The loader refers to the technique that is used for unloading and loading operations and has the ability to move itself, grab the load, raise or lower it, stacking it in stacks or placing it on racks.
The device of a forklift depends on its purpose. Most of all, the industry produces universal machines that are used in various sectors of the national economy. They can handle loads of various sizes and weights. There are special loaders that are used to move a strictly defined load or used in special conditions of work performed, for example, mines.
A forklift mounted on a mast or carriage is mainly used to transport goods on special pallets. Loading equipment can be three-wheel or four-wheel. A machine with three points of support is much more maneuverable than a four-point counterpart, but it is less stable in the transverse direction, which does not allow it to be used to move large loads.
Loaders are equipped with engines internal combustion or are produced on electric traction. Electric forklifts are mainly used for work in warehouses or on sites with high-quality coverage. Equipment with diesel or gasoline engines designed for outdoor use and has a large load capacity.
The first loaders appeared almost a hundred years ago in America, this is primarily due to the economic boom in the industry. The rapid development of industry, the emergence of ports and railway communication, the increase in freight traffic contributed to the mechanization of loading and unloading operations.
Of course, the first models were significantly different from modern forklifts, but in 1923 the design of forklifts began to resemble modern counterparts.
First World War contributed to the fact that the development of loading equipment only accelerated, and the Second World War further pushed the design idea, since it was necessary to unload a large amount of cargo in a short period of time.
The United States at that time was the main leader in the production of loading equipment, as countries were recovering from the war and could not become competitors in this industry. Over time, Europe and Japan caught up with America and began to create loaders that are better in quality than American cars.
Japanese firms used additional options to break into the loading equipment market, that is, they completed their loaders additional equipment. This knocked down market prices by almost a third. Now manufacturers great attention pay not only to technical aspects, but also on appearance loaders.
More articles from this category:
Typically include:
- engine;
- control system;
- chassis;
- lifting device;
- brake systems;
- and so on.
The engine is the heart of every car
For any loader, the power unit is the most important structural element. It is worth noting that on modern machines basically install a few different types engines: , . However, some manufacturers create hybrid engines, which can use several types of fuel at once or at the same time work on electricity. In addition, most of the forklifts in European cities are this moment operate either by electricity or by gas.
Engine management systems
Every year there are more and more thoughtful and practical systems that greatly simplify the management of the machine. Thus, the development of cable connections gave a new impetus to the implementation of completely new schemes for transmitting information. In this regard, it became possible to control all loader systems through digital information or in other words at a distance.
lifting device
First of all, it is worth noting that the maximum height of modern loaders sometimes reaches eight meters, however, when using high-altitude cranes, the load can be lifted to a height of up to 18 meters. In order to lift the goods to such a great height as safely as possible, the machines have a system of protection against uneven floors or vibration.
The engineers managed to achieve this due to the fact that at the same time they were able to reduce the weight of the mast, but at the same time increased its rigidity and strength. Moreover, the new models are equipped with masts, which carry out lifting due to hydraulic cylinders.
Hydraulic systems
In the lifting mechanisms of the loader, the hydraulics proved to be quite worthy. This system is constantly being improved, so every year it becomes safer and more ergonomic. It has been used quite successfully in brake system. Thus, hydraulic boosters were installed on steel. Thanks to this, you can quickly and comfortably leave the car at almost any speed with a light pedal.
construction loader - This is a type of self-propelled load-lifting equipment of discontinuous action. Its main working body is a lifting mechanism with an installed bucket, forks, or other lifting device. The main purpose is lifting, moving, loading or unloading, storage of medium-sized cargo. He is able to combine the above operations to increase productivity, which also depends on the maneuverability and skill of the operator.
A loader, like a crane, belongs to lifting equipment, but, unlike it, it is capable of transporting goods over long distances. He is able to serve warehouses, construction sites, perform work in cramped conditions, for example, unload covered wagons, or store goods on racks. Autonomous movement and work, high mobility and ergonomics make it universal machine, capable of performing the tasks of cargo transportation at a construction site. The functionality of the loader is expanded due to the presence a large number lifting gear and other equipment.
