Anti-rollover Control of Counterbalanced Forklift Truck Based on Stable Zone Partition

doi:10.3901/JME.2022.06.153

Abstract

Abstract: In order to improve the anti-rollover capacity of a counterbalanced forklift under the rapid rotation condition, a two-stage rollover dynamic model is established on the basis of the forklift structure. Based on the two-stage lateral load transfer rate, the mechanism of forklift rollover is analyzed and the stable zones are divided into stable zone, relatively stable zone, dangerous zone and abnormal dangerous zone. An anti-rollover layered control strategy based on stable zone partition is proposed, and different anti-rollover control actuators are selected according to different stable zones: dynamic balance block, hydraulic support cylinder and steering cylinder. Anti-rollover controller is composed of the upper stable domain identification controller, the middle-level controller based on model predictive control (MPC) and the lower layer executive controller. The upper stable domain identification controller performs forklift stable zone recognition based on the two-stage lateral load transfer rate, while the mid-level MPC controller calculates the required control torque with the body’s lateral angle and yaw rate as the control objectives, and the lower-level executive controller adopts an improved chain incremental allocation method to control the dynamic balance block, hydraulic support cylinder and steering cylinder to meet the target control torque. This experiment uses Matlab/Simulink for simulation and actual vehicle test verification. The results show that the anti-rollover control of counterbalanced forklift truck based on stable zone partition can greatly reduce the risk of forklift rollover and improve the the forklift safety.

Key words: counterbalanced forklift truck, stable zone partition, lateral load transfer rate, model predictive control, improved chain incremental allocation

CLC Number:

U270

XIA Guang, XU Liping, TANG Xiwen, CHEN Wuwei. Anti-rollover Control of Counterbalanced Forklift Truck Based on Stable Zone Partition[J]. Journal of Mechanical Engineering, 2022, 58(6): 153-168.

