicles (AREA)
Abstract
The invention discloses a high-cargo-space forklift safety operation control system and method. The device comprises a load weight measuring component, a forklift controller component, a lifting height measuring component and an external output component. The load weight measuring component detects the load weight of forklift operation and transmits the load weight to the forklift controller component, the lifting height measuring component detects the lifting height of forklift operation and transmits the lifting height to the forklift controller component, and the forklift controller component combines the load weight of forklift operation and the lifting height to generate state information and transmits the state information to the external output component for display. The invention reasonably limits the lifting height on the basis of maximally utilizing the high lifting function of the forklift, realizes the safe operation of the forklift with high goods space, and has the advantages of simple principle, low cost and convenient engineering realization.
Description
Technical Field
The invention relates to a forklift work control system and method, in particular to a high-cargo-space forklift safety work control system and method.
Background
The lack of land resources and the rising of land prices have to go to the strategy of space warehouse and high-altitude development of space benefit, so that the lifting height of the forklift is also higher and higher, the working environment is also more and more complex, and the operation safety of the forklift, particularly the high-order picking forklift, is in need of improvement. Under the action of gravity and inertia force of goods, the fork truck in operation is easy to tilt forwards and longitudinally; during turning, transverse tipping easily occurs due to centrifugal inertia force. Research students at home and abroad have conducted a great deal of research on lateral stability and anti-tipping technology in the forklift driving process. For the longitudinal stability of the forklift, the longitudinal stability is generally realized by limiting the lifting height of cargoes, so that the load weight, namely the forklift load curve, of the forklift fork, which can be actually loaded at the lifting corresponding height is given before the forklift leaves the factory. The weighing function of the forklift in the operation process is realized rapidly in real time, and the lifting height is reasonably limited on the basis of maximally utilizing the high lifting function of the forklift according to the weight of goods, so that the forklift is an effective solution.
Disclosure of Invention
The invention aims at the safe operation of the high-cargo-space forklift and aims at the autonomous weighing and the safe operation control of the forklift, and the invention aims at providing the safe operation control system and the safe operation control method of the high-cargo-space forklift, which have the advantages of simple principle, convenient realization and no influence on the structure and the appearance of the forklift and can well meet the requirement of the high-cargo-space forklift on the load weight measurement.
In order to achieve the aim of the invention, the invention adopts the following technical scheme:
1. a high-cargo-space forklift safety operation control system comprises:
the system comprises a load weight measuring component, a forklift controller component, a lifting height measuring component and an external output component; the load weight measuring component detects the load weight of forklift operation and transmits the load weight to the forklift controller component, the lifting height measuring component detects the lifting height of forklift operation and transmits the lifting height to the forklift controller component, and the forklift controller component combines the load weight of forklift operation and the lifting height to generate state information and transmits the state information to the external output component for display.
The load weight measurement component comprises a pressure acquisition module, an analog-to-digital conversion module, a main controller module, a least square fitting module, a CAN bus communication module and a forklift instrument display module; the pressure acquisition module is connected with the main controller module through the analog-to-digital conversion module, the main controller module is connected with the forklift instrument display module through the CAN bus communication module, the least square fitting and fitting module is an off-line software module and is used for calculating to obtain a pressure-load relation, and the pressure-load relation is programmed into the main controller module through a software programming mode.
The external output component is a display.
2. A high-cargo-space forklift safety operation control method comprises the following steps:
s1: the load weight measuring part is used for measuring and acquiring the load weight of the forklift during operation;
s2: writing a pre-established lifting height upper limit-load curve into a forklift controller component in advance;
s3: the forklift controller component obtains the lifting height upper limit H in real time according to the current load weight and the lifting height upper limit-load curve L ；
S4: the lifting height H is measured and obtained by a lifting height measuring component when the forklift works;
s5: interpretation of the upper limit of lift height H L The magnitude relation with the current lifting height H;
s6: the forklift controller part is controlled according to the lifting height upper limit H L And the size relation with the current lifting height H carries out overload alarm information or allows the display of the continuous lifting state through an external output part of the forklift.
The specific implementation steps of the step S1 are as follows:
s11: the method comprises the steps that a pressure acquisition module is used for acquiring a pressure analog value of a hydraulic loop of a lifting hydraulic cylinder in a forklift and sending the pressure analog value to an analog-to-digital conversion module;
s12: converting the pressure analog quantity value into a pressure digital quantity by an analog-to-digital conversion module, and transmitting the pressure digital quantity value to a main control module;
s13: the main control module obtains a pressure-load weight relation by using a least square method in an off-line calibration mode, the main control module inputs the pressure-load relation according to the pressure digital quantity to calculate to obtain load weight, and the load weight calculated by the main control module is communicated to the forklift instrument display module through the CAN bus communication module;
the pressure-load weight relation is specifically obtained by a forklift working under the condition of known load to obtain a pressure digital quantity in advance.
S14: and the forklift instrument display module displays the load weight.