There is the following classification of loaders:
For maximum payload:
Light load capacity 1 - 4 t;
Average load capacity 4 - 10 t;
High load capacity 10 - 16 t;
Ultra-high load capacity - from 16 tons and above.
By type of lifting device construction loaders are divided into three types:
1. . Its lifting device is a mast, consists of several sections inserted one into one, a hydraulic cylinder and a carriage. It moves up and down the mast, raising and lowering the load, and a load gripping body is attached to it.
2. . lifting device represents space frame, fixed at one end on the horizontal shaft of the front of the machine, a lifting hydraulic cylinder is installed in the middle, and a load gripping device is installed at the other end. There are two designs of the front loader: with a front linkage mechanism and with the possibility of rear unloading of the load gripper.
3. . Its load gripping device is mounted on a telescopic boom. It is attached to the frame on the shaft, and can be lowered and raised using a hydraulic cylinder. Depending on the design, it can be with a swivel or non-swivel boom.
According to the location of the lifting device:
A) frontal - the lifting mechanism is located in front of the loader. It has the greatest distribution because of its functionality.
B) side - the mechanism for lifting the load is located on the side. Performs specific tasks in the maintenance of warehouses with narrow aisles and long loads. Basically, it is equipped with a fork load gripping body.
By type of main power unit:
Petrol / gas;
Electrical;
Diesel / gas-diesel.
By type of chassis:
Caterpillar loader (can be equipped with both rubber and iron tracks);
The wheel loader, in turn, is divided into two categories according to the type of installed wheels and their number:
Type of wheels: chamber-pneumatic, not pierced-superelastic and bandage made of solid rubber tape;
Number of wheels: three-wheel, four-wheel, six or more wheels.
According to the maximum height to which it is possible to lift the load, they are divided into two groups:
Up to 4 meters;
Above 4 meters.
A modern loader consists of a self-propelled chassis with the following units installed on it:
hydromechanical lift with interchangeable working body, counterweight, internal combustion engine or electric motor, transmission, chassis, operator's cabin with controls and hydraulic system.
Fork (mast) lifting mechanism consists of the main frame, fastened to the frame of the forklift truck on a swivel joint, and with the help of a hydraulic cylinder, its angle of inclination is changed forward up to 8 ° and back up to 15 °. The main frame of the mast carries a movable frame, which is raised or lowered by the operation of the central hydraulic cylinder. At the top of the mast are two sprockets through which the chains are thrown. They are attached at one end to the fixed main frame of the lifting mechanism, and at the other - to the carriage with a gripper.
The forklift can be equipped mast following construction:
Duplex or two-section;
Mast - duplex with the possibility of free running of the carriage - the design is similar to the duplex, an additional third cylinder is installed, which increases the height of free lifting (lifting the lifting carriage, without moving the second section of the mast);
Triplex or three-section - all structures of this type are equipped with freewheeling carriages.
Loaders having a free-wheel duplex or triplex mast design, and having a maximum mast height of 2.2 m, are called: "car loader". The triplex mast is capable of lifting the load to the highest height in comparison with other types. This type of equipment is used to move calibrated cargo on pallets in production or in a warehouse.
Let's take a look at one of the most common Z-shaped linkage hoist devices. At the front end of the boom, on a swivel, a front bucket is attached. It has the ability to change the slope using a hydromechanical mechanism consisting of one or two hydraulic cylinders and levers attached to the bucket. The hydraulic cylinders themselves rest on the frame and are hinged. In such a mechanism, the fulcrum of the lever is between the points of application of forces, this creates an increased force on the edge of the bucket. Rubber seals on the linkage and boom pivot joints keep grease in place and prevent moisture, dirt and dust from getting inside. This increases the durability of the swivel joints, and reduces labor costs for their maintenance.
telescopic loader equipped with a multi-section boom-telescope. An increase in the length of the boom occurs by extending the sections with the help of an internal hydraulic cylinder. At the end of the boom, a lever mechanism with a hydraulic cylinder is installed to change the angle of inclination of the load gripping body.
