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An AC drive has become the mainstream of electric forklift driver
Electric forklift is an integrated technology, including electric drive system is one of the key technologies
for electric forklift. With the development of AC motor control technology and high power electronic devices,
the AC drive has gradually become the mainstream of the electric forklift driver. Vector control of induction
motor drive technology, the motor structure is simple,
skid steer rock bucket sturdy, and good control performance has been widely
used in
vehicles-3/">electric vehicles.
Over the years, DC has been the main changes in power sources for electric warehouse handling equipment, and
DC drive as a cheaper drive way in a long time ago had been widely used in electrical equipment. However, the
DC system performance, maintenance, etc., there are some inherent flaws, while the AC and the AC motor in this
regard than in far better, so something big indoor handling equipment manufacturers have started to focus on
research and development of the exchange of technical applications.
In fact, since the end of the 19th century, the AC power is already widely accepted,
skid steer loader attachmentsis exactly what the AC
motor technology to promote the industrial, rail and other areas of the electrification process. Now,
application of communication technologies and el ectronic products has been everywhere, the exchange might have
become the most extensive testing and inspection and verification technology. Advantage of communication
technologies is mainly reflected in the following areas: high and low voltage conversion is simple; motor into
a strong and efficient, and can withstand the impact of the high current. The number of motor parts is greatly
reduced, and wear-free, durable; DC motor, the cost is reduced significantly. However, the AC motors in
battery-powered equipment such as forklift receive certain restrictions, for two main reasons: low system
voltage of 80V DC to AC conversion by high-energy semiconductor, the cost of the high ; the conversion process
itself consumes energy, the battery capacity is very limited. BT company has now developed a new series of AC
power reach forklifts - Reflex Aci. The new series forklifts overcome th e following issues to realize the full
potential of the exchange of technology, forklift operations to lower costs and significantly improve
performance and reliability.
Forklift several motor technology are described below.
Series DC motor. This is the oldest and most traditional motor. The current delivered to the battery and
transfers, and spread to the stator through the carbon brushes. In this way has two drawbacks: all the current
must be made through the transmission of carbon brushes, performance depends on physical size and wear of
carbon brushes. The most important thing is, this limits the braking performance of the play. In addition,
motor carbon brushes as wearing parts must be periodically replaced, otherwise it will greatly affect the
motor life. With this in mind, many manufacturers will be configured to detect the forklift wear and warning
devices, this device increases the cost of the forklift. The motor will heat the internal components, DC
motor, the heat is mainly generated in the motor, so most of the DC motor will be equipped with a fan for
cooling.
He wound motor. This is a more advanced DC motor, the stator and armature of the energy input. Series motor,
this technique has been applied for quite a long time. The new technology uses separate excitation and the
excitation field and armature, so that the motor performance control is much better than series motors. Such a
motor is often called four-quadrant motor, because it can travel in both directions of the front and rear and
brake. However, the motor carbon brush defects still exist.
Three-phase AC motor. Technically, this is the most simple structure of a motor. The principle is to be three
-phase alternating current fed to the fixed coil, to produce the voltage on the sho rted rotor of the rotating
magnetic field induction. AC motor no hairbrush, no DC motor is usually the limit on the maximum current,
which means that more students and greater braking torque motor can be obtained in actual use, so the faster
the speed of operation. AC motors, heat occurs mainly in the motor housing part of the fixed sub-coil, to
facilitate cooling and heat dissipation. If necessary, the rotor can be sealed. AC motor does not need regular
replacement of wearing parts, at the same time, it is efficient than the DC motor, durable, and less costly.
2, battery forklift application of appropriate measures of the exchange of technical
Battery forklift applications exchange of technology, there are two problems: low system voltage of 80V and
the corresponding higher current; energy loss in the DC-AC converter. Nevertheless, the exchange of power in
the forklift truck is sti ll gradually expanding. But most of the manufacturers of AC powered forklifts is a
variant of the DC forklift used in explosion-proof environment, the price is quite expensive. BT forklifts
series is different, it is not just using AC power, and application of a series of new design concepts, so
that the exchange of technical advantage to be fully reflected and development. To achieve this goal, we must
first solve three problems: to convert energy loss; hardware costs; manufacturing technology for low voltage
AC motors. Appropriate measures are as follows:
To balance the energy loss. The solution to convert energy loss to the forklift as a complete system, not just
focus on a component. Ultimately boils down to the energy loss in the flow of AC conversion is equivalent to
DC motor carbon brush part of the energy loss (AC motor no carbon brushes), this process can be achieved
through advanced electronic systems.
