Welke motor gebruikt een elektrische kleine vorkheftruck??

Welke motor gebruikt een elektrische kleine vorkheftruck??

In de afgelopen jaren, met de voortdurende stijging van de arbeidskosten en de verbetering van de eisen op het gebied van werkefficiëntie, steeds meer fabrieken gebruiken kleine elektrische apparaten vorkheftrucks ter vervanging van de originele handmatige vorkheftrucks. Het aandrijfsysteem van elektrische kleine vorkheftrucks maakt gebruik van aandrijfmotoren, en de aandrijfmotoren van kleine elektrische vorkheftrucks hebben meestal gelijkstroommotoren en wisselstroommotoren. Dus wat is het verschil tussen hen?

De gelijkstroommotor van een elektrische kleine vorkheftruck gebruikt gelijkstroom als stroombron, Terwijl de AC-motor van een vorkheftruck gebruikt AC-elektriciteit als stroombron. Structureel gesproken, het principe van elektrische gelijkstroommotoren voor vorkheftrucks is relatief eenvoudig, maar de structuur is complexer, wat niet bevorderlijk is voor het latere onderhoud van mini-elektrische vorkheftruckmotoren. Hoewel het principe van de AC-motor voor vorkheftrucks relatief complex is, de structuur is relatief eenvoudig, waardoor het gemakkelijker te onderhouden is dan DC-motoren.

De gelijkstroommotor van een mini-elektrische vorkheftruck introduceert stroom in het rotoranker via borstels en commutatoren, waardoor de rotor onder kracht roteert in het magnetische veld van de stator. De structuur van de gelijkstroommotor van een elektrische vorkheftruck moet uit twee hoofdonderdelen bestaan: stator en rotor. Het stationaire deel van de gelijkstroommotor van een elektrische vorkheftruck tijdens bedrijf wordt de stator genoemd. De belangrijkste functie van de stator is het genereren van een magnetisch veld, die uit het frame bestaat, magnetische hoofdpool, commutator, afsluitdeksel, lagers, en borstelapparaat.

Het roterende deel van de motor van de elektrische vorkheftruck tijdens bedrijf wordt de rotor genoemd, die voornamelijk wordt gebruikt om elektromagnetisch koppel en geïnduceerde elektromotorische kracht te genereren. Het is de hub voor energieconversie in DC-motoren, dus het wordt meestal het anker genoemd, bestaande uit een schacht, anker kern, ankerwikkeling, commutator, en ventilator.

De AC-motor van een elektrische vorkheftruck geeft AC-elektriciteit door aan de statorwikkeling, het genereren van een roterend magnetisch veld in de luchtspleet tussen de stator en de rotor. Het roterende magnetische veld induceert stroom in de rotorwikkeling, waardoor de rotor onder kracht roteert in het magnetische veld van de stator. AC-motor: een mechanisch apparaat dat wordt gebruikt om mechanische energie om te zetten in elektrische wisselstroomenergie. Vanwege de enorme ontwikkeling van wisselstroomsystemen, AC-motoren zijn de meest gebruikte motor voor elektrische vorkheftrucks geworden.

Vergeleken met DC-motoren, AC-motoren hebben een eenvoudige structuur, zijn eenvoudig te vervaardigen, zijn steviger, en kan gemakkelijk worden omgezet in motoren met hoge snelheid, hoog voltage, hoge stroming, en grote capaciteit vanwege het ontbreken van een commutator.

Bij praktische toepassingen, hun specifieke verschillen zijn als volgt:

Snelheidsregeling: DC-motoren hebben een eenvoudige snelheidsregeling, maar het gebruik ervan is beperkt. De snelheidsregeling van AC-motoren is relatief complex, maar het wordt veel gebruikt vanwege het gebruik van wisselstroombronnen.
Lawaai: De gelijkstroommotor van een elektrische vorkheftruck heeft borstels en commutatoren, dus het geluid tijdens bedrijf is iets hoger.
Gebruik en onderhoud: De borstels en commutatoren van de gelijkstroommotor van elektrische vorkheftrucks zijn ernstig versleten, ze moeten dus regelmatig vervangen worden; AC-motoren hebben geen borstels of commutatoren, waardoor onderhoud relatief eenvoudig is. Op lange termijn, de onderhoudskosten van elektrische vorkheftrucks zijn ook lager voor AC-motoren, Daarom worden AC-motoren steeds vaker gebruikt door elektrische vorkheftrucks.