The telescopic boom loader consists of a base chassis with undercarriage and a turntable mounted on it. The boom itself, the operator's cabin, the power unit, the counterweight, and the hydraulic system are mounted on it. The fixed boom, together with the rest of the equipment of the loader, is mounted on the chassis of the special equipment. The advantage of a loader with a telescopic boom is an incomparable maximum lifting height of the load (the average among existing models is 18 m) and large load capacity(the most common models lift about 5t.).
Diesel and gasoline engines are known for their reliability, ease of execution and maintainability. But they are almost impossible to operate indoors due to the emitted exhaust gases, and high noise levels. The situation can be corrected by installing an expensive cleaning filter.
A gas engine is structurally similar to a gasoline engine. It is not only more profitable in terms of fuel costs, but also has a lower level of emissions. Loader with gas engine can work freely in a poorly ventilated building. It is equipped with replaceable cylinders with a capacity of 27 to 50 liters.
The forklift with an electric motor is designed for indoor use. Such machines are advantageous due to lowest cost fuel, low noise level and absence of gaseous emissions into the atmosphere. But they cannot be operated at low temperatures - batteries have a limited resource and a high cost.
Information instruments and controls are located in the operator's cab. Due to the danger of operating the machine, special safety requirements for the driver are set for the cab. It must be strong enough to withstand a fall of a forklift or load. In the case of handling bulk materials, it must protect the operator from dust, or the possibility of injury from solids. The cab must have a heating or air conditioning system to operate in hot or cold climates, respectively.
The specifics of the loader application and its purpose determines the design running suspension. In particular, important parameter is the number of wheels. Tricycle models have two drive wheels and single or dual wheel. This design is excellent for working in narrow spaces where maneuverability is required. The disadvantage of the three-wheel loader is the reduced carrying capacity and operation only on flat surfaces, due to lower stability. Four-bearing models have other advantages and disadvantages. They are not as maneuverable, but are able to lift larger load, and be used outdoors, drive long distances on a bumpy road.
When purchasing a loader, the owner should think about what surface the equipment will drive on. When driving on uneven surfaces, pneumatic tires with good shock absorption properties are suitable. They will protect the suspension units from rapid wear. For driving on a flat surface with the presence of small, hard fractions, expensive, wear-resistant superelastic tires can be used. Because of low profile they have almost no depreciation, and quickly wear out the fasteners of the chassis. The common solid rubber belt tires can also be used on slightly uneven paved roads. They offer balanced performance, value for money, and will satisfy any practical small loader owner.
To capture the load, loaders are equipped not only with simple forks or buckets of various sizes. Modern technology can be equipped with complex devices, ranging from clamshell, two-bucket grabs to a mini excavator unit or a hydraulic pit drill. Forklift manufacturers offer a very wide range of attachments. They satisfy the needs in any field: construction, agriculture and forestry, cleaning of the territory, etc. The picture shows only some examples of equipment.
The forklift is designed to carry out loading and unloading work in and on the street.
For warehouse closed type use an electric forklift.
The main volume of the loader is occupied by the battery acid batteries that power the motor.
Electric forklifts are compact machines ideal for warehouse work.
The loader driven by an internal combustion engine is designed to work under sheds and in open areas. The main condition of their work is related to the safety of personnel. Traffic fumes should not cause poisoning of people.
For the lifting device in the form of a pitchfork, pallets of a special design have been developed, on which the cargo is stored.
When choosing an electric forklift, you should pay attention to its load capacity. As a rule, these are three types; 1000, 2000, 3000 kg. The lower the load capacity of the machine, the smaller and more agile it is. They exist for the production of warehousing in narrow aisles. When choosing gasoline and you should pay attention to the following indicators:
- Load capacity (it does not exceed 3.5 tons);
- Tire type. They are solid and pneumatic;
- Cass. most high class These are loaders capable of working on heavy soils. With an increase in class and carrying capacity, the price of the product increases. There are many forklifts on the market. different firms. All of them compete with each other. each loader performs its own tasks. The differences are mainly in design and service functions.