Reduce costs. The next second step is to maintain the hardware part of low-cost, this goal is ultimately
achieved through extensive testing to find the best type and number of semiconductor components, electronic
component prices continue to fall in this process a considerable help, while proved that the exchange of
technical strategic vision. However, the most important factor in vehicle design based on the tributary of the
AC motor high braking torque is the key. In fact, the braking capacity of the AC motor is equivalent to its
acceleration. Electrical braking by changing the driving direction. If the major and more powerful brakes, you
must use traditional brakes. Through careful study of the motor size, a lot stronger than the acceleration
torque is much greater braking torque, AC motor\\ s electric braking effect than DC motors.
Efficient braking means the brake system can be greatly simplified in the BT forklifts, ordinary vehicular
brake parking brake alternative. The driver through the brake pedal brake, or conversion traveling direction
of the brake, the motor will stall and produce the role of similar generators. This means that the brake
lining wear and tear to a minimum.
Energy recovery. AC motor driving and braking efficiency, brake, motor reverse rotation means that the
frequency of the alternating voltage is lower than the rotor frequency, and the motor discharge the role. The
brake is more intense, more renewable energy.
A forklift has two large
electric motors, one for driving, one for the upgrade. Both can produce energy
regeneration. Typical reach forklift truck use, all the energy consumption can be divided into the following
sections: 50% used for driving; 4O% for the upgrade and other actions of the door frame with cargo defined;
10% for the steering, fans, etc.. Load to enhance energy consumption, energy can be recycled when the goods
with the fork down, field tests show that 19% of the total consumption of energy consumption when the load
upgrade.
Forklift series of BT\\ s energy regeneration priority for the moving part, because it can significantly consume
the largest part, and without increasing the complexity of the system, that is, without any increase in costs
can be achieved. Because of its high braking torque, almost all braking and produce energy born. Electrical
regenerative braking, but it must be strong when the brake may occur on some DC-powered forklifts, this also
means that part of the renewable energy converted into heat in the brake lining part. In almost all
circumstances, Aci will produc e energy regeneration, and the continuing role perfectly still until the
forklift. How much energy can be recovered it is impossible to be calculated, it depends on the usage, and
began to brake when the speed is a more reasonable figure is 10% ~ 15%, 5% of the the forklift overall energy
consumption to 7 %.
Improve performance. The recovered energy can not reasonably use, its benefits are limited. The easiest way is
to recharge the first battery to extend the use of time. Forklift series, BT this part of the energy used to
improve the overall performance of the forklift. The result is the maximum speed increased by 10%, a more
obvious role is reflected in the acceleration on.
In summary, the exchange of technology on the forklift, making the forklift performance of the overall
improvement of the fault and event replacement rate was significantly lower, reliability is greatly enhanc ed.
The client that reflects the higher productivity per unit time, lower operating and maintenance costs. The
exchange of technology on the battery forklift known as the future of technology is bound to get more and more
widely used.
Chinese electric forklift market potential is yet to be developed
Although in recent years the Chinese electric forklift sales increase every year, and achieved certain
results, but sales of electric vehicles has always been only about 20% of the total forklift sales, market
share of about 60% of Europe and the United States, Japan and other mature forklift market rate compared to
the significant gaps. The gap between means room for growth. Ownership of the Chinese electric vehicle market
is still in a relatively low magnitude, its very broad space for development. With the healthy awareness of
environmental protection for domestic users, i ncrease the national energy saving policy implementation
efforts, as well as medicine, food and many other higher forklift penetration rate in the industry to further
improve the vehicle environmental performance requirements, electric forklift market in China is bound to be
an unprecedented growth.
