1 current situation of forklift engine
The main power unit of the existing fork is the diesel engine of the gasoline engine. Very few manufacturers are equipped with liquefied engines. Domestic gasoline engines include 475, 480, 492, 495 and Jiefang CA10; There are 285, 290, 485, 490, 495, 498, 4100, 4105, 698, 6102, 6110, 6130 and other diesel engines. Except for a few engines for construction machinery, most of the above models are vehicle type, general type or similar variant 名媛直播.
Due to the limitations of accessories, materials and process level, the supporting engines used in domestic forklifts still have a certain gap compared with similar foreign 名媛直播 in terms of noise, smoke, emission, reliability and service life. Forklifts exported and used by domestic airports, ports and foreign-funded enterprises mostly use imported engines. It mainly includes A15, H20, H25 and other gasoline engines of Nissan, flb1, C240, 6BD1 and other diesel engines of Isuzu, DC24 diesel engine of Daewoo, Korea, Xa, HA and other diesel engines of maesta, 1004 of Perkins engine, 8061si35 of Iveco, Italy, 6d16, 6d22c and 6d22tc of Mitsubishi, Japan.
2 matching requirements of forklift engine
Forklifts are used in a wide range of areas, with great differences in climate, harsh working environment, large dust, frequent changes in working conditions and heavy load. Therefore, the forklift shall have good performance, fuel economy and maintenance, and good service life. At the same time, it is also required to have compact structure, small volume and meet the damage protection index of standards and regulations. Generally, a good forklift engine should have the following basic characteristics:
(1) It can adapt to continuous and lasting work and bear heavy load, and the rated power is hourly power. Forklift Gasoline Engine shall be equipped with speed limiter.
(2) Forklift engines are often subject to large impact and strong vibration during operation, so the body and accessories should have sufficient stiffness and strength, and three-point support is mostly used for installation and fixation.
(3) In order to ensure that it can work under the rapidly changing load state, the full program governor should be generally adopted, with the instantaneous speed regulation rate of less than 12% and the stable speed regulation rate of less than 8%.
(4) In order to adapt to the working environment of ports and docks, the engine is required to have greater torque adaptability. Generally, the torque reserve coefficient shall be greater than 12% (except for torque converter).
(5) In order to meet the needs of hydraulic pump and auxiliary equipment, the engine shall have auxiliary power output. For medium and small tonnage forklifts, the hydraulic pump shall be directly installed on the engine, and its auxiliary output power shall be 50% - 100% of the total power.
(6) Forklifts are often operated on inclined ground. It is required that the engine can work normally in the state of front and rear or left and right inclination. Generally, the engine is required to work under the conditions of 20 ? trim and 15 ? heel.
(7) Forklifts often operate in environments with high dust content in the air. It is required to have a high-efficiency air filter, and dust-proof seals shall be provided at the oil filler, vent and pipe joint.
(8) In order to adapt to work in various climatic environments of - 40 ? C - + 45 ? C, there are special requirements for fuel, lubricating oil, grease, coolant, battery, etc., and the relevant systems shall be modified. The problem of cold start shall be solved in cold areas, and the potential zone shall be equipped with anti overheating devices.
(9) In order to meet the needs of work in plateau areas, superchargers should be set to compensate for the reduction of plateau power. It is required to operate in areas with an altitude of 1000-2000m or even 3000m without reducing power.
(10) Forklifts operating in tunnels, cabins and other environments shall be equipped with waste gas purification devices; The electrical equipment of forklift truck with large wading depth shall be sealed and protected; Special explosion-proof facilities are required for operation in the environment with gas.
(11) It should have high reliability and long service life. The target value for the newly developed forklift engine shall be: the first failure period of the diesel engine shall be greater than 800H. The first overhaul period is 6000-10000h; The target value of gasoline engine refers to the requirements of automobile engine.
(12) The exhaust emission, smoke, noise and other environmental protection indicators of forklift engine shall meet the provisions of national standards or industrial standards, and shall be in line with international standards as soon as possible.