In the step S13, the pressure-load relation is specifically as follows:
establishing a linear relation between the lifting load weight m and a pressure digital value p of a lifting hydraulic cylinder hydraulic circuit in the forklift, and fitting to obtain a zero drift quantity beta and a proportionality coefficient alpha to obtain a pressure-load relation formula:
m＝αp+β
wherein alpha is a proportionality coefficient, beta is a zero drift amount, and the alpha is obtained by using a fitting calculation mode through test data.
The test data are used for obtaining a proportional coefficient alpha and a zero drift quantity beta in a fitting mode, and the method specifically comprises the following steps:
a set of sample points for the test data is (p i ,m i ) I=0, 1,2,3, …, n, i denotes sample point ordinal number, p i Representing the ith pressure figure number, m i Representing the i-th pressure digital quantity value, weighting the residuals for each sample point:
wherein lambda is i Is a sample point (p i ,m i ) The residual weighting coefficient of (2) satisfies the following formula
Setting a binary function of a coefficient to be determined by taking the proportional coefficient alpha and the zero drift quantity beta as the coefficient to be determined and taking the sum of squares of residual errors after sample point weighting:
the weighted residual square sum is set to be minimum, and the following formula is satisfied:
the proportionality coefficient alpha and the zero drift quantity beta are obtained by taking test data from the above binary first-order equation set.
The invention has the beneficial effects that:
1. the load weight measuring component has the advantage of having no influence on the structure and the appearance of the forklift.
2. The invention has simple principle, low cost and convenient engineering realization.
3. The invention reasonably limits the lifting height on the basis of maximally utilizing the high lifting function of the forklift, and realizes the safe operation of the forklift with high goods space.
Drawings
Fig. 1 is a diagram showing the construction of a safety operation control system for a high-cargo-space forklift according to the present invention.
Fig. 2 is a diagram showing the constitution of the load weight measuring system of the present invention.
Fig. 3 is a flowchart of a high cargo space forklift safety operation control method of the present invention.
Fig. 4 is a flow chart of a load weight measurement method of the present invention.
Fig. 5 is a schematic diagram of the load bearing process of the forklift truck according to the present invention.
Fig. 6 is a graph of load weight-pressure fit results for the present invention.
In the figure: 1. the device comprises a load weight measuring component 2, a forklift controller component 3, a lifting height measuring component 4, an external output component 11, a pressure acquisition module 12, an analog-to-digital conversion module 13, a main controller module 14, a least square fitting module 15, a CAN bus communication module 16 and a forklift instrument display module.
Detailed Description
The invention is further described below with reference to the drawings and the detailed description.
As shown in fig. 1, the system comprises a load weight measuring part 1, a forklift controller part 2, a lifting height measuring part 3 and an external output part 4; the load weight measuring part 1, the lifting height measuring part 3 and the external output part 4 are respectively connected with the forklift controller part 2, the load weight measuring part 1 detects the load weight of forklift operation and transmits the load weight to the forklift controller part 2, the lifting height measuring part 3 detects the lifting height of forklift operation and transmits the lifting height to the forklift controller part 2, and the forklift controller part 2 generates state information according to the combination of the load weight and the lifting height of forklift operation and transmits the state information to the external output part 4 for display.
As shown in fig. 2, the load weight measurement component 1 comprises a pressure acquisition module 11, an analog-to-digital conversion module 12, a main controller module 13, a least squares fitting module 14, a CAN bus communication module 15 and a forklift instrument display module 16; the pressure acquisition module 11 is connected with the main controller module 13 through the analog-to-digital conversion module 12, the main controller module 13 is connected with the forklift instrument display module 16 through the CAN bus communication module 15, the least square fitting module 14 is an off-line software module and is used for calculating to obtain a pressure-load relation, and the pressure-load relation is programmed into the main controller module 13 through a software programming mode.
In a specific implementation, the pressure acquisition module 11 adopts a monocrystalline silicon type liquid pressure sensor, and the external output component 4 is a display.
As shown in fig. 3, an embodiment of the present invention is as follows:
s1: as shown in fig. 4, the load weight of the forklift during the forklift operation is measured and acquired by the load weight measuring part 1;
s11: the pressure analog value of the hydraulic loop of the lifting hydraulic cylinder in the forklift is acquired through the pressure acquisition module 11 and is sent to the analog-to-digital conversion module 12;
s12: converting the pressure analog quantity value into a pressure digital quantity by an analog-to-digital conversion module 12, and sending the pressure digital quantity value to a main control module 13;
s13: the main control module 13 obtains a pressure-load weight relation by using a least square method in an off-line calibration mode, the main control module 13 inputs the pressure-load relation according to the pressure digital quantity to calculate to obtain load weight, and the load weight calculated by the main control module 13 is communicated to the forklift instrument display module 16 through the CAN bus communication module 15;
in step S13, the pressure-load relation is specifically as follows:
as shown in fig. 5, the lifting load weight is m, the hydraulic cylinder lifting force is F, the cargo lifting acceleration is a, the local gravitational acceleration is g, and the pressure load relationship analysis is performed.