Introduction to Electric Forklifts

Electric small forklifts play a crucial role in the modern logistics and warehousing industry, with their importance reflected in various aspects:

Extensive Application Range

Electric forklifts are widely used in various warehouses, distribution centers, and logistics parks for loading, unloading, moving, and stacking goods. They are suitable not only for indoor environments but also for efficient outdoor operations.

Increased Work Efficiency

Compared to traditional manual handling, electric forklifts can quickly and accurately move goods from one place to another, significantly improving the efficiency of warehousing operations. Bovendien, the operation and control of electric forklifts are simple and flexible, greatly reducing the labor intensity of operators.

Environmental Protection and Sustainability

Electric forklifts are characterized by zero emissions and low noise, which are important for reducing environmental pollution and achieving green logistics. Powered by batteries, they reduce carbon emissions, aligning with modern enterprises’ requirements for environmental protection and sustainable development.

Intelligent Integration and Technology

In smart warehouses, electric forklifts are further enhanced in speed and accuracy by integrating with the Internet of Things (IoT) and automation technologies. This intelligent development trend makes electric forklifts more efficient and intelligent in modern logistics management.

Economic Benefits

Electric forklifts have the advantages of high cost-effectiveness and simple maintenance, which can reduce the operating costs of enterprises. Aanvullend, due to their high efficiency and energy-saving characteristics, they can save a significant amount of energy costs for the enterprise in the long run.

Labor Replacement

Electric forklifts have largely replaced manual handling, especially in the context of labor shortages and rising labor costs, making them an important tool for enterprises to improve production efficiency.

samengevat, as a core equipment in the modern logistics and warehousing industry, electric forklifts, with their advantages of efficiency, environmental friendliness, economy, and intelligence, play an irreplaceable role in improving enterprise logistics efficiency and achieving sustainable development.

Development Trends and Environmental Advantages of Electric Forklifts

The development trends and environmental advantages of electric forklifts can be analyzed from multiple perspectives.

Development Trends

• Intelligent Integration with IoT: With the increasing penetration of smart warehousing, electric forklifts are gradually developing towards intelligent products and industry integration. This includes the application of technologies such as AGVs (Automated Guided Vehicles) for more efficient logistics management.
• Market Penetration Increase: The proportion of electric forklifts in the market is continuously rising, especially under the “dual carbon” background. National policies advocating energy conservation, emission reduction, and new energy have made electric forklifts the mainstream choice. Bijvoorbeeld, in 2022, the sales volume of electric forklifts in China reached 675,000 eenheden, with a penetration rate of 64.4%; the global sales volume of electric forklifts was 1.416 miljoen eenheden, with a penetration rate of 70%.
• Technological Advancement and Durability Improvement: With continuous technological progress, electric forklifts have significantly improved in terms of durability, betrouwbaarheid, and applicability, gradually replacing traditional internal combustion engine forklifts.
• Lithium Battery Trend: In de toekomst, as the cost of lithium batteries continues to decrease, the cost advantage of lithium forklifts throughout their life cycle will become more apparent. It is expected that by 2025, the demand for lithium batteries for electric forklifts will reach 19.2GWh.

Milieuvoordelen

• Reduction of Air Pollution and Greenhouse Gas Emissions: Electric forklifts use electricity as a power source and do not require fuel, thus producing no exhaust emissions, effectively reducing air pollution and greenhouse gas emissions.
• Low Noise and Zero Emissions: Compared with traditional fuel forklifts, electric forklifts operate almost silently and do not produce harmful gases, effectively avoiding noise and dust pollution.
• Energie-efficiëntie: Electric forklifts have higher energy efficiency, significantly reducing operating costs and energy consumption over the same working time.
• Alignment with Sustainable Development Needs: The research and development and production of electric forklifts increasingly focus on the recyclability of materials and environmental friendliness, further reducing the environmental impact throughout the entire life cycle.
• Significant Economic Benefits: Although the initial purchase cost of electric forklifts is higher than that of internal combustion forklifts, their maintenance costs are lower in the long run, and they can achieve higher production efficiency and save time and labor costs.

