KR20120043934A - Device and method for durability test of electric forklift controller using plc - Google Patents

Abstract

PURPOSE: A device and method for inspecting the durability of a controller of an electric forklift truck by using a PLC(Programmable Logic Controller) are provided to successively and repetitively inspect the durability of a controller without a time limit and to measure a workable time with one battery charge. CONSTITUTION: A device for inspecting the durability of a controller of an electric forklift truck by using a PLC comprises a hydraulic controller(100), a traveling controller(200), and a PLC(300). The hydraulic controller controls a hydraulic motor(110) supplying a driving force for lifting to a fork of an electric forklift truck. The hydraulic controller comprises a first reactor(120) of a three-phase to add a load for a test to the hydraulic motor by a power supply. The traveling controller comprises a second reactor of a three-phase to add the load for the test to each traveling motor by the power supply. The PLC applies signals for driving/pause to the hydraulic motor at the same time while applying information of driving/pause and advance/moving back to the traveling controller. The PLC evaluates the durability of the traveling controller and hydraulic controller.

Description

DEVICE AND METHOD FOR DURABILITY TEST OF ELECTRIC FORKLIFT CONTROLLER USING PLC

The present invention relates to an apparatus and method for testing the durability of an electric forklift, and in particular, since the apparatus using a PL (PLC) is used for the durability test of the electric forklift controller, accurate and repeatable tests are possible, thereby reducing the durability test time. In addition, long-term durability test is possible through unmanned driving, and setting of various driving patterns can simulate the difficult situation in the vehicle directly. In addition, it is possible to measure the time that can be worked by one charge by applying one charge work cycle (CYCLE) pattern to PLC operation pattern, so it is possible to measure the performance of the electric forklift control program. Durability testing apparatus and method.

In general, the main functions of the electric forklift truck are divided into a traveling function and a loading and unloading function, and all of the components for driving, loading and unloading functions are driven by an AC motor.

The most important component of the drive control system, which includes the protection circuit that controls the speed of the AC motor and prevents equipment and components from malfunctioning, is the controller.

Therefore, it can be seen that the durability of the controller is representative of the durability of the electric forklift, and the present invention uses a single charge work cycle (CYCLE) test using a PLC for durability evaluation.

One charge work cycle (CYCLE) test is performed by recharging the forklift battery only and repeating the operation according to a predetermined pattern called one charge work cycle (CYCLE) to measure the working time until the battery falls to 20% of the full charge voltage. A method of evaluating the control performance of a forklift control program.

1 Charging operation The CYCLE test is described in more detail as follows.

(1) Fully charge the electric forklift and check and record the condition and test conditions of the equipment.

(2) Repeat the work cycle (CYCLE) to run, ascend, and descend the 30m section with load and no load.

(3) Work cycle (CYCLE) test is completed at the battery level is 100%, run continuously until the end of one cycle (CYCLE).

(4) At this time, whenever the remaining battery indication drops by 10%, record the operating time, the number of cycles, and the battery voltage.

(5) Continue until the battery level indicator reaches 20%. However, since the driver directly rides the vehicle and repeatedly drives, even if one driver tests, there may be a difference in performing the same work according to the number of tests. Therefore, the test cannot be performed in the same manner, and there is a problem in that it is restricted in the daily operation time and the number of times.

Accordingly, the present invention is to solve the above-mentioned conventional problem, the present invention is to solve the above problem is to store the one charge working cycle (CYCLE) pattern in the PLC (PLC) and When the operation command is given to the electric forklift controller, the controller receives a command and outputs a current according to the pre-programmed contents, thereby providing a durability test apparatus and method for the electric forklift controller using a PLC to repeat the same test infinitely without a driver. There is a purpose.

The durability test apparatus of the electric forklift controller using the PLC of the present invention for achieving the above object, to control the hydraulic motor for providing a lift drive force to the fork of the electric forklift, and to apply a test load to the hydraulic motor by power supply The hydraulic controller is provided with a three-phase first reactor for controlling the traveling motor that provides driving driving force to the wheels of the electric forklift, and the three-phase second reactor for applying a test load to each of the traveling motors by power supply. Apply one charging work cycle step information to the travel controller and the travel controller and the hydraulic controller, and apply the run / stop and forward / reverse information to the travel controller and simultaneously apply the operation / stop signal to the hydraulic controller. Thus, it characterized in that it comprises a PLC for evaluating the durability of the travel controller and the hydraulic controller.

