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Analysis of electric forklift control system

Author : Hitop

Update time : 2020-08-13 15:09:48

The continuous growth of market demand has prompted the continuous growth of electric forklifts. In the field of electric forklifts, the development of AC electric drive systems is very rapid. Compared with the DC drive system, the AC electric drive system has attracted the attention of many manufacturers and users by virtue of its high efficiency, maintenance-free, long life and other advantages, and has been successfully applied. However, the full AC electric drive system also has disadvantages such as high cost, complex technology, and difficulty for domestic users to accept the price of the whole machine for a while.
The advantages of electric forklifts using AC travel control system are mainly reflected in the following aspects:

1. Low operating and maintenance costs, AC motors are maintenance-free for life

The AC motor does not need a reversing contactor (forward and backward reversing), saving parts. More importantly, the AC motor has no carbon brushes and commutator, not only the size of the motor is lighter and smaller, the running speed is increased, but also the trouble of regular inspection and replacement of carbon brushes is completely eliminated, which greatly enhances the reliability of the forklift. At the same time, there is no need to reserve space for motor maintenance when designing the forklift, and the motor can even be sealed to make the forklift structural design more compact.

Regenerative braking is a kind of non-contact braking. Whether the driver throws off the accelerator pedal to slow down, steps on the brake pedal to brake, or switches the direction of travel to brake, the AC motor will be in the generator state, and its electromagnetic torque will be converted into braking. Moment. This means reducing the wear of brake pads, extending brake life, reducing brake maintenance costs, and making operating costs lower. At the same time, because the AC motor is very efficient in driving and braking, and when braking or reversing, there will be regenerative energy generation, up to 30%, and can feed the regenerative energy back to the battery, which will extend the working time of the battery. The life span is also longer. Although the DC separately-excited walking motor also has regenerative braking, it must be started under strong braking, and the regenerative energy is only 15%. In the AC travel control system, almost in all cases, the AC motor will generate energy regeneration and continue to act until the forklift is completely stationary, which is obviously more efficient than the DC motor in energy regeneration.

2. Improve production efficiency

The maximum speed of AC motors is much higher than that of DC motors, and the power is stronger. Moreover, the AC motor can feed the obtained regenerative energy back to the battery, which not only prolongs the battery life, but also improves the overall performance of the forklift: faster startup, improved acceleration/deceleration performance, shortened the time to reach the highest speed, and extended The endurance distance and work efficiency are significantly improved.

3. Easy to program, greatly enhanced control ability

With the breakthrough development of frequency conversion speed regulation technology, the AC controller can control the operation of the AC motor in real time, which greatly enhances the control ability of the AC motor and obtains the same speed regulation performance as the DC motor. The AC drive adopts speed and torque control, the control sensitivity is improved, and the operation efficiency of the forklift can be improved; the accelerator pedal is used to release the brake function, and the transition can be smooth during the forward process, which improves the stability and reliability of the forklift. At the same time, Using CAN bus makes system integration simpler and unit design more flexible.

4. Forklift operation is more comfortable

The AC drive system plays a unique role in improving the operating comfort of the forklift driver. Because the AC motor is smaller and lighter than the DC motor, this makes the forklift design relatively more flexible.

Currently, all series of Hitop electric forklifts are equipped with AC motors.

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Analysis of electric forklift control system