Electric forklifts show strong development momentum in terms of intelligence, market penetration, technological advancement, and environmental advantages. These advantages not only meet the needs of modern industrial development but also contribute to the goal of sustainable development.

Overview of Electric Forklifts

Definition and Working Principle of Electric Forklifts

An electric forklift is a material handling equipment primarily powered by electricity, widely used in warehousing, logistiek, and manufacturing industries. Its core components include batteries, motoren, Controlesystemen, and hydraulic systems, among others.

Definition

An electric forklift refers to a forklift powered by electricity, most commonly using a battery as the source of power. This type of forklift converts chemical energy into electrical energy and uses an electric motor to drive the travel and lifting systems for the handling and stacking of goods.

Working Principle

The working principle of an electric forklift can be divided into the following aspects:

1. Battery Pack: Electric forklifts use a rechargeable battery pack as the energy source, responsible for storing and providing electrical energy.
2. Motor: Electric forklifts use alternating current (AC) or direct current (gelijkstroom) motors as the power source. The motor converts electrical energy into mechanical energy, driving the forklift to move forward, backward, steer, and lift loads.
3. Control System: The control system coordinates the operation of the motor and battery, ensuring efficient energy utilization. Operators can control the movement and lifting actions of the electric forklift through pedals or levers.
4. Transmission System: The transmission system includes components such as gears, chains, and drive shafts, transferring the mechanical energy generated by the motor to the wheels or hydraulic system, thus enabling the movement and lifting of the forklift.
5. Hydraulic System: The hydraulic system consists of hydraulic cylinders and lifting chains, using hydraulic pressure to lift the goods to the required height or lower them to the ground.

Types and Application Scenarios of Electric Forklifts

Electric forklifts are widely used in various industrial and logistics fields. Based on their style and operational purposes, they can be divided into several types. Common types of electric forklifts include:

1. Electric Pallet Trucks: Mainly used for point-to-point material movement on flat surfaces, without a mast lifting system, suitable for places that focus on handling without stacking.
2. Reach Trucks: Have good channel passing ability, suitable for work in narrow spaces.
3. Warehouse Electric Forklifts: Used for internal storage and handling of goods in warehouses, usually without lifting capabilities, mainly playing the role of handling and loading/unloading.
4. Counterbalanced Electric Forklifts: Powered by electric motors and battery energy, with a carrying capacity generally between 1.0 naar 4.8 tons, and the working channel width is generally 3.5 naar 5.0 meters.
5. Four-Way Electric Forklifts: Can move in four directions, suitable for complex storage environments.
6. Electric Tuggers: Used to tow other material handling equipment.

These different types of electric forklifts each have their unique application areas:

1. Factory Workshops: Used for the transportation and organization of materials within the workshop.
2. Ports and Docks: Widely used in container yards, docks, and other places for the rapid handling of containers.
3. Stations and Airports: Used for the loading and handling of goods.
4. Storage Centers: Flexibly shuttle between shelves, efficiently handling goods.
5. Logistics Systems: Improve the efficiency of logistics operations and reduce labor costs.
6. Department Stores: Used for the organization of shelves and handling of goods.
7. Supermarket Logistics: Used for the handling and organization of goods, improving shelf utilization and display effects.
8. Agricultural Fields: Used for handling crops, fertilizers, and tools.
9. Manufacturing Industry: Used for raw material supply, production line support, finished product transportation, and waste material processing.

In aanvulling, with the development of technology, intelligent forklifts and unmanned electric forklifts AGV are also gradually introduced into more scenes, such as material handling in manufacturing, storage, and logistics, further improving production efficiency and job safety.

Types of Motors Used in Small Electric Forklifts

DC-motoren

• Advantages: Lower cost, volwassen technologie
• Toepassingen: Travel motors, lifting motors, and steering motors
• Functies: The output torque is directly proportional to the armature current, with low efficiency, large size, en hoge onderhoudskosten

AC Motors

• Three-phase AC Motors: Eenvoudige structuur, the principle is to deliver three-phase AC to the fixed coil to generate a rotating magnetic field
• Permanent Magnet Synchronous Motors: Comprehensive performance exceeds other types of motors, making them an ideal choice for electric forklift drive motors
• Toepassingen: All-AC motors, standard with solid tires on all four wheels, adaptable to different road surfaces

