How to properly use the forklift

   Adhere to the process of using warm start, cold roll slowly turn the idle temperature, low speed start, maintaining a normal working temperature and at a moderate speed.
Should strengthen the "three filter" maintenance
   Air filter directly affect the life of the engine, if the filtration efficiency air filter, low or poor quality, soft sealing engagement lax, make all kinds of dust leaking directly into the cylinder, thus exacerbating the cylinder, piston rings and other machines wear parts. Practice has proved that if you do not install the air filter, liner wear will increase 8, piston ring wear will increase 9 times, wear the piston will increase by 3 times. Especially in the field of industrial dust concentrations are at work most of the truck or several tens of per cubic meter surface mg, if not strictly control the sources of pollution or air filter maintenance is not timely, and the use of perforated, fracture and soft sealing lax filter, the consequences will be more serious.
   In polluted job site, it is preferable to use two or more fitted in series composite type air filter, in order to ensure the quality of the filtered air.
   Oil filter maintenance is also very important, YTO rough terrain forklift operation in harsh environments, every 2-3 months or every job should be the correct selection of lubricants 150h
   Should consider all relevant quality indicators, often under heavy load function for variable load, 2tons Lpg Forklift severe contamination frequently stop and start the work around, slightly higher viscosity should be used, or a smaller temperature changes affect the lubricant viscosity by .
   Grade diesel engine lubricating oil used should strictly enforce the factory specified varieties. For the same model, the use of different conditions, the requirements of the lubricating oil should also be different. Frequent or frequent cold start when you start, the higher the load, the load off a large range, the greater the need to use advanced lubrication.

Forklift truck Body Analysis

Forklift body is the main structure, usually made of more than 5mm steel plate, which is characterized by monocoque, high body strength, can withstand heavy load.
    On the truck body on the battery placement is concerned, there are two different manufacturing techniques. That is on top of the battery placed in the rear axle or between the front and rear axles.
    Both technologies represent two YTO rough terrain forklift design the optimal choice, and their advantages and disadvantages, good stability, but the car body can use less space, thus limiting the capacity of the battery, which does not exceed the carrying capacity of 3t forklift not outstanding, but for those sports complex situation, working hours within 8h battery capacity demanding large-tonnage truck becomes serious.
    Using large-capacity battery to extend the period of operation of electric

battery forklift trucks

, electric forklifts thereby expanding the scope of use, which is all forklift manufacturer common goal.
    For example, STILL's R60 / 40 system, forklift, thanks to the first technique, the maximum battery capacity of 80V, 870A.h; 69.6kW.h, while the company's R40 forklift CARER second thanks to technology, battery capacity of 960A.h; 76.8kW.h (higher than 10.35%). On LINDE company uses a technology first E40 series forklift battery can be installed maximum capacity 735A.h, 58.8kW.h. CARER company forklift same specifications, the use of the second technique, the maximum capacity of the battery can be installed to increase by 30.6%.
    The second case, when the battery is arranged in the rear axle truck, forklift raise the center of gravity, and machine stability is affected, due to the high increase in the forklift driver's seat to improve, so the driver when operating a broader perspective, especially when handling a large volume of goods even apply. When the battery is placed in the rear axle, motor and pump maintenance more convenient, because the pedals removed the battery and the motor and pump it at a glance.
    At present, the domestic production of electric rough terrain trucks, is the second most used technology, and foreign companies are both.

The technical requirements should be run

The new machines generally go through the factory inspection and running to meet the technical requirements of the product. After installed must further run-in period for the general provisions 2000-3000km or 50-100h, mainly to improve the quality of fit Friction surfaces.
   Wear parts according to the characteristic curve known, the running-in period of the machine parts wear out quickly, this is due to the new process of the part surface is rough, uneven wear generating meshingly, the peeling off of the metal or oxide formed severe abrasive wear . Therefore, the new machine must be running - according to certain procedures and technical requirements process.
   The new machine according to the technical requirements driving the speed limit, load limit and change the off road rough terrain forklift oil, and pay attention to maintaining good thermal (cooling water temperature 80-90 ℃) driving and normal oil pressure, non-sudden boom throttle, which can greatly reduce with deputy the amount of wear of the friction surface, to improve the life of the part. Avoid and reduce premature failure.
   The results from the wear of the cylinder, piston rings and other parts of the watch, two-thirds are caused when you start, from the start to the amount of lubricating oil into the friction surface wear this time 2/3 of the total amount of wear.
   Low temperature operation, the lubricating oil is very thick, difficult to enter the friction surface; due to poor lubrication, lubricating oil drain between the friction surfaces and the formation of dry friction, wear particularly severe; from high sulfur fuel 2 Ton Diesel Forklift Truck oil, gas and acid anhydride more, at the cooling water temperature is low, the cylinder wall will form acids, resulting in a strong etching cylinder wall; low temperature of the piston, and the thermal expansion has not yet occurred, and the gap between the cylinders is also large. In the above case, the lateral movement of the piston also increases, the occurrence of a large piston ring in the groove ran. At this point, if a sudden load increase, will increase the wear of the components.