(13) The volume power ratio, fuel and oil consumption rate, rotational speed reserve coefficient, minimum working stable speed and mechanical vibration technical performance indexes of the engine shall meet the supporting requirements of the forklift.
3 suggestions for future development
(1) Special engines for forklifts should be developed. For many years, the forklift industry strongly hopes to have domestic special forklift engines, especially the forklift project of Yinshi has not introduced corresponding supporting engines, which limits the comprehensive localization of the introduced technology. Over the past 30 years, great progress has been made in the level of forklift 名媛直播, but the maximum annual output has been hovering around 20000. The demand for forklift engines is less than 1% of the output of all multi cylinder internal combustion engines. Because the internal combustion engine industry is a highly technology intensive industry. The 名媛直播 are suitable for mass production according to professional division of labor, and the forklift is characterized by small batch and multiple varieties. Therefore, it is uneconomical to build a forklift special engine factory. It is suggested that the forklift industry should strengthen cooperation with the internal combustion engine industry, research and test the internal combustion engine of forklift as a whole, optimize the product structure of engine, and meet the needs of the development of forklift industry.
(2) The selection of forklift engine should be relatively concentrated. At present, the selection of engine in forklift industry has the phenomenon of "miscellaneous, disorderly and scattered". Forklifts of the same tonnage often choose 名媛直播 from multiple engine factories. According to incomplete statistics, the forklift industry now selects more than 50 models of domestic engines (excluding more than 10 imported models), with more than 100 variants, which are supplied by more than 30 engine manufacturers. For example, a factory produces two models of 485 and 490 engines. In order to meet the requirements of the forklift host factory, it also produces special forklift water inlet pipes with little difference in size, structure and shape, crankshaft pulley, flywheel, clutch shell, air inlet pipe, chlorine exhaust pipe, thermostat shell and fan cushion block, forming more than 40 variants. This situation has also brought difficulties to the production organization of the engine factory, and the production cost has increased accordingly, which has brought trouble to the maintenance and spare parts purchase of users. It is suggested to select and plan forklift engines for key enterprises and famous and high-quality 名媛直播, formulate forklift engine series and specification spectrum as soon as possible, and change the current situation of "miscellaneous, scattered and disorderly".
(3) The manufacturing quality of forklift engine is urgently improved. It is reported that the failure rate of domestic engines generally accounts for about 40% of the number of failures. The prominent problem is the poor reliability, the first failure period and failure interval are orderly, and there is a large gap compared with foreign advanced 名媛直播. The main faults are "water leakage, oil leakage and air leakage", which not only has a large number of faults, but also has a high fault repetition rate; The second is the failure of fuel system and electrical system, and it is difficult to start some diesel engines with non direct injection combustion chamber. This is a problem that the internal combustion engine industry is trying to solve.
(4) Environmental protection indicators need to be improved. Forklifts mostly work in workshops, warehouses, cabins, docks and other places, and have high requirements for environmental protection indicators such as waste gas emission, smoke and noise. At present, there is a big gap between the corresponding standards formulated by China's internal combustion engine industry and the similar standards of advanced countries. Environmental protection has become a global focus in the 21st century. China's engine manufacturing level is about 10-20 years behind that of advanced countries. Among domestic engines, the application of supercharging technology is not common, the electronic control technology is far from reaching the practical stage, and the LPG engine has not been mass produced. At present, it is the common wish of the engine industry and forklift industry to apply new technologies, develop forklift engines with energy saving, material saving, low pollution and high reliability, and change the passive situation of relying on imports.
(5) Promote joint and develop economies of scale. When establishing a forklift enterprise group, we should consider the production and supporting problems of engines. It is suggested to adopt various ways to carry out horizontal combination with supporting engine plants, from close combination to merging some suitable and better condition engine plants, so that they can directly serve forklifts and construction machinery, so as to better solve the supporting problems of forklift engines.