Special Type Motors

• Three-phase Asynchronous AC Drive Motors: Used in new energy forklifts, with high performance and stable, reliable product characteristics
• Borstelloze gelijkstroommotoren: Provide an efficient and stable control drive solution for small electric vehicles

Motor Selection Criteria

• Choose the appropriate motor type based on the operational requirements
• Consider factors such as motor power, efficiëntie, and maintenance costs

Factors for Selecting Electric Forklift Motors

Impact of Motor Selection on Load Capacity, Lifting Height, and Operating Environment

• Load Capacity: Choose a powerful motor based on customer needs
  • Consider the weight of the load, lifting height, and travel distance
  • Select the appropriate electric forklift to improve work efficiency
• Lifting Height: Indoor smooth surfaces can meet requirements
  • Outdoor use requires consideration of environmental adaptability
  • The maximum lifting height affects the density of goods storage and unloading time
• Operating Environment: Extreme harsh working environments may negatively impact battery performance and lifespan
  • For indoor and outdoor operations with poor road conditions, choose a three-wheel drive electric forklift
  • When there are no channel restrictions, a four-wheel electric forklift is more suitable
• Motor Type and Configuration: Reasons for selecting DC motors and power
  • The position of the battery pack affects the center of gravity and overall stability
  • Electric power steering system improves operational convenience
• Technical Parameters and Performance Requirements: Maximum lifting height, maximum travel speed, maximum gradient, and other technical parameters directly affect work capabilities
  • The selection of carrying capacity and forklift height for electric pallet trucks
  • The electric stacking machine ES20-WA has a maximum lifting height of 3000 millimeters, providing an additional 100 millimeters of free lift

Influence of Electric Forklift Technical Parameters on Motor Performance

• Motor Power: Motor power determines the working capability of the forklift under different load conditions. Bijvoorbeeld, the driving motor of the 2.5-ton electric forklift from Haohang is 7.5KW, and the hydraulic power steering system requires higher power to ensure flexibility and stability in operation.
• Voltage and Current: Voltage and current directly affect the efficiency and output power of the motor. Bijvoorbeeld, some electric forklifts use a high-voltage platform with high-performance configurations to achieve high-power traction motors, thereby improving overall performance.
• Temperature and Load: Temperature and load significantly affect the power output of the motor. Under high loads, the motor may overheat, leading to reduced efficiency or damage.
• Motortype: Permanent magnet synchronous motors are widely used in electric forklifts due to their superior comprehensive performance. These motors have higher efficiency and stronger torque output, suitable for complex working environments. In aanvulling, AC-motoren (such as three-phase asynchronous AC drive motors) are also widely used due to their maintenance-free, hoge betrouwbaarheid, and wide speed range.
• Control System: Modern electric forklifts are usually equipped with advanced electronic control systems that achieve precise control of the motor through devices such as speed sensors and temperature sensors, thereby improving operational efficiency and safety.
• Battery Capacity and Charging Method: Battery capacity and charging methods also affect motor performance. Bijvoorbeeld, high-performance batteries with fast charging can shorten charging time and maintain continuous operation capabilities in high-temperature weather.

Maintenance and Cost Analysis of Electric Forklift Motors

Maintenance Methods for Electric Forklift Motors

• Daily Cleaning and Inspection
  1. Regularly clean the surface of the motor to prevent dust and debris from affecting heat dissipation.
  2. Check whether the motor’s wiring connections are correct and secure.
  3. Pay attention to the working environment to avoid placing the motor in excessively jolting conditions.
• Regular Testing and Maintenance
  1. Measure the insulation resistance of the motor with a 250-volt megohmmeter every three months when the motor is cold; the resistance should be greater than 0.5mΩ. If it is less than 0.5 mΩ, drying treatment is required.
  2. Conduct an external inspection and surface cleaning once every six months.
  3. Regularly inspect and tighten key components such as the fork frame, mast guide, and generator.
• Lubrication and Replacement
  1. Apply lubricating oil or replace grease at regular intervals to parts that require lubrication (such as bearings and chains) to reduce wear and maintain smooth operation.
  2. During the fifth-level maintenance, hydraulic oil and air filters should be replaced every 5,000 hours.
• Battery Maintenance
  1. Frequently replenish distilled water, and when not in use for a long time, charge the battery and store it fully charged, charging once every 1 naar 2 maanden.
  2. Ensure the battery is always fully charged and regularly check the battery fluid level.

