Development and Validation of a Forklift Truck Powertrain Simulation

Fuel economy has become an important consideration in forklift truck design, particularly in Europe. A simulation of the fuel consumption and performance of a forklift truck has been developed, validated and subsequently used to determine the energy consumed by individual powertrain components during drive cycles.
The truck used in this study has a rated lifting capacity of 2500kg, and is powered by a 2.6 litre naturally aspirated diesel engine with a fuel pump containing a mechanical variable-speed governor. The drivetrain consisted of a torque convertor, hydraulic clutch and single speed transmission.
AVL Cruise was used to simulate the vehicle powertrain, with coupled Mathworks Simulink models used to simulate the hydraulic and control systems and governor. The vehicle has been simulated on several performance and fuel consumption drive cycles with the main focus being the VDI 2198 fuel consumption drive cycle.
To validate the model, a truck was instrumented and measurements taken to compare the performance and instantaneous fuel consumption to simulated values. The fuel injector pump was modified and calibrated to enable instantaneous fuel flow to be measured.
The model has been validated to within acceptable limits and has been used to investigate the effect four different torque converters have on the fuel consumption and performance of the forklift truck. The study demonstrates how the model can be used to compare the fuel consumption and performance trade-offs when selecting drivetrain components.

Towards a better energy efficiency through a systems approach in an industrial forklift

The purpose of this study is to improve the potential energy recovery to electric energy in an electrohydraulic forklift system. The initial achieved result for energy saving ratio after structural optimization is 40 %. Component optimization is applied to the tested drive which consists of a DTC controlled electric servo motor directly running a reversible hydraulic pump. According to the study the energy efficiency and the energy recovery from the electro-hydraulic forklift system can be increased by 11 % units. New ideas and directions of further research were obtained during the study.

Operator's manual : truck, forklift, DED, pneumatic tire, articulated, frame steer, 4,000 lb. capacity, rough terrain, Army model MHE 237 (J.I. Case model M4K) (NSN 3930-01-076-4237).

"May 1980."

Unit, direct support, and general support maintenance manual : truck, forklift, 6000 lbs, variable reach, rough terrain, model 6000M, NSN 3930-01-158-0849 (Army model MHE 269).

"October 1989."

Unit, direct support, and general support maintenance repair parts and special tools lists (including depot maintenance repair parts and special tools lists) : truck, forklift, power shift GED, 6000 lb capacity, SRT, 180 in. lift height, Army model MHE-212 (NSN 3930-00-489-0263), Allis Chalmers model F-60-24PS-180.

"October 1992."

Direct support and general support maintenance manual for truck, forklift, 6,000 lb., variable reach, rough terrain, NSN 3930-01-158-0849.

"March 1993."

Unit, direct support, and general support maintenance repair parts and special tools lists : truck, forklift, electric, solid rubber tires, 6000 lb capacity, 180 in. lift (Drexel Dynamics model FL60-EE5600) (Army model MHE206), NSN 3930-00-935-7867.

"November 1992."

Operator, organizational, direct and general support, and depot maintenance manual : loader, scoop type, DED, 4-wheel drive, pneumatic tires, hinged frame steer, w/forklift, front mounted, hydraulic operated, 10,500-lb capacity (Eaton, Yale & Towne Trojan model 3000M) FSN 3805-074-6378.

Includes index.

Technical manual, maintenance instructions, organizational maintenance : truck, forklift, DED, pneumatic tire, 10,000 lb. capacity, rough terrain, articulated frame steer (Dresser Industries model M10A, MHE 236) (NSN 3930-01-054-3833).

Includes index.

Unit maintenance, direct support, and general support maintenance repair parts and special tools lists : truck, forklift, DED, pneumatic tire, articulated, frame steer, 4000 lb capacity, rough terrain, Army model MHE 237, NSN 3930-01-076-4237, J.I. Case model M4K.

"April 1992."

Unit, direct support, and general support repair parts manual : truck, forklift, 6000 lbs, variable reach, rough terrain, model 6000M, NSN 3930-01-158-0849 (Army model MHE 269).

"October 1989."

Operator's manual : truck, forklift, 6000 lbs, variable reach, rough terrain, model 6000M, NSN 3930-01-158-0849 (Army model MHE 269).

"October 1989."

Direct support and general support maintenance repair parts and special tools lists : truck, forklift, gasoline engine driven, pneumatic-tired, 4,000 lbs capacity, 144" lift height Army model MHE-221, NSN 3930-00-151-4428 Baker model FJF-040.

Includes index.

Organizational maintenance repair parts and special tools lists : truck, forklift, gasoline engine driven, pneumatic-tired, 4,000 lbs capacity, 144" lift height, Army model MHE-221, 3930-00-151-4428, Baker model FJF-040.

Includes index.

Unit, direct support, and general support maintenance repair parts and special tools lists : truck, forklift, EMD, solid rubber tired wheels, 2000 lb capacity, 144 in. lift, Army model MHE 219, (NSN 3930-00-151-4432) : Allis-Chalmers model FE20-24EE.

"March 1992."