Structural characteristics and technical characteristics of electric forklifts

An electric forklift is a loading and unloading and handling vehicle powered by a DC power source (battery). According to foreign statistics, the production of electric forklift trucks in Japan has exceeded one-third of the total number of forklifts. In some Western European countries such as Germany and Italy, the percentage of electric forklift trucks has reached about 50%. The rapid growth of electric forklifts is mainly due to the constant advancement of different manufacturers. Most of the products adopt streamlined design, the shape is more beautiful. Major manufacturers have achieved large-scale production, specialized production of parts and assembly line operations. Machining accuracy and degree of automation are improved. Its appearance has greatly improved the performance of electric forklifts. In general, the durability, reliability and applicability of electric forklifts have been significantly improved, which can completely compete with internal combustion engine forklifts. This article mainly briefly introduces the structural characteristics and development of the four-point electric balance forklift with a large number of sales in the market.

Lifting frame

At present, most domestic and foreign electric forklift trucks use a wide-view mast, and the lifting hydraulic cylinders have been placed on both sides instead of the middle. There are two hydraulic cylinder positions: one is the hydraulic cylinder located behind the mast; The second is the hydraulic cylinder which is located outside the mast. Columns are usually divided into standard type, two part type or three part type. The lifting height of domestic forklifts is usually from 2 to 5m, most are from 3m to less than 3m, while the lifting height of foreign electric forklifts is usually 2 to 6m. forklift is much higher than in China.

Forklift body

The trunk is the main structure of the forklift truck, usually made of steel plate with a thickness of over 5mm, characterized by no beams, high body strength, and can withstand large loads. Regarding the location of the battery on the forklift body, there are two different manufacturing technologies, that is, the battery is placed between the front and rear axles or on the rear axle. These two technologies represent two optimal options for forklift design, each with its own advantages and disadvantages, good stability, but less free space in the trunk, limiting battery capacity. For forklifts with large tonnage, complicated moving conditions, high battery capacity requirements within 8 working hours become serious.

Forklift cab

Since most electric forklifts are used for indoor transportation, there is usually no enclosed cockpit, only a roof guard installed. The world’s more advanced electric forklift is developed according to advanced ergonomics principles and uses a comfortable hydraulic shock absorber suspension seat, which can be adjusted according to the height and weight of the driver. The dual pedal acceleration system does not require steering when the forklift changes its steering direction and the tilt angle of the steering column can be adjusted according to the driver’s requirements. The central hydraulic control lever integrates the lift and the front and rear of the fork. Therefore, these new designs have greatly reduced the labor intensity of the driver.

The use of large capacity batteries to prolong the continuous working life of electric forklifts, thereby expanding the use of electric forklifts is a common goal of all forklift manufacturers. In the second case, when the battery is located on the rear axle of the forklift, the forklift’s center of gravity will increase and the stability of the whole machine is affected. The raised driver’s seat helps the driver have a wider view when operating, especially when carrying bulky goods. When the battery is placed on the rear axle, it is more convenient to maintain the motor and hydraulic pump, because after removing the battery and the pedals, a glimpse of the motor and hydraulic pump can be seen. Currently, most electric forklifts manufactured by domestic companies use the latter technology, while foreign companies have both.

Drive system of electric forklift

The drive system is one of the important parts of an electric forklift. There is a big difference in the structure of the drive system of different forklifts, and there is also a difference in the layout of the single engines. Due to the dual-motor drive, good acceleration and climbing ability, great traction, electronic top speed system is used to replace the original mechanical differential system, usability has been improved. very good.

Hydraulic system of electric forklift

Electric forklifts generally use a separate motor to drive the gear pump to provide hydraulic power to the lifting and tilting working system of the mast. New forklifts from famous brands, such as LINDE’s E20 electric forklift. Adopting advanced hydraulic pulse control technology, the hydraulic pump pulse controller can automatically balance the motor speed and oil consumption according to the response of the hydraulic circuit, thereby saving electrical energy. The energy utilization rate is high, there is no voltage peak, the noise of the hydraulic system is low, and the wear of the hydraulic components is also low, thus greatly improving the reliability and service life of the vehicle.

Electric forklift brake system

General electric forklift trucks mainly use mechanical parking brake and hydraulic service brake. Hand brake is used for parking and foot brake is used for driving. The brake system of the BX series electric forklift is equipped with a leading vacuum booster, which can ensure sufficient active pressure at any time, not only increasing the safety of braking, but also reducing the labor intensity of driver. Electric forklifts use hydraulic brakes. The extension brake is controlled externally and uses a power-assisted brake (a form of power assist similar to power steering). The use of SCR and MOS tubes helps to regenerate the braking energy of the battery forklift. Energy regeneration is also the process of electronic braking and electronic braking occurs in the following three cases:

– When releasing the accelerator pedal.

– When the accelerator pedal is depressed.

– When stepping on the first stage of the hydraulic brake pedal.