Cost Analysis of Electric Forklift Motors

• Initial Purchase Cost
  1. Although the initial purchase cost of electric forklifts is about 30% higher than that of internal combustion forklifts with the same load capacity, their overall use and maintenance costs are lower.
• Operating and Maintenance Costs
  1. The maintenance cycle of electric forklifts is longer, tot 1,500 hours before maintenance is required, in vergelijking tot 500 hours for internal combustion forklifts.
  2. By the second year of use, electric forklifts can save about 40,000 yuan, and even more by the third year.
  3. Annual energy consumption is lower, with no need to replace consumables such as fuel and oil.
• reparatiekosten
  1. Although the replacement and charging of batteries require investment, with technological advancements, battery life and charging efficiency are continuously improving, effectively controlling the overall operating cost.
  2. The main large component repairs are for the electric control, oil pump motor, and lifting motor, costing about 10,000 yuan, and the transmission overhaul is about 3,000 yuan.
• Economic Comparison
  1. Taking a 3-ton counterbalanced forklift as an example, it can save 42,000 yuan in energy costs each year, plus maintenance costs, making the total cost lower than that of internal combustion forklifts, saving a company 380,000 yuan in costs over the entire life cycle.
  2. Lithium forklifts have more economical and environmentally friendly advantages compared to fuel and lead-acid forklifts, and the trend of lithium replacing internal combustion and lead-acid forklifts is an inevitable trend.

From the above analysis, it can be seen that although the initial purchase cost of electric forklifts is higher, due to their lower use and maintenance costs and longer maintenance cycle, they have significant economic benefits in the long run. Daarom, in the modern logistics industry, choosing electric forklifts is a wise choice that saves both money and worry.

Market Mainstream Electric Forklift Brands and Products

2024 Electric Forklift Brand Ranking

• Heli: Heli forklifts consistently rank at the top in various lists and are a leading brand in the industry.
• Hangcha: Hangcha is also a well-known brand in the electric forklift market, frequently appearing at the top of the rankings.
• Linde: Linde forklifts are highly regarded in the market for their technological advantages and high-quality services.
• Changhe: Changhe forklifts are also one of the well-known electric forklift brands in China.
• Nuli: Nuli forklifts also stand out in various lists.
• Long King: Long King forklifts have a certain market share in the electric forklift sector.
• BYD: BYD is not only notably successful in the new energy vehicle sector, but its electric forklift products are also widely welcomed.
• Toyota: Toyota forklifts are recognized globally for their reliability and efficiency.
• Jungheinrich: Jungheinrich forklifts hold an important position in the market with their innovative technology and excellent performance.
• Liugong: Liugong forklifts have a certain influence in the domestic Chinese market.

Technical Features and Market Performance of Mainstream Brand Electric Forklifts

• Lithium Battery Trend: In de afgelopen jaren, with the maturation and cost reduction of lithium battery technology, more and more electric forklifts are using lithium batteries as the power source. Bijvoorbeeld, some products from brands like Linde and Jungheinrich have achieved full lithium battery adoption.
• Diversified Product Lines: Different brands offer a variety of electric forklifts, including electric counterbalanced forklifts, reach trucks, stackers, tractors, enz., to meet the needs of different application scenarios.
• Technological Innovation: Many brands continue to launch new products, such as Hangcha’s XH series heavy-duty high-pressure lithium-electric special forklifts and XC series lithium-electric special reach trucks, which further enhance the competitiveness of the brand.

samengevat, the current mainstream electric forklift brands in the market include Heli, Hangcha, Linde, Changhe, Nuli, Long King, BYD, Toyota, Jungheinrich, and Liugong. These brands play an important role in the logistics industry with their leading technology, first-class services, and other characteristics. When choosing, factors such as brand strength, technologische innovatie, prestatie, and specific needs should be considered.

Future Development of Electric Forklift Motors

Application of New Energy Technology in Electric Forklift Motors

Lithium batteries, due to their high energy density, long driving range, and lower maintenance costs, are gradually becoming the main power source for electric forklifts. In de afgelopen jaren, with the continuous reduction of lithium battery costs, the cost advantage of lithium forklifts throughout their life cycle has become more apparent. Bijvoorbeeld, Heli shares have launched several models of electric forklifts based on lithium batteries and have achieved rapid growth.