Warehouse Forklifts: Forklifts and Electric Forklifts
Warehouse forklifts are divided into electric forklifts (powered by battery) and lift trucks (with internal combustion engines).
Electric forklifts
- Cheaper in price;
- Silent;
- Safe for human health, as there are no harmful emissions. Therefore, they are mainly used indoors.
Minuses:
- Need periodic recharging, so they can not work a long period time;
- Less performance;
- You need to constantly monitor the battery and charge it in a timely manner;
- You need a special room for recharging.
JCB warehouse trucks are very popular in the market because they have good balance price quality.
Forklifts
- High performance;
- Can work around the clock;
- Expensive;
- They emit harmful exhausts, so they can only be used in open or well-ventilated areas.
Forklifts, depending on the fuel consumed, are gas, gasoline, diesel, gas-gasoline.
Diesel forklifts
- The most powerful;
- Economical: some models consume three times less fuel compared to gasoline
- Average price range fuel;
- Very noisy;
- Apply only outdoors;
Petrol forklifts
- They can be used in well ventilated areas;
- Average fuel consumption;
- The most common fuel;
- Average noise level.
- Expensive fuel;
- Warm up before starting work.
LPG forklifts
- The engine does not need to be preheated;
- Cheap fuel;
- The most silent;
- Eco-friendly, as they emit a minimum number of harmful impurities;
- Can be used both outdoors and indoors.
- Most high flow fuel;
- Fuel is less common, as the number of gas stations is small.
At LPG lift trucks in addition to gasoline engine the gas system is running.
- Used indoors and outdoors;
- Less need to refuel as two power sources, in fact, as a rule, one source is used;
- Need to warm up;
- Accounting for two types of fuel at once;
- Small load capacity;
- Less performance.
Forklift truck - suitable for working in open warehouses.
On Russian market most common warehouse loaders following companies: Yale, Unilift, Maximal, Toyota.
The device and technical characteristics of the forklift
Forklifts have become indispensable equipment in construction, manufacturing, warehouses and trade. They are used for unloading, loading and moving various goods.
These units have high performance, small turning radius, low level noise, environmental friendliness during operation, easy control and long-term use under the most difficult conditions and loads. Therefore, they are used in enterprises, construction sites, and warehouses.
The design of the forklift is characterized by the presence of a fork mounted on the mast this equipment. This device greatly facilitates the transportation of cargo on pallets.
During the operation of a forklift, various conditions may arise, therefore, its design provides for the change of attachments if, for example, the nature of the transported cargo has changed.
The technical characteristics of this equipment include: the maximum, nominal and alternative load capacity of the machine, the height of the forks, the position of the center of gravity of the load. According to these characteristics, you can determine the performance of the loader. Important role engine plays: , . 
Comparison of forklifts Bull, Jac, Hangcha, Linde
Forklifts are used for transporting small loads. High maneuverability, low noise level during operation, low gas pollution, ease of operation and maintenance have made them reliable assistants in open areas and closed warehouses.
How difficult it is to choose among such a variety of models and attachments for forklifts!
In this article, we will compare forklifts under the Bull brand with its competitors - Jac, Hangcha, Linde.
Chinese Jac forklifts are Bull's closest competitors. Jac has obtained the ISO 9001 international quality certificate for the production of 1-10t forklifts.
Loaders are equipped with diesel and gasoline engines, as well as run on gas and electricity. The scope of Jac equipment is open areas and storage areas of manufacturing enterprises. Jac loaders can be equipped with different types cargo captures in addition to forklifts. The lifting height is up to 6 meters.
In many ways, Jac loaders are not far behind Bull, however, Bull has a European CE quality standard certificate (in addition to the ISO certificate), has a wide range of load capacities (up to 46 tons) and is designed to work in Russian conditions with sharp drop temperatures.
Chinese forklift trucks Hangcha not so long ago presented on the Russian market. These loaders are equipped with engines manufactured by Nissan, Danahe, Isuzu, Yanmar. Hangcha equipment has effective soundproofing of moldings and a metal hood, machine control requires a minimum of effort from the operator, and easy access to units and assemblies allows for quick maintenance and replacement of parts.