For LINDE E20 and CARER’s P50 electric forklift trucks, when the brake is applied for the first time or lightly, the traction motor becomes a generator and electrical energy is sent back to the battery, instead of wasting energy. Useful when braking conventional forklifts. Only with extra braking will the hydraulic brake system really come into play. The advantage of this brake system is that it prolongs the working time after each charge, reduces the wear of the brake system and transmission components, and also reduces the time to stop the machine for maintenance, so costs are reduced.

All balance forklifts use rear wheel steering, small working range and frequent steering movements. If a mechanical steering system is used, the driver’s work intensity will be high. If using hydraulic power steering system, labor intensity will be greatly reduced. Therefore, the existing forklifts on the market have basically realized the power steering system. However, the power steering of electric forklifts such as LINDE, NISSAN goes a step further, that is, when the steering wheel does not move, the steering motor does not work. This feature not only saves energy, but also increases the operating time after recharging and reduces the idling time of the driving motor, thereby reducing wear on the engine and hydraulic pump.

Electronic control and display system

The electric control unit is an important element that shows the technical level of the electric forklift. Therefore, with the development of electronic technology, the electronic control of battery forklifts is also more and more perfect. The development of the motor controller mainly goes through the following stages:

– Battery starts directly, relying only on complex adjustments or battery discharge control.

– Starter resistor. The control energy loss is large and the decomposition rate can only be limited.

– Control the thyristor controller (also called thyristor controller). Transistor control greatly improves reliability.

– Bipolar transistor control. Compared with thyristor, it is easier to use, but the circuit reliability requirements are relatively high.