High-voltage lithium battery technology allows electric forklifts to achieve longer driving times (zoals 12 hours) and is compatible with car charging piles, further improving convenience.

The development of fast charging technology is also increasingly mature, which not only improves the efficiency of using electric forklifts but also extends the life of lithium batteries.

Permanent magnet synchronous motors, due to their superior comprehensive performance, are widely used in electric forklifts. These motors are characterized by high efficiency and low energy consumption, making them an ideal choice for the drive motors of future electric forklifts.

Prediction of Development Trends in Electric Forklift Motor Technology

Electrification and intelligence are the inevitable trends in the development of the forklift industry. Electric forklifts not only meet environmental requirements but also significantly improve in terms of durability, betrouwbaarheid, and applicability, gradually replacing internal combustion forklifts. In aanvulling, products such as intelligent forklifts and unmanned forklifts are also encouraged to develop to further improve work efficiency and safety.

Globally, the market share of electric forklifts continues to increase, especially in Europe, where the market share of electric forklifts has reached 88.31%. With the advancement of industrialization, the electric forklift market in developing regions will also have broad development space.

The cost advantage of lithium forklifts throughout their life cycle will become more and more apparent, which will further promote the growth of market demand. It is expected that by 2025, the demand for lithium batteries for electric forklifts in China will reach 19.2GWh.

The national policy of “carbon neutrality and peak carbon” has promoted the green development of the forklift industry, with various regions promoting the replacement of fuel forklifts with new energy forklift products. Tegelijkertijd, the national encouragement and support for intelligent forklifts and unmanned forklifts will also promote the application and development of these new technologies.

samengevat, the future development of electric forklift motors will focus on the application of new energy technology, the popularization of fast charging technology, the deep integration of intelligence and electrification, and the expansion of the international market. These factors collectively promote the rapid development of the electric forklift industry and give it a broad prospect for the future.

Conclusie

Summary of Key Points for Selecting Electric Forklift Motors

1. Power Selection: Determine based on the operating environment and workload intensity. If used in harsh environments, such as high temperatures or climbing, a motor with a higher power rating is needed.
2. Drive Method: AC motors have the advantages of high efficiency, kleine maat, and low maintenance costs, while DC motors, although less expensive, have low efficiency and require frequent maintenance.
3. Energy Efficiency and Energy Saving: Use advanced motor technology and efficient energy management systems to maximize energy utilization and reduce operating costs.
4. Voltage and Heating: Modern AC motors operate at higher voltages, resulting in less heat generation and higher efficiency during operation.
5. Technical Parameters: Include technical parameters such as motor power, koppel, and continuous operation time, as well as speed and motor type (electric or internal combustion engine).

Emphasizing the Importance of Electric Forklift Motors in Improving Work Efficiency and Reducing Operating Costs

1. Improving Production Efficiency: Electric forklifts use batteries as the power source, avoiding exhaust emissions from traditional internal combustion engine forklifts, and their efficient energy utilization reduces unnecessary energy loss, thereby improving overall work efficiency.
2. Reducing Operating Costs: Since electric forklifts have no fuel consumption and lower maintenance costs, they can significantly save the enterprise’s energy and maintenance expenses in long-term operations.
3. Environmental Benefits: Electric forklifts do not produce exhaust, meeting the requirements of current environmental policies and helping enterprises achieve green production and sustainable development.
4. Safety Improvement: Compared to internal combustion engine forklifts, electric forklifts are quieter and safer during operation, reducing noise pollution and potential safety hazards.

Call to Action

When selecting an electric forklift motor, it should be decided based on individual needs and operating environment. Power selection should be based on the forklift’s operating environment and workload intensity, such as higher power motors needed for harsh conditions like high temperatures or climbing.

Greensky Power Co., Ltd. is een professionele fabrikant die zich bezighoudt met het onderzoek, ontwikkeling, productie, OEM-motoren, verkoop van elektrische kleine vorkheftruckmotor.

Als u op zoek bent naar een elektrische vorkheftruckmotor voor uw project, neem dan contact op met ons verkoopteam.

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