The core technology of electric forklifts is the \"electricity\", that is, motors, electronic control, battery,
AC technology more widely in recent years, making the contemporary electric forklifts have become increasingly
demanding technical level. Electric vehicles for its low power consumption, no pollution, convenient
operation, easy maintenance and other advantages is bound to be everywhere on the forklift truck market in
China. More noteworthy is that the future development of electric warehouse vehicles, will become a sudden
emergence of the trend is expected in t he next 3 to 5 years. It can be said that the Chinese forklift market
development, depends on the development of electric vehicles, in particular, depends on the development of
markets for electric warehouse vehicles.
In recent years the Chinese forklift industry is hot, is not only reflected in the domestic market has grown
rapidly, export business grew rapidly, one of the best evidence is the industry hot trend. Chinese forklift
exports going to the United States, Germany, France, Russia, Italy and other machinery manufacturing power
market. The one hand reflects the domestic forklift upgrade of the level of quality, mature markets in the
world has been recognized by the other hand, the domestic forklift, its a good price advantage in
international competition with high market competitiveness. Chinese forklift truck market, imported forklifts
and industrial trucks fitted wi th lifting or handling equipment in the first half of 2007, a total of 7349
units, with the same period in 2006, the 6702 increase of 9.65%, the varieties are listed imported forklift,
electric forklift main , indicating that the domestic market has a certain demand on the electric forklift.
Domestic production of electric forklift trucks for various reasons can not fully meet the needs of users of
electric forklift.
Storage vehicles, concrete electric track retrieval machine and electric trackless retrieval machine two
models. Both stacker is often used as a shelf replenishment in the warehouse stacker machines of the scope of
a storage vehicle. High quality storage and vehicle production is very limited, is bound to compensate for
this gap in the market through import channels. In addition, to the large-scale development trend of the
demand for internal combustion forklifts , container is a species of large forklift trucks. Import and export
trade have become increasingly frequent have a great relationship.
Forklift import situation, the supply gap, the Chinese market for electric forklift trucks, forklift
equipment, the storage of vehicles and large port container forklift.
4, AC power electric forklift development trends
Electric forklift power development trend of the exchange system. Hefei move ETS Technology has now launched a
number of electric forklift trucks with AC drive system. Its new dual-drive full exchange counterbalanced
battery forklift strengthen the performance of advanced AC drive system, the system provided by the
performance level of control with any product in the past. For example, AC power system provides power control
before the dual-drive full-exchange balance battery lift truck to be able to take full advantage of every
battery charge potential. So far, all electric forklifts have experienced a gradual decline in performance
with the battery power consumption. Before the dual-drive full-exchange balance battery lift truck because of
the power hold function, so the operator can enjoy the \"power\" strong momentum just after charging time than
existing forklift model of 40%.
Forklift exchange high-performance, high reliability, maintenance-free advantages, the world\\ s electric
forklift is converted to the exchange of technology from the DC technology, this trend is fully reflected in
the Chinese market, a lot of Chinese forklift plant in the development of AC forklifts . However, in this
area, China is still in its infancy, the country has several major forklift businesses to use the AC drive
system to produce electric forklift provided by the Danaher Motion company, and its series products ar e being
developed to trial in. The four 1.5t AC drive truck, Hefei move ETS Technology Development Co., Ltd. all ac
drive system is to start mass production. At present, the major forklift manufacturers have developed a new
development program of the AC drive forklift. With the forklift market in China gradually with the
international market, exchange drive forklift showing the momentum of the accelerated development of a huge
market potential, and prospects.
In short, the AC drive system as a forklift replacement technology, is bound to be more and more widely used.
This is called the 21st century the revolutionary technology of electric forklift, forklift technological
level of enterprises, product sales, market share, profits and even innovative image will have some impact.
After all, competition in the future reflected in more technical contest. Who has mastered the new t echnology,
who will be able to gain more advantage in the future market, occupying a more favorable position. Can be
predicted that the next five years, made in China will have half of the forklift exchanges. Technically
speaking, the more important trend is matched with the control technology development, the development
requirements of the power systems of electric forklift motor and electronic control.