   

 

Forklift works

When lifting the load, energy consumption began, when the goods with the High Mast Diesel Forklift down energy to recycling, field tests show that the total energy consumption of 19% load consumption boost.
BT's Reflex Aci series priority regenerative driving portion, because this is the largest part of the energy consumption significantly, and without increasing the complexity of the system, i.e., without any increase in cost can be achieved. Due to its high braking torque, almost all of the braking mode and generating energy are born.
On some trucks also have a DC electric power regenerative braking, but must occur when a strong braking, which means that part of the energy regeneration in the brake lining part is converted into heat. And almost all of the condition, Reflex
Aci will generate renewable energy, and continuing role in the truck until completely still.
How much energy can be recovered in fact can not be calculated, which depending on the use condition, when the brake start speed, a more reasonable number is 10% -15%, i.e. the overall energy consumption of the truck 5% -7 %.
Improve performance
If you can not be reasonably recovered energy use, the benefits are limited. The easiest approach is to be able to recharge the battery to extend the use of time-oriented. In ReflexAci in, BT this part of the energy is used to improve the overall performance of the truck. As a result, the maximum speed is increased by 10% more visible role is reflected in the acceleration.
Reflex Aci reach top speed is only 15m, and dc truck needs at least more than twice its distance. Studies have shown that, in most practical use, since the launch of a Diesel Rough Terrain Forklift Truck handling operations to stop the few people in the distance 20m. Only BT exchanges forklift makes excellent acceleration in such a short distance to achieve full speed as possible.
In summary, the exchange of technology in the truck, making the overall improvement of the performance of the Wheel Driving Diesel Forklift, fault and event replacement rate was significantly reduced, reliability is greatly enhanced. In the client that reflects higher productivity per unit time, lower operating and maintenance costs. Exchange of technology in the future forklift battery technology is called, will get more and more widely used.

Domestic diesel forklift prevention of premature wear

     Part High Mast Diesel Forklift equipped with Japanese-made Isuzu's diesel engine, some users in the use of the machine running less than 1000H appeared early wear and tear, the reason is mainly due to improper use. Based on experience, proposed several measures to prolong its life.
   1, because the early symptoms and caused wear
   The main symptoms of premature wear is: use less than 1000H appeared cylinder pressure drop; cold start problems; crankcase emissions serious blow-hole; large work load exhaust black smoke; dynamic performance decreased significantly.
   When disintegration found badly worn piston rings, the first ring opening gap of about 2mm (using the limit of 2mm); liner appeared stairs, on the point of maximum clearance only wear up 0.18-0.29mm; down from top dead center within 25mm range, external discolored, the inner surface layer of chrome mechanical properties deteriorate, and dry friction marks produced after the lubricant drain.
   The main cause of failure is that the new machine initially, did not strictly enforce the run-in with the requirements specified by the manufacturer; frequent cold start or frequent starts and sudden load after starting; improper use and maintenance.