The PLC includes an analog input / output module for applying step information as an analog voltage output signal to the travel controller and the hydraulic controller, and a digital contact signal to the travel controller for driving / stopping and forward / reverse step information. And a digital input / output module for applying operation / stop step information by applying a digital contact signal to the hydraulic controller.

The driving motor is provided with a left driving motor and a right driving motor, respectively, which provide driving driving force to both wheels of the front wheel, and the second reactor includes a left reactor for applying a load to the left driving motor, and the right driving motor. It is preferable to be provided with the right reactor which loads, respectively.

It is preferable that the PLC increases the count by one after the last step of the one charging work cycle pattern is completed, and returns to the first step again.

On the other hand, the durability test method of the electric forklift controller using the PLC of the present invention for achieving the above object, the first step of determining the 1 charging work cycle pattern for durability test to the traveling controller and the hydraulic controller using the PLC, and the 1 A second step of determining a time required for each step of the charging work cycle pattern and output currents of the travel controller and the hydraulic controller; and an output current according to each step of the one PLC, the travel controller, and the hydraulic controller in one charging work cycle pattern. And a fourth step of starting the operation according to the first charging work cycle pattern by the start signal, receiving the step signal from the PLC, and determining the current step in the travel controller and the hydraulic controller. Step and the current to be output in the current step through the current control in the travel controller and the hydraulic controller It characterized in that it comprises a fifth step of outputting.

The first step is a first step of tilting the load after raising the load to a certain height from the ground at point A, the second step step of driving a fixed point to a point B at a certain distance with the load, and the B A third step of bringing the load down to the ground and making it unloaded, a fourth step of steady running back to the point A without loads, and a fork at the point A unloaded; A fifth step of tilting after raising to a certain height from the ground, a sixth step of forward driving to the point B at a predetermined distance, and a second step of raising the load from the ground to a predetermined height at the point of B and tilting it; It is preferable to include a seven-step step, and the eighth step of moving back to the point A at a certain distance with the load and then lowering the load.

The first step S500 is performed a plurality of times through the process of returning to the first step S110 after increasing the count COUNT by 1 after finishing the eighth step S180. The ninth step S190 may be further included.

In the fourth step, after the power is turned on, the driving controller and the hydraulic controller program are operated to wait for the first charging work cycle start command of the first stage, and the user presses a start button to start or stop driving. It is preferable to include a step of pressing a button, and determining the current step by the traveling controller and the hydraulic controller by receiving the step signal from the PLC.

In the fourth step, it is preferable to distinguish each step of the one charging work cycle by using an analog output voltage instead of the digital contact output of the PLC.

The fourth step may pre-program the corresponding rule as the first step step when the analog output voltage of the PLC is 0V and the second step step when 0.5V, and the analog voltage output of the PLC. Preferably, a signal is converted by the hydraulic controller and the travel controller to A / D conversion to determine a current step of the first charging work cycle.

As described above, the present invention, by applying the PL (PLC) to the durability test of the electric forklift controller, it is possible to test the durability of the continuous and repeated controller without time constraints, it is possible to shorten the durability test time, Unattended driving enables long-term durability test, and the setting of various driving patterns has the advantage of simulating a difficult situation directly in the vehicle.

And, by applying the one-cycle working cycle (CYCLE) pattern to the durability test can measure the time available to work with a single charge, there is an advantage that can evaluate the control performance of the controller program for electric forklift.

In addition, since the first and second reactor loads of the three phases used in the test are reactive power loads, one continuous charge of about five times or more when used with the same inverter output current as when using a real vehicle motor load with the same charged battery Since the test can be performed, there is an advantage that the utilization effect of the controller durability test can be maximized.

1 is an overall block diagram of a PLC and a traveling and hydraulic controller of a durability test apparatus for an electric forklift controller using a PLC according to the present invention.
Figure 2 is a flow chart of the durability test of the durability test method of the electric forklift controller using a PLC according to the present invention.
Figure 3 is an illustration of one charging work cycle (CYCLE) pattern of the durability test method of the electric forklift controller using a PLC according to the present invention.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

In describing the present invention, the defined terms are defined in consideration of the function of the present invention, and should not be understood in a limiting sense of the technical elements of the present invention.

