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.

Sustainable non-automotive vehicles: The simulation challenges

Simulation is a well-established and effective approach to the development of fuel-efficient and low-emissions vehicles in both on-highway and off-highway applications.

The simulation of on-highway automotive vehicles is widely reported in literature, whereas research relating to non-automotive and off-highway vehicles is relatively sparse. This review paper focuses on the challenges of simulating such vehicles and discusses the differences in the approach to drive cycle testing and experimental validation of vehicle simulations. In particular, an inner-city diesel-electric hybrid bus and an ICE (Internal Combustion Engine) powered forklift truck will be used as case studies.

Computer prediction of fuel consumption and emissions of automotive vehicles on standardised drive cycles is well-established and commercial software packages such as AVL CRUISE have been specifically developed for this purpose. The vehicles considered in this review paper present new challenges from both the simulation and drive-cycle testing perspectives. For example, in the case of the forklift truck, the drive cycles involve reversing elements, variable mass, lifting operations, and do not specify a precise velocity-time profile. In particular, the difficulties associated with the prediction of productivity, i.e. the maximum rate of completing a series of defined operations, are discussed. In the case of the hybrid bus, the standardised drive cycles are unrepresentative of real-life use and alternative approaches are required in the development of efficient and low-emission vehicles.

Two simulation approaches are reviewed: the adaptation of a standard automotive vehicle simulation package, and the development of bespoke models using packages such as MATLAB/Simulink.

Kennzahlenbasierte Bewertung von RFID-Systemen

Der Beitrag beschreibt ein optimiertes Kennzahlensystem zur Bewertung von RFID-Systemen beim Einsatz in logistischen Prozessen. Das Verfahren bildet die Verhaltensmerkmale eines RFID-Systems in unterschiedlichen Kennzahlen ab. Die neu definierte Kommunikationsbelastbarkeit ermöglicht erstmals eine anwendungsbezogene Bewertung verschiedener RFID-Systeme auf Basis einer Kennzahl. Am Beispiel der Identifikation eines Regallagerplatzes wird die Aussagekraft des Kennzahlensystems dargestellt.

Integration von 3D-Kamerasystemen am Gabelstapler

Dieser Beitrag beschreibt die Integration von laufzeitmessenden 3D Kamerasystemen in die Gabelzinkenspitzen eines Flurförderzeugs. Mit Hilfe der integrierten Kameras und deren ausgewerteter Aufnahmen wurde ein Assistenzsystem für die Handhabung von Ladungsträgern realisiert, das dem Fahrer des Flurförderzeugs Verfahrempfehlungen für die Optimierung der Relativposition zwischen Gabelzinken und Ladungsträger bzw. Lagerplatz ausgibt. Neben der Vorstellung der verwendeten Kamera-Hardware und der Integration am Fahrzeug wird auch der Ablauf der Bildverarbeitung beschrieben.

Untersuchung und Modellierung der Schwingungsübertragung von Flurförderzeugreifen

In einem Gemeinschaftsprojekt der Technischen Universität München und der Helmut-Schmidt-Universität Hamburg werden die vertikaldynamischen Eigenschaften der bei Gabelstaplern verbreiteten Superelastik-Reifen (SE-Reifen) experimentell untersucht und das dynamische Verhalten der Reifen in ein numerisches Modell überführt. Der Beitrag geht auf die hierzu aufgebauten Versuchsstände, die Ermittlung der Kennwerte und den Aufbau des numerischen Reifenmodells ein.

Untersuchungen Gewichtsreduktionspotentiale Gegengewichtsgabelstapler

Die Masse eines Gegengewichtstaplers beeinflusst den Energieverbrauch beim Fahren maßgeblich. Steigende Energiepreise und steigendes Umweltbewusstsein führen zu grünen Trends in Logistik. Durch Reduktion der Gesamtmasse eines Gabelstaplers können große Einsparungen erreicht werden. Eine Machbarkeitsstudie soll mithilfe der numerischen Simulationen zeigen, dass neuartige Fahrzeuge mit aktiven Systemen trotz geringerer Masse hinreichend hohe Standsicherheit aufweisen können. In diesem Beitrag sollen die ersten Ergebnisse dieses Forschungsvorhabens vorgestellt werden.

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."

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."