Forklift engine energy conversion

Converting the energy loss solution is to Wheel Driving Diesel Forklift as a complete system, not just focus on certain parts. Boils down to the energy flow of the AC adapter when the loss is equivalent to the carbon brush DC motor energy loss portion (AC motors without carbon brushes), this process through advanced electronic systems can be achieved.
Reduce costs
The second step is to take over the maintenance of the hardware part of the cost, the ultimate goal of finding the best type and number of semiconductor components through extensive testing and can be achieved, in the process of falling prices of electronic components, there are quite a help, but proven strategic outlook exchange technology.
However, the most important factor is the vehicle design are based on a tributary of the high braking torque AC motor technology is the key. In fact, the AC motor braking capacity is equal to its acceleration capabilities. Electrical braking can be achieved by changing the direction of travel. If you want a more powerful big brakes, you must use traditional brakes. Through careful study of the motor size, has been much greater than the acceleration torque braking torque so that the braking effect of the AC electric motor a lot stronger than DC motors.
Brake mean effective conventional braking system can be greatly simplified, in the BT Reflex Aci, the ordinary brake parking brake has been replaced. Regardless of the brake pedal by the driver brakes, brake or convert the direction of travel, the motor will stop and produce an effect similar to the generator. This means that the brake lining wear is minimized.
Energy Recovery
As previously described, the AC motor efficiency with the brake on both higher, braking, the motor reverse rotation, that is to say the frequency of the alternating voltage is lower than the frequency of the rotor, and the motor to generate a discharge effect. The more intense the brake, more regenerative energy.

Forklifts and electric control system of self-diagnosis and LCD

Electrical control is an important factor of electric off road rough terrain forklift technical level display. Thus, with the development of electronic technology, battery electric forklift is also maturing. Development of motor controller mainly through the following stages:
    (1) directly to the battery to start alone complex adjustments or battery discharge control.
    (2) a resistor starts. Controlling energy loss is large, only limited decomposition rate.
    (3) thyristor controller (also called SCR controller).
    Transistor control so that the reliability is greatly increased.
    (4) bipolar transistor control. Compared with the thyristor, the use of more simple, but the circuit is relatively high reliability requirements.
    (5) MOS FET (i.e. metal - oxide - semiconductor field effect transistors) control. Gate drive current is small, good control characteristics in parallel, the forward voltage drop is small, reducing the switching loss, MOS FET better than the control characteristics of a bipolar transistor. By reducing the components, and a fully enclosed device reliability are increased. Outlet voltage is usually SCR (silicon controlled rectifier) controller for 1 ~ 1.5V, while the MOS FET controller socket voltage 0.25V. Higher efficiency MOS FET tube, the greater the maximum allowable speed, smaller operating noise, stronger protection measures, so the user has the power to protect against short circuit devices, and has a unique three security measures, namely automatic protection software, hardware, automatic protection and self-diagnostic hardware protection.
    Transistor chopper on the successful application of the truck, in addition to achieve variable speed and regenerative braking, but also increased the self-diagnostics and LCD digital display.

Motor Technology in forklift

Below, we give a brief introduction for several existing motor technology.
Series DC motor
This is the oldest and most traditional motors. Current is supplied to the battery and turn dry and carbon brushes spread through the stator. This approach has two drawbacks: All the current must be sent via carbon brushes, carbon brushes performance depends on the physical size and wear. Most importantly, it limits the play braking performance. In addition, the motor carbon brushes as wearing parts must be replaced periodically, otherwise it will greatly affect the motor life. With this in mind, many manufacturers are configured to detect wear and tear on the truck and issued a warning device, the device increases the cost of the truck.
All motors are fever, but in the DC motor, the motor heat is mainly produced in the interior parts, so most of the DC motor will be equipped with a fan for cooling.
He shunt motor
This is a more advanced DC motor, the stator and armature, respectively the energy input. Motor in series with the same, this technology has been applied for a long time. The new technology uses separate excitation and the excitation field and armature, the performance of the motor control is much better than the series motor. Such a motor is often called four-quadrant motor, since it can travel in both directions around the brake. However, motor carbon brushes defect still exists.
Three-phase AC motor
Technically speaking, this is the most simple structure of an electric motor. The principle is a three-phase alternating current delivered to the fixed coil, a voltage is generated on the rotor rotating magnetic field induction shorted. AC motor no brushes, a DC motor is generally no limit on the maximum current terms, this means that the motor can be obtained in actual use can be born more and larger brake torque, then faster speed.
AC motor, the heat occurs mainly in the motor housing part of stator coils for cooling and heat dissipation. If desired, the rotor can be sealed. AC motors do not require periodic replacement of wearing parts, at the same time, it is more than a DC motor efficiency, durability, and less expensive.
As mentioned earlier, the presence of equipment such as 2 Ton Diesel Forklift Truck battery and AC technology are two problems: low system voltage of 80V and the corresponding high current; energy loss when switching AC and DC.