As shown in FIG. 1, the durability test apparatus of the electric forklift controller using the PLC of the present invention controls the hydraulic motor 110 to provide a lift driving force to the fork of the electric forklift, and the hydraulic motor 110 by power supply. Control the hydraulic controller (100) having a three-phase first reactor (120) for applying a test load to the motor) and a driving motor (210) for providing driving driving force to the wheels of the electric forklift truck, The traveling controller 200 is provided with a three-phase second reactor 220 for applying a test load to each of the motors 210, and one charging work cycle step (STEP) is provided to the traveling controller 200 and the hydraulic controller 100. The information is applied, the driving / stop and forward / reverse information are applied to the traveling controller 200, and the operation / stop signal is applied to the hydraulic controller 100, thereby the traveling controller 200 and the hydraulic controller 100 are applied. To evaluate the durability of the product (PLC, 300) It includes. Here, the PLC 300 is provided with a CPU for calculation.

In addition, the hydraulic controller 100 and the traveling controller 200 may be connected to the battery 400, 400 ', or a separate power supply cable for supplying power. In addition, the PLC 300 may further include a separate operation unit 330 for starting / stopping the DPSMS operation.

The test apparatus of the present invention having such a configuration is operated by receiving the driving and stop signals from the PLC 300 without receiving the forklift vehicle.

In other words, lift the front and left driving wheels of the electric forklift truck on the ground, load the inertia load on the driving wheels, load the load corresponding to the tonnage of the electric forklift truck, and then start / stop and 1 charge work in the PLC. When the cycle pattern command is given, one charge test is enabled in unattended operation.

The PLC 300 described above is provided to the analog input / output module 310 and the traveling controller 200 that apply step (STEP) information to the traveling controller 200 and the hydraulic controller 100 as analog voltage output signals. The digital input / output module 320 applying the digital contact signal to apply driving / stop step information and the forward / reverse step information, and applying the digital contact signal to the hydraulic controller 100 to apply the operation / stop step information. It is provided.

The driving motor 210 is provided as a left driving motor 211 and a right driving motor 212 which provide driving driving force to both wheels of the front wheel, respectively. The second reactor 220 may be provided as a left reactor 221 for applying a load to the left driving motor 211 and a right reactor 222 for applying a load to the right traveling motor 212.

As described above, the load of the three-phase first reactor 120 and the second reactor 220 may simulate a situation in which it is difficult to directly test the vehicle by setting various driving patterns as reactive power loads. The controller's durability can be evaluated by continuously repeating one charging work cycle operation, and the controller's temperature rise test can be performed through inverter output current control.

In addition, since the loads of the first reactor 120 and the second reactor 220 of the three phases are reactive power loads, when used with the same inverter output current as the case of using the actual vehicle motor load with the same charged battery, it is about five times or more. A long continuous 1 charge test can be performed. Therefore, the utilization effect can be maximized in the durability test of the hydraulic controller and the traveling controller of the electric forklift.

In addition, the PLC 300 may increase the count COUNT by one after the last step of the one charging work cycle pattern is completed, and may return to the first step again.

Hereinafter, each step of the durability test method of the electric forklift controller using the PLC according to the present invention with reference to Figure 2 as follows, and the above-described configuration will not be described repeatedly.

First, the first step (S100) determines the one-charge working cycle (CYCLE) pattern for durability test in the travel controller 200 and the hydraulic controller 100 using the PLC 300. The above-mentioned one filling working cycle (CYCLE) pattern may be composed of a total of eight steps.

As shown in FIG. 3, the first step S100 includes a first step step S110 of tilting the load at a point A on the ground and then tilting the load, and a point B at a predetermined distance from the load state. The second step (S120) to run in a steady state, the third step step (S130) to reach the point B and then put the load on the ground to be unloaded state, and from the unloaded state to the point A again The fourth step (S140) of driving, the fifth step (S150) of tilting after raising the fork to a certain height from the ground in the unloaded state at the point A, and driving forward to the point B at a predetermined distance The sixth step step (S160) and the seventh step step (S170) of raising the load to a certain height from the ground at the point B and tilting, and moving back to the point A at a certain distance holding the load Next, an eighth step of lowering the load (S18) 0).