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Common Errors in Electric Forklifts
I. Common errors in electric forklifts Maintaining and repairing electric forklifts is crucial to ensure their performance and lifespan. During usage, electric forklifts may encounter common errors, including electrical system failures, mechanical issues, and battery problems. These errors can be caused by improper usage, lack of regular maintenance, and the impact of weather conditions. To effectively handle and maintain electric forklifts, regular inspections and maintenance should be conducted, users should be trained properly, and genuine spare parts should be used. Additionally, preventive measures such as safety instructions during usage, proposing basic repair training for managers, and enhancing maintenance awareness among users should be implemented. 1. Electrical system failures in forklifts Electrical system failures are one of the common errors in electric forklifts. Power loss is a common issue that can be caused by weak or faulty batteries. To address this problem, batteries should be checked and replaced if necessary. Controller malfunctions can also occur due to damaged or improperly functioning components. To resolve this issue, components should be inspected and repaired or replaced if necessary. 2. Mechanical issues in forklifts Mechanical issues are another problem that electric forklifts may encounter. The steering system can experience malfunctions due to damaged or improperly functioning components. To address this problem, components should be checked and replaced if necessary. The lifting system can also experience malfunctions due to damaged or improperly functioning parts. To resolve this issue, parts should be inspected and repaired or replaced. 3. Battery-related issues in forklifts Battery problems are also crucial factors affecting the performance of electric forklifts. Battery lifespan can be affected by various factors such as battery age, usage conditions, and maintenance procedures. To maintain battery lifespan, proper maintenance and charging procedures should be followed. Decreased battery performance is another issue that can be caused by battery age, overloading, or incomplete charging. To address this problem, batteries should be checked and charged according to proper procedures. II. Causes of errors in electric forklifts – Causes of errors in electric forklifts can be attributed to improper usage, lack of regular maintenance, and the impact of weather conditions. Improper usage can lead to errors such as overloading the forklift or using incorrect procedures. To avoid these errors, adherence to usage procedures and limiting forklift overload is necessary. – Lack of regular maintenance is also a common cause of errors. Failure to conduct regular maintenance can affect the performance and lifespan of the forklift. To keep the forklift operating well, regular maintenance should be performed following manufacturer instructions. – Weather conditions can also impact the operation of electric forklifts. Factors such as high temperatures, cold weather, or dampness can cause issues for the forklift. To minimize the impact of weather conditions, proper protection and storage practices should be implemented. III. Handling and maintaining electric forklifts – To effectively handle and maintain electric forklifts, regular inspections and maintenance are necessary. Regular inspection and maintenance procedures help maintain the performance of the forklift and detect potential issues early on. – Proper training of users is also crucial, providing users with instructions on safe and efficient usage of electric forklifts. The use of genuine spare parts is another essential factor that cannot be overlooked as it ensures quality and longevity. – Additionally, preventive measures should be implemented to avoid errors from occurring. Safety instructions during usage are one important measure, providing safety guidelines to users of electric forklifts. – Proposing basic repair training for managers is another suggestion; training managers on basic knowledge about repairing electric forklifts enables them to handle minor issues without having to call technical staff. – Enhancing maintenance awareness among users is also an important measure, strengthening maintenance and management awareness of electric forklifts from the users. This can be achieved through providing usage instructions, reminders about regular maintenance, and creating a safe and professional working environment. In conclusion, maintaining and repairing electric forklifts is crucial to ensure their performance and lifespan. Addressing common errors such as electrical system failures, mechanical issues, and battery problems should be done meticulously and accurately. Regular inspections and maintenance, proper user training, and the use of genuine spare parts are important measures to handle and maintain electric forklifts effectively. Preventive measures such as safety instructions during usage, proposing basic repair training for managers, and enhancing maintenance awareness among users are also crucial to prevent errors from occurring.
FAQs about Forklift Battery and Electrical System
FAQs about Forklift Battery and Electrical System 1. What is the average lifespan of a forklift battery? The average lifespan of a forklift battery is typically between 4-6 years for lead-acid batteries, depending on usage, working conditions, and maintenance. Gel batteries have a shorter lifespan, around 3-5 years. 2. How should I maintain my forklift battery? To maintain your forklift battery, you should regularly check and top up the water level, clean the charging terminals and battery poles, ensure full charging without overcharging, regularly check electrolyte density and cell voltage. 3. How can I maximize the lifespan of my forklift battery? To maximize the lifespan of your forklift battery, you should use the correct capacity battery, follow proper installation procedures, maintain full charging, avoid deep discharging, perform regular maintenance, adjust electrolyte density as needed, and keep it clean. 4. What factors affect the lifespan of a forklift battery? The main factors that affect the lifespan of a forklift battery include initial battery quality, using the correct capacity battery, charging and discharging methods, operating temperature conditions, maintenance and storage practices, and working conditions (vibration, humidity, dust). 5. When should I replace my forklift battery? Typically, you should replace your forklift battery after 4-6 years of use depending on the quality of the battery, usage level, and maintenance conditions. If the battery experiences severe performance degradation before that time frame, it should be replaced earlier. Monitoring electrolyte density can help evaluate remaining battery life. 6. When and how should I charge my forklift battery? You should charge your forklift battery after each work shift. The best method is to use an automatic three-stage controlled charger (bulk-float-equal) with periodic water replenishment for lead-acid batteries. The charger should provide the appropriate current and voltage according to the battery’s requirements. 7. What causes and how to fix a swollen forklift battery? Causes: Excessive heat generated during charging, resulting in hydrogen and oxygen gas buildup. Heat causes expansion of the welding circuit, leading to battery case rupture. Solutions: Check and clean the charger, ventilation system. Replace the damaged battery case. Follow proper charging procedures. Purchase batteries with good quality. 8. How to prevent battery gassing in forklifts? To prevent battery gassing, avoid discharging below 80% of rated capacity, avoid hot charging at high temperatures, maintain proper electrolyte density, perform regular equalizing charges, and use an automatic three-stage controlled charger. 9. Which type of battery is suitable for different types of forklifts? The choice of battery depends on the motor power requirement, lifting capacity, continuous usage time, and working environment conditions. Lead-acid batteries are suitable for high-power forklifts with long working hours. Gel batteries are suitable for small-capacity forklifts used internally. 10. Evaluate the advantages and disadvantages of gel batteries compared to lead-acid batteries. Advantages of gel batteries: No acid spillage, low maintenance, no fumes emission, safer and environmentally friendly. Disadvantages: Shorter lifespan, higher cost, cannot replenish water levels, prone to overheating. Advantages of lead-acid batteries: Lower cost, longer lifespan; however, they require more maintenance and have a risk of acid leakage. 11. How often should I replace distilled water in lead-acid batteries? Distilled water in lead-acid batteries should be replaced every 6-12 months depending on evaporation levels. The replacement frequency may be shorter if the forklift operates in hot and dusty environments. Regularly check water levels to determine when it needs replacement. 12. What are the standards for distilled water used in forklift batteries? Distilled water used in forklift batteries must meet high purity standards (≥99.5%), be free from large impurities, and have a resistivity of ≥5 MΩ.cm. Water that does not meet these standards can corrode battery components, create deposits, and reduce performance. 13. What causes and how to fix a short-circuited forklift battery? Causes: Damaged or corroded wires causing ground contact and short circuits. Dirt and high humidity inside the battery can also cause shorts. Solutions: Check and repair damaged wires. Clean the battery to remove dirt. Maintain proper humidity levels. Replace the battery if it is too old. 14. How should I maintain electrical components on a forklift? Electrical components should be regularly maintained, including checking and cleaning the charger, control circuitry, motor, conductors, and tightening all electrical connections. Ensure effective cooling ventilation systems. Check and replace any faulty components to ensure electrical safety. 15. What are the signs of electrical system issues in a forklift? Signs of electrical system issues in a forklift include slow movement or failure to reach desired speed, underperforming motor power, abnormal battery heat or swelling, smoke smell from electrical devices, unusual noise from motor or drivetrain, malfunctioning warning lights or display screens. 16. What does regular maintenance of the forklift’s electrical system involve? Regular maintenance of the forklift’s electrical system includes checking and cleaning the battery, replenishing distilled water, measuring electrolyte density; checking and cleaning the charger; inspecting control circuits; motors; conductors; tightening all electrical connections; ensuring effective cooling ventilation systems; checking and replacing faulty components to ensure electrical safety.
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