Forklift steering system

 
    Balance forklifts are used rear-wheel steering, and a small operating range, steering movements frequently. If mechanical steering, the driver's work intensity will be high. If the hydraulic power steering, will greatly reduce the labor intensity. Therefore, the forklift on the market now is basically realized the power steering. Domestic battery forklift hydraulic steering is generally steering motor kept running at full capacity in all terrain forklifts operation, thus causing unnecessary waste of energy, as well as electrical and hydraulic reduce wear. However, LINDE and NISSAN companies such as battery forklift, the power steering goes further, through the steering wheel does not move, then turn the motor does not work. This feature not only saves energy, but also extend the charge again after working hours can shorten the steering motor idling time, and therefore reduce the motor and pump wear.
    Japan's Komatsu Forklift battery power steering EPS speed sensor. The system is a "load sensing type" steering, brake and power with a servo-hydraulic steering type priority dispensing valve. Power steering system to enhance the power of the motor can automatically select the best power steering required

Exchange of technology in the battery forklift

Over the years, DC has been the main source of electric power changes warehouse handling equipment, the DC drive as a cheaper way to drive long ago been widely used in the electrical equipment. However, the DC system itself in terms of performance, maintenance and other aspects of some inherent defects, and AC and AC motor in this regard than the far better, so big fan of indoor handling equipment manufacturers have begun committed to developing the exchange of technical applications.
In fact, since the late 19th century, AC power already been widely used, but also it is an AC motor technology to promote the electrification process industries, railways and other areas. Now, the application of communication technology electrical products have been everywhere, communication has become perhaps the most widely tested and proven technology and experience.
The main advantage of communication technologies in the following areas:
l, a simple conversion between high and low voltage.
2, the motor becomes strong and efficient, and can withstand the impact of high current.
3, greatly reducing the number of parts of the motor, and no wear and durable.
However, the AC motor applications in battery-powered equipment such as off road rough terrain forklift receive certain restrictions, for two main reasons: low system voltage of 80V is required to achieve the high-energy semiconductor DC to AC conversion, the high cost of this one next; the conversion process itself consumes energy, and battery capacity is quite limited.

Forklift truck brake system

    General electric Wheel Driving Diesel Forklift mainly mechanical parking brake and hydraulic brake. Stop using the hand brake, driving using the foot brake.
    NISSAN company BX series electric forklift brake system is equipped with a leading vacuum booster, can ensure that any time there are enough active pressure, not only increasing the braking safety, but also reduce the labor intensity of the driver.
    CARER electric forklift hydraulic brake system. Intumescent external brake control, and the use of power-assisted braking (with the power steering system power form the same).
    The use of SCR and MOS transistors, enabling the regeneration of braking energy telehandlers possible. Regenerative process is an electronic braking, electronic brake produced in the following three cases:
    (1) Loosen the accelerator pedal control.
    (2) Depress the accelerator pedal when the reverse.
    (3) Depress the first level when the hydraulic brake pedal.
    For LINDE the E20 and P50 CARER of Off road forklifts, had once or lightly depress the brake, traction motors will become a generator, the battery will power back up, rather than as a general truck braking energy in vain wasted. Only further brake, hydraulic brake really work. The advantage of this brake system is to extend the working time per charge, reducing the wear and tear of the braking system and transmission components, but also reduces maintenance downtime, thus reducing the cost.

forklift's future

   truck engine manufacturers to improve the quality of urgent. According to reports, the failure rate of domestic engines are generally accounted for about 40% of the number of failures. Prominent problem is poor reliability, fault first period and MTBF orderly, compared with foreign advanced products, there is a big gap. The main fault was "leaking oil spills, leaks," not only the fault and the fault is repeated a few more subsidized rate; followed by the fuel system, electrical system failure, using some non-direct-injection diesel engine difficult to start the combustion chamber and so on. This is the internal combustion engine industry is working to resolve the problem.
   The urgent need to improve environmental indicators. Off road forklifts more in workshops, warehouses, cabins, docks, etc. work on emissions, smoke, noise and other environmental indicators higher. At present, our internal combustion engine industry to develop appropriate standards, compared with the same standard of advanced countries, a large gap. Environmental issues have become a 21st century global attention. Our engine manufacturing level about 10-20 years behind the advanced countries. In domestic engine, the application of turbocharger technology is not yet widespread, electronic control technology is far from practical stage, nor LPG engine production. At present, the application of new technologies, development of energy, materials, low pollution, high reliability forklift engine, rely on imports to change the passive situation, the engine industry and the common aspiration of the forklift industry.
   promote joint development of economies of scale. In the formation of the all terrain forklifts business groups, should consider the production and logistic problems of the engine, it is recommended to take a variety of ways with supporting horizontal joint engine plant, a close associate of the merger by some appropriate conditions better engine plant, it directly for forklifts and construction machinery services, in order to better solve the matching problem of truck engines.