Here, it is preferable that the height which raises a load is 30 cm, and the distance to which a fixed run is 30 m. Of course, the numerical values can be applied differently.

In addition, the first step S500 may be performed a plurality of times through the process of returning to the first step S110 after increasing the count COUNT by 1 after finishing the eighth step S180. A ninth step step S190 may be further included.

That is, after the eighth step S180 is finished, the ninth step S190 of returning to the first step S110 may be further included.

Next, the second step (S200) is the required time for each step (STEP) of the one charging work cycle (CYCLE) pattern determined in the first step (S100), and the output of the travel controller 200 and the hydraulic controller 100 Determine the current.

Next, in the third step S300, the output current according to each step STEP of the one charging work cycle CYCLE pattern is programmed in the PLC 300, the travel controller 200, and the hydraulic controller 100.

Next, the fourth step S400 starts operation according to the first charging work cycle CYCLE pattern by the START signal. In addition, the step signal is received from the PLC 300 and the driving controller 200 and the hydraulic controller 100 determine the current step STEP.

The fourth step (S400), after the power is turned on waiting for the first charge work cycle (CYCLE) start (START) command of the first step (S100) while the run controller 200 and the hydraulic controller 100 program operating Step (S410), the user presses the START button to start the operation, or by pressing the STOP button (S420) to stop the operation, and each step (STEP) step signal from the PLC 300 In operation S430, the driving controller 200 and the hydraulic controller 100 determine the current step.

In the fourth step S400, each step STEP of the first charging work cycle CYCLE is distinguished using an analog output voltage instead of the digital contact output of the PLC 300.

In addition, the fourth step (S400), the first step step (S110) when the analog output voltage of the PLC 300 is 0V, the corresponding rule as the second step step (S120) when 0.5V in advance Program.

In addition, the fourth step (S400) is the A / D conversion of the analog voltage output signal of the PLC 300 in the hydraulic controller 100 and the travel controller 200, the current step of the one charging work cycle (CYCLE) ( STEP) can be determined.

Finally, the fifth step S500 outputs a current to be output in the current step STEP through current control in the travel controller 200 and the hydraulic controller 100.

As a result, by applying PLC to the durability test of the electric forklift controller, continuous and repeated durability test of the controller can be performed without time constraints, the durability test time can be shortened, and long-term durability through unmanned operation It is possible to test, and by setting various driving patterns, there is an advantage that it is possible to simulate a difficult situation in the vehicle directly. And, by applying the one-cycle working cycle (CYCLE) pattern to the durability test can measure the time available to work with a single charge, there is an advantage that can evaluate the control performance of the controller program for electric forklift.

In addition, since the first and second reactor loads of the three phases used in the test are reactive power loads, one continuous charge of about five times or more when used with the same inverter output current as when using a real vehicle motor load with the same charged battery Since the test can be performed, there is an advantage that the utilization effect of the controller durability test can be maximized.

Although the technical idea of the durability test apparatus and method for an electric forklift controller using a PLC according to the present invention has been described with the accompanying drawings, the present invention has been described by way of example only and is not intended to limit the present invention. no.

Accordingly, it is a matter of course that various modifications and variations of the present invention are possible without departing from the scope of the present invention. And are included in the technical scope of the present invention.

100: hydraulic controller 110: hydraulic motor
120: first reactor 200: driving controller
210: driving motor 211: left driving motor
212: right driving motor 220: second reactor
221: left reactor 222: right reactor
300: PLC 310: analog input / output module
320: digital input / output module 330: control panel
400, 400 ': battery

Claims (10)