Taking the influence of factors such as a fork hydraulic cylinder and a truck dead weight into consideration, establishing a linear relation between the lifting load weight m and a pressure digital value p of a lifting hydraulic cylinder hydraulic circuit in a forklift, and fitting to obtain a zero drift amount beta and a proportionality coefficient alpha to obtain a pressure-load relation formula:
m＝αp+β
wherein alpha is a proportionality coefficient, beta is a zero drift amount, and the zero drift amount is obtained by using a specific fitting calculation mode through test data.
A set of sample points for the test data is (p i ,m i ) I=0, 1,2,3, …, n, i denotes sample point ordinal number, p i Representing the ith pressure figure number, m i The ith pressure digital value is represented, residual errors of each sample point are weighted, and weighing precision under the condition of heavy load is improved:
wherein lambda is i Is a sample point (p i ,m i ) The residual weighting coefficient of (2) satisfies the following formula
Setting a binary function of a coefficient to be determined by taking the proportional coefficient alpha and the zero drift quantity beta as the coefficient to be determined and taking the sum of squares of residual errors after sample point weighting:
the weighted residual square sum is set to be minimum, and the following formula is satisfied:
the proportionality coefficient alpha and the zero drift quantity beta are obtained by taking test data from the above binary first-order equation set.
The pressure-load relationship obtained from the final fit results of the examples is shown in fig. 6.
S14: the forklift meter display module 16 displays the load weight.
S2: writing a pre-established lifting height upper limit-load curve into the forklift controller part 2 in advance;
s3: the forklift controller component obtains the lifting height upper limit H in real time according to the current load weight and the lifting height upper limit-load curve L ；
S4: the lifting height H during forklift operation is measured and acquired by the lifting height measuring part 3;
s5: interpretation of the upper limit of lift height H L The magnitude relation with the current lifting height H;
s6: the forklift control part 2 is based on the upper limit H of the lifting height L The magnitude relation with the current lifting height H is used for carrying out overload alarm information or allowing the lifting state to be displayed continuously through the external output part 4 of the forklift.
Therefore, the invention reasonably limits the lifting height on the basis of maximally utilizing the high lifting function of the forklift, realizes the safe operation of the forklift with high goods space, has the advantages of simple principle, low cost and convenient engineering realization, and achieves remarkable effect.
Claims (1)
1. The safety operation control method for the high-cargo-space forklift truck is characterized by comprising the following steps of:
s1: the load weight measuring component (1) is used for measuring and acquiring the load weight of the forklift during the operation;
s2: writing a pre-established lifting height upper limit-load curve into a forklift controller component (2) in advance;
s3: the forklift controller component obtains the lifting height upper limit H in real time according to the current load weight and the lifting height upper limit-load curve L ；
S4: the lifting height H during forklift operation is measured and acquired through a lifting height measuring component (3);
s5: interpretation of the upper limit of lift height H L The magnitude relation with the current lifting height H;
s6: the forklift controller part (2) is based on the upper limit H of the lifting height L The size relation with the current lifting height H carries out overload alarm information or allows continuous lifting state display through an external output part (4) of the forklift;
the specific implementation steps of the step S1 are as follows:
s11: the pressure analog value of a hydraulic loop of a lifting hydraulic cylinder in the forklift is obtained through a pressure acquisition module (11) and is sent to an analog-to-digital conversion module (12);
s12: converting the pressure analog quantity value into a pressure digital quantity by an analog-digital conversion module (12), and transmitting the pressure digital quantity value to a main control module (13);
s13: the main control module (13) obtains a pressure-load weight relation by using a least square method in an off-line calibration mode, the main control module (13) inputs the pressure-load relation according to the pressure digital quantity to calculate to obtain load weight, and the load weight calculated by the main control module (13) is communicated to the forklift instrument display module (16) through the CAN bus communication module (15);
s14: the forklift instrument display module (16) displays the load weight;
in the step S13, the pressure-load relation is specifically as follows:
establishing a linear relation between the lifting load weight m and a pressure digital value p of a lifting hydraulic cylinder hydraulic circuit in the forklift, and fitting to obtain a zero drift quantity beta and a proportionality coefficient alpha to obtain a pressure-load relation formula:
m＝αp+β
wherein alpha is a proportionality coefficient, beta is a zero drift amount, and the alpha is obtained by using a fitting calculation mode through test data;
the test data are used for obtaining a proportional coefficient alpha and a zero drift quantity beta in a fitting mode, and the method specifically comprises the following steps:
a set of sample points for the test data is (p i ,m i ) I=0, 1,2,3, …, n, i denotes sample point ordinal number, p i Representing the ith pressure figure number, m i Representing the i-th pressure digital quantity value, weighting the residuals for each sample point:
wherein lambda is i Is a sample point (p i ,m i ) The residual weighting coefficient of (2) satisfies the following formula
Setting a binary function of a coefficient to be determined by taking the proportional coefficient alpha and the zero drift quantity beta as the coefficient to be determined and taking the sum of squares of residual errors after sample point weighting:
the weighted residual square sum is set to be minimum, and the following formula is satisfied:
the proportionality coefficient alpha and the zero drift quantity beta are obtained by taking test data from the above binary first-order equation set.
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