Forklift truck cab and drive systems

 Since the majority of electric forklifts for indoor handling, it is generally not closed cab, only to install from the protective effect of the overhead guard. The world's more advanced electric Lpg Gas Forklift Truck, such as: LINDE the E20 the new truck cab, according to the advanced ergonomically developed using hydraulic damping comfort suspension seat can be adjusted according to the height and weight of the driver . Acceleration-pedal system when the truck steering without changing the direction of travel, the steering wheel column inclination can be adjusted according to the driver requirements. Lifting and hydraulic joystick around the center of the door frame in one set. These new designs are so greatly reduce the labor intensity of the driver.
2 drive systems
    Drive system is one of the key components of electric forklifts. Various forklift exists on the drive system is very different structure, a single motor is disposed, there are differences in form, such as domestic production Fushun forklift, whose motor shaft and drive axle is T-shaped structure, while the foreign TOYOTA and BALKANCAR forklift drive motor shaft and the drive axle is arranged, compact structure. LINDE the E20 electric forklift trucks and off road rough terrain forklift CARER the P50 is composed of two independent front-wheel drive motor to complete, and the motor is placed in parallel with the drive shaft, compact structure. Because it is dual-motor drive, good acceleration and hill climbing performance, traction, with a full-speed electronic systems, replace the original mechanical differential system, usability has been greatly improved.
3 hydraulic system
    Electric forklifts are generally used separate motor driven gear pump to provide hydraulic power for lifting and tilting mast operation of the system. Currently domestic forklift, did not materialize due to the hydraulic motor speed, hydraulic motor starts, only the high-speed rotation, will not change with the function and automatically adjust the pressure, excess traffic can flow back into the tank through the relief valve, cause energy waste. The new foreign forklifts, such as the E20 electric Wheel Driving Diesel Forklift, using an advanced hydraulic impulse control, hydraulic pulse controller can react according to the hydraulic circuit, self-balancing motor speed and fuel consumption, thus saving energy, the advantages of this control power utilization is high, no voltage peaks, low noise hydraulic system, hydraulic components wear too low, thus greatly improving the reliability and service life of the vehicle.

Recommendations for the forklift future development

(1) should be developed engine forklift. Lpg Gas Forklift Truck industry for many years a strong desire to have a domestic truck engine, especially when the forklift project cited no corresponding supporting the introduction of the engine, limiting the introduction of technology, comprehensive localization. For over 30 years, the level of forklift products have made great progress, but the maximum annual production has been hovering at around 20,000 units, truck engine to see the demand for multi-cylinder internal combustion engine is less than 1% of total production. Due to the internal combustion engine industry is highly technology-intensive industries. Products suitable for mass production by the Organization of specialization, and the truck is characterized by small quantities of many varieties, so the construction of a dedicated truck engine plant is uneconomic. Recommend diesel engine parts industry and internal combustion engine industry to strengthen cooperation, the internal combustion engine as a whole forklift research, test, and optimize the product structure of the engine to meet the needs of the development of the truck industry.
   (2) Selection of the truck engine should be relatively concentrated, at present, the choice of engine forklift industry has "complex, chaotic, scattered" phenomenon. The same tonnage trucks often have a number of selected engine plant products. According to incomplete statistics, now use Chinese forklift industry multiple engine models up to 50 (not including the more than 10 imported models), more than one hundred kinds of varieties variant, launched by more than 30 flower plant supplier. For example, a factory producing 485,490 two model engine, in order to meet the requirements of the truck OEMs, but also the size of the structure and shape of the production Duozan little difference forklift into the water, crankshaft pulley, flywheel, clutch housing, intake manifold, exhaust chlorine tube, thermostat housing and fan pad, forming more than 40 kinds of variants species. This situation gave the duo launched factory production organization also come difficulties rising production costs corresponding to the user's maintenance and parts purchased trouble. Proposes to focus on business and Famous for the object, truck engine selection and planning, development forklift spare parts engine series and specifications type spectrum as soon as possible, change the status quo, "miscellaneous, scattered, chaotic".