A hydraulic controller for controlling a hydraulic motor that provides a lift driving force to the fork of the electric forklift, and having a three-phase first reactor for applying a test load to the hydraulic motor by power supply;
A traveling controller configured to control a traveling motor providing driving driving force to wheels of the electric forklift, and having a three-phase second reactor for applying a test load to each of the traveling motors by supplying power; And
By applying one charging work cycle step (STEP) information to the traveling controller and the hydraulic controller, and applying run / stop and forward / reverse information to the traveling controller, and simultaneously applying an operation / stop signal to the hydraulic controller, Durability test apparatus of the electric forklift controller using a PLC, characterized in that it comprises; PLC (PLC) for evaluating the durability of the traveling controller and the hydraulic controller. The method of claim 1,
The PLC may include an analog input / output module configured to apply step information to the traveling controller and the hydraulic controller using an analog voltage output signal; And
And a digital input / output module for applying driving / stop and forward / reverse step information by applying a digital contact signal to the driving controller, and applying operation / stop step information by applying a digital contact signal to the hydraulic controller. Durability test apparatus of the electric forklift controller using a PLC. The method of claim 1,
The driving motor is provided with a left driving motor and a right driving motor, respectively, which provide driving driving force to both wheels of the front wheel.
The second reactor may include a left reactor for applying a load to the left traveling motor and a right reactor for applying a load to the right traveling motor, respectively. The method of claim 1,
The PLC increases the count by one after the last step of the one charging work cycle pattern is completed, and returns to the first step. The durability of the electric forklift controller using the PLC is characterized by the above-mentioned. Test equipment. A first step (S100) of determining a one-charge working cycle (CYCLE) pattern for durability test in the travel controller and the hydraulic controller using PLC;
A second step (S200) of determining a time required for each step of the first charging work cycle (CYCLE) pattern and output currents of the travel controller and the hydraulic controller;
A third step (S300) of programming an output current according to each step (STEP) of one charging work cycle (CYCLE) pattern to the PLC, the driving controller, and the hydraulic controller;
The driving signal is started according to the first charging work cycle (CYCLE) pattern by the START signal, and the step controller receives the step signal from the PLC and receives the current step by the driving controller and the hydraulic controller. Step 4 (S400) to determine the STEP; And
And a fifth step (S500) of outputting a current to be output at a current step (STEP) through current control in the traveling controller and the hydraulic controller (S500). The method of claim 5,
The first step (S100), a first step step (S110) for tilting after raising the load to a certain height on the ground at point A;
A second step (S120) of driving at a point B at a predetermined distance in the state of carrying a load;
A third step (S130) of reaching the point B and then placing the load on the ground to make it unloaded;
A fourth step (S140) of forward driving to the point A in the no-load state;
A fifth step (S150) of tilting the fork after raising the fork to a predetermined height from the ground in the unloaded state at the point A;
A sixth step step S160 of forward driving to the point B at a predetermined distance;
A seventh step S170 of raising the load at a point B from the ground to a predetermined height and then tilting the load; And
And an eighth step (S180) of moving the load back to the point A at a predetermined distance and then lowering the load. The durability test method of claim 1, further comprising a load controller. The method of claim 6,
The first step S500 is performed a plurality of times through the process of returning to the first step S110 after increasing the count COUNT by 1 after finishing the eighth step S180. Durability test method of the electric forklift controller using a PLC, characterized in that it further comprises a ninth step (S190). The method of claim 6,
The fourth step (S400), after the power is turned on waiting for the first charge operation cycle (CYCLE) start (START) command of the first step (S100) while operating the driving controller and the hydraulic controller program (S410) );
The user pressing the START button to start the operation or pressing the STOP button to stop the operation (S420); And
The step of receiving the respective step (STEP) step signal from the PLC (PLC) to determine the current step (STEP) in the traveling controller and the hydraulic controller (S430); including a transmission using a PLC Durability test method of forklift controller. The method of claim 6,
The fourth step (S400), using the analog output voltage of the PLC (PLC), by using the analog output voltage, characterized in that each step (STEP) of the one charging work cycle (CYCLE) is distinguished Durability test method of electric forklift controller using 10. The method of claim 9,
In the fourth step S400, the first step step S110 when the analog output voltage of the PLC PLC is 0 V, and the corresponding rule as in the second step step S120 when 0.5 V is applied. Pre-programmed,
A / D conversion of the analog voltage output signal of the PLC by the hydraulic controller and the travel controller is used to determine the current step of the first charging work cycle (CYCLE). Durability test method of electric forklift controller.

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