References

[1] 张民生. 2019年中国叉车行业数据简析[EB/OL]. [2020-02-07]. https://www.chinaforklift.com/news/detail/202002/69987.html. ZHANG Minsheng. A brief analysis of China's forklift industry data in 2019[EB/OL]. [2020-02-07]. https://www.chinaforklift.com/news/detail/202002/69987.html.
[2] ROEBUCK R L. A systems approach to controlled heavy vehicle suspensions[J]. International Journal of Heavy Vehicle Systems，2005，12(3)：169-192.
[3] SOLMAZ S，CORLESS M，SHORTEN R. A methodology for the design of robust rollover prevention controllers for automotive vehicles：Part 2-Active steering[C]// Proceedings of the American Control Conference，July 9-13，2007，New York，NY，USA：IEEE，2007：1606-1611.
[4] GHAZALI M，DURALI M，SALARIEH H，et al. Vehicle trajectory challenge in predictive active steering rollover prevention[J]. International Journal of Automotive Technology，2017，18(3)：511-521.
[5] TREETIPSOUNTHORN K ，PHANOMCHOENG G. Real-time rollover warning in tripped and un-tripped rollovers with a neural network[C]// 2018 IEEE 4th International Conference on Control Science and Systems Engineering，August 21-23，2018，Wuhan，China：IEEE，2018，95-100.
[6] TERMOUS H，SHRAIM H，TALJ R，et al. Coordinated control strategies for active steering，differential braking and active suspension for vehicle stability，handling and safety improvement[J]. Vehicle System Dynamics，2018， 57(10)：1494-1529.
[7] MOHAMMAD A S. A new robust combined control system for improving manoeuvrability，lateral stability and rollover prevention of a vehicle[J]. Proceedings of the Institution of Mechanical Engineers，Part K：Journal of Multi-body Dynamics，2019，234(1)： 198-213.
[8] NGUYEN A，CHEVREL P，CLAVEAU F. LPV static output feedback for constrained direct tilt control of narrow tilting vehicles[J]. IEEE Transactions on Control Systems Technology，2020，28(2)：661-670.
[9] 金智林. 运动型多功能汽车侧翻稳定性及防侧翻控制[D]. 南京：南京航空航天大学，2008. JIN Zhilin. Stability and anti-rollover control of sports multi-function vehicles[D]. Nanjing：Nanjing University of Aeronautics and Astronautics，2008.
[10] 贺宜，褚端峰，吴超仲，等. 基于MPC的大型车辆防侧翻控制方法[J]. 交通运输系统工程与信息，2015，15(3)：89-99. HE Yi，CHU Duanfeng，WU Chaozhong，et al. MPC-based anti-rollover control method for large vehicles[J]. Transportation System Engineering and Information，2015，15(3)：89-99.
[11] 宗长富，韩小健，赵伟强，等. 基于动态LTR的客车防侧翻控制[J]. 中国公路学报，2016，29(9)：136-142. ZONG Changfu，HAN Xiaojian，ZHAO Weiqiang，et al. Passenger car anti-rollover control based on dynamic LTR[J]. Journal of China Highway Engineering，2016，29(9)：136-142.
[12] 翟德. 半挂汽车列车侧向稳定性判定及控制研究[D]. 长春：吉林大学，2019. ZHAI De. Study on the determination and control of the lateral stability of semi-trailer trains[D]. Changchun：Jilin University，2019.
[13] 祁炳楠，王胜，张思龙，等. 基于能量法的分布式驱动电动汽车防侧翻控制[J]. 机械工程学报，2019，55(22)： 183-192. QI Bingnan，WANG Sheng，ZHANG Silong，et al. Anti-rollover control of distributed-driven electric vehicles based on energy method[J]. Journal of Mechanical Engineering，2019，55(22)：183-192.
[14] KASAHARA M，MORI Y. Relation between overturn and the center of gravity of a forklift truck[C]// 2017 56th Annual Conference of the Society of Instrument and Control Engineers of Japan，September 19-22，2017，Kanazawa Univ.，Kanazawa，Japan：IEEE，2017：135-140.
[15] 余绍华，任家权. 叉车主动式稳定系统研究[J]. 物流技术与应用，2013，18(8)：125-129. YU Shaohua，REN Jiaquan. Research on forklift active stability system[J]. Logistics Technology and Application， 2013，18 (8)：125-129.
[16] NAIR H M，SUJATHA C. Prevention of vehicle rollover after wheel lift-off using energy-based controller with proportional gain augmentation[J]. Proceedings of the Institution of Mechanical Engineers Part D Journal of Automobile Engineering，2019，234(4)：963-980.
[17] FELEZ J，BERMEJO A. Design of a counterbalance forklift based on a predictive anti-tip-over controller[J]. Integrated Computer Aided Engineering，2018，25(3)：273-288.
[18] NIKYAR E，VENKATACHALAM V，DRUGGE L. Designing and evaluating active safety systems for rollover prevention of all-terrain vehicles[C]// Advances in Dynamics of Vehicles on Roads and Tracks，Proceedings of the 26th Symposium of the International Association of Vehicle System Dynami，August12-16，2019，Gothenburg，Sweden：Springer，2020：989-999.
[19] 李学飞. 铰接转向车辆侧倾失稳机理及主动防倾翻控制方法研究[D]. 长春：吉林大学，2014. LI Xuefei. Research on the mechanism of articulated steering vehicle roll instability and active anti-rollover control method[D]. Changchun：Jilin University，2014.
[20] TAO P，JIN X，WU H，et al. Research on control strategy of the side forklift steering movement stability and its simulation analysis[C]//2018 5th International Conference on Information Science and Control Engineering，July 20-22，2018，Zhengzhou，China：IEEE，2018：927-931.
[21] 夏光，杜克，谢海，等. 基于侧倾分级的叉车横向稳定性变论域模糊控制[J]. 机械工程学报，2019，55(12)： 157-167. XIA Guang，DU Ke，XIE Hai，et al. Variable domain fuzzy control of forklift lateral stability based on roll classification[J]. Journal of Mechanical Engineering，2019，55(12)：157-167.
[22] SMIDL V，JANOUS S，PEROUTKA Z. Improved stability of DC catenaryfed traction drives using two-stage predictive control[J]. IEEE Transactions on Industrial Electronics，2015，62(5)：3192-3201.
[23] IMINE H，BENALLEGUE A，MADANI T，et al. Rollover risk prediction of heavy vehicle using high-order sliding-mode observer：experimental results[J]. IEEE Transactions Vehicluar Technology，2014，63(6)：2533-2543.
[24] 陈伟强. 平衡重式叉车空载行驶倾翻原因及预防措施[J]. 工程机械与维修，2011(8)：172-173. CHEN Weiqiang. Reasons and preventive measures for tipping of a counterbalanced forklift truck under no-load driving[J]. Construction Machinery and Maintenance，2011(8)：172-173.
[25] YOON J，CHO W，KOO B，et al. Unified chassis control for rollover prevention and lateral stability[J]. IEEE Transactions Vehicluar Technology，2009，58(2)：596-609.
[26] ADIREDDY G，SHIM T. MPC based integrated chassis control to enhance vehicle handling considering roll stability[C]// ASME 2011 Dynamic Systems and Control Conference and Bath/ASME Symposium on Fluid Power and Motion Control. American Society of Mechanical Engineers，October 31-November 2，2011，Arlington， VA：ASME，2012：877-884.
[27] 高凤杰. 旋转弹的质量矩/直接力复合控制方法研究[D].北京：北京理工大学，2016. GAO Fengjie. Research on rotating projectile mass moment/direct force compound control method[D]. Beijing：Beijing Institute of Technology，2016.