Forklift mast analysis

    Currently, domestic electric forklift has been largely adopted a wide view mast, lifting cylinders on both sides of the intermediate place to place. The placement of the hydraulic cylinder, there are two: one is located behind the door frame hydraulic cylinders, such as

Lpg Gas Forklift

 plant and electric forklifts; the other is the mast hydraulic cylinders located outside the test, such as the Nanjing Huarui electric forklifts and forklift BALKANCAR . CARER's R40 / 45 series electric forklift hydraulic cylinders located outside of the door frame, R50 / 60/70 series forklift hydraulic cylinders are located behind the door frame.
    Mast is generally divided into standard, two-section type or Section III. Since domestic forklift lifting height is generally between 2 ~ 5m, 3m and 3m below and to the majority, but from foreign electric forklift lifting height is generally between 2 ~ 6m, due to the high degree of three-dimensional warehouse, thus lifting height of 3m above, much higher than the domestic demand for electric forklift.

Forklift engine matching requirements

Widespread use of regional truck, climate varies greatly, poor working conditions, dusty, constantly changing conditions, heavy load. Therefore, the duo launched gas powered forklift and fuel economy should be operational reliability, long life good power, good cold start performance and ease of maintenance and repair. At the same time, also called compact structure, small size, in line with standards and regulations of the bad security indicators. Typically, a good truck engine should have the following basic characteristics:
    (1) able to adapt to continuous work and bear lasting than the load, the rated power for hours of power. Gasoline truck shall be equipped with speed limiter.
    (2) truck engine at work are often subject to greater impact and strong vibration, and thus the body and attachments should have sufficient stiffness and strength, and the mounting multi-use three-point support.
    (3) is guaranteed to work under varying load state of emergency, general governor should adopt the whole program, the instantaneous transfer rate should be less than 12%, stable transfer rate is less than 8%.
    (4) In order to meet ports, terminals operating environment requires greater engine torque adaptive torque reserve coefficient is usually greater than 12% (also excluding the torque converter).
    (5) To meet the needs of pumps and auxiliary equipment, auxiliary power output of the engine should be like home. For small and medium tonnage trucks, the hydraulic pump to be mounted directly on the engine, the auxiliary output power requirement is 50% -100% of the total power.
    (6) Lpg Gas Forklift often on sloping ground operations, require to be able to tilt the engine work around the state or around. Usually requires the engine can trim 20 & ordm ;, heeling 15 & ordm; state job.
    (7) Forklift often work in more air dust content of the environment. Requires a high efficiency air filter, fuel filler, vent and pipe joints should have a dust seal.
    (8) To meet the -40 & ordm; C- + 45 & ordm; C under a variety of climatic and environmental work, fuel, oil, grease, coolant, battery and other special requirements, and its related systems to make modifications. Cold regions to solve the problem of cold start, with the region have the potential to prevent overheating device.
    (9) In order to meet operational needs plateau region, should be set to reduce the compensation turbocharger power plateau, at an altitude of 1000-2000m require even 3000m regional job without reducing power.
    (10) of the truck in the tunnel, cabin operations, such as the environment, should exhaust gas purification device; wading depth work on a larger electrical equipment, such as YTO 2 Ton Battery Forklift have sealed their protection; there is gas in the work environment, the need for special explosion-proof facilities.
    (11) have high reliability and long life. New development should target forklift engine: diesel first failure of more than 800h. The first overhaul of 6000-10000h; target reference automotive gasoline engines.
    Emissions (12) truck engines, smoke, noise and other environmental indicators should meet national standards or industry standards and regulations in line with international standards as soon as possible.
    (13) The volume of engine power ratio, fuel and oil consumption, speed reserve coefficient, the minimum stable speed and mechanical vibration thinking technical performance indicators should meet the matching requirements of the truck.