Hangcha loaders are shipped to 25 countries worldwide.
As we can see, Hangcha is a worthy competitor to the Bull technique. However, Bull provides customers with more wide choose specifications: Bull lifts to a height of up to 7 meters, Hangcha - up to 3 meters, Bull works with loads weighing up to 46 tons, Hangcha - up to 16 tons.
Linde forklifts deserved popularity in the field warehouse equipment. These trucks are divided into conventional forklifts with electric drive, gas, petrol or diesel engine. Linde produces a diverse range of equipment that solves special tasks. The level of noise and emissions complies with all European standards, about 90% of all materials Linde loaders can be recycled. Work nodes are able to provide more power, smooth running, as well as easy and precise control. The most powerful Linde forklifts can lift loads of up to 46 tons to a height of 10 meters.
The disadvantages of Linde loaders include their price, which is on average 20% higher than that of similar Bull loaders.
If you are looking for a forklift for Russian conditions for an optimal price-quality ratio, then pay attention to Bull loaders.
Bull loaders. The Bull brand is own development Rusbiznesavto company and is produced on Chinese factory Heli for over 20 years!
Bull loaders have a carrying capacity of up to 46 tons, lift loads to a height of up to 7 meters, work on unprepared unpaved grounds and in equipped warehouses, have a small turning radius (this ensures high maneuverability in enclosed spaces), and remain operational at temperatures from +400 to -300 C, are equipped with masts of various heights according to your order.
Repair of Bull loaders is carried out in the shortest possible time, because it is not difficult to find necessary spare parts mechanical or electronic system when equipment breaks down. The service department consists of qualified engineers who will produce scheduled maintenance and repair of equipment in your territory on the job.
Toyota 7FBJ35 and Toyota 7FBE / 7FB forklifts
Toyota 7FBJ35 - . The model is popular in a closed type or when unloading products that have the ability to absorb foreign odors.
https://www.youtube.com/watch?v=XmO-1nESMgQ
Equipped enough powerful engine(12kW). Weight Limit lifted load 3.5 t. dimensions loaders allow loading and unloading operations directly from the wagon, without the use of deadweights, the radius of a full turn of 360 degrees does not exceed 2.8 m.
Compared to three wheeled larger radius reversal, but much more stable. It does not require a perfectly flat area between the car and the warehouse.
It is almost impossible to find shortcomings in this car, except that the operation on acid batteries at low temperatures is slightly reduced. The average price of such a model is 250 thousand rubles.
Electric forklift trucks 7FBE / 7FB
https://www.youtube.com/watch?v=zGqM2b296xg
Compact, which are simply indispensable for use in warehouses, in production and in trade.
TO Category:
Load handling devices
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The main components and systems of loaders associated with attachments
General purpose loaders consist of the following components and systems: main frame, transmission, running gear, control mechanism, engines, braking device, electrical equipment, lifting device and hydraulic drive.
From the point of view of the use of attachments, the lifting device and its hydraulic drive are of fundamental importance.
Lifting device (forklift) for loaders general purpose it is installed frontally and consists of telescopic frames, a cargo carriage with a load gripping device, a lifting mechanism and a tilting mechanism.
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The forklift on operated loaders is made according to the most common scheme and consists of vertical telescopic sliding frames pivotally connected to the chassis of the machine using brackets. The telescopic frame consists of a fixed outer frame and a movable upward moving inner frame. The cargo carriage moves on rollers along the inner frame. It is connected by crossbars, on which load-handling devices are hung.
The lifting mechanism consists of plate-roller chains that wrap around guide rollers or sprockets. The outer branches of the chains are connected to the carriage, and the inner ones - to the cross member of the fixed frame. When the rod of the hydraulic cylinder installed in the middle of the frame moves, the inner frame rises. At the same time, the load carriage also rises from the tension of the chains. The carriage, moving along with the inner frame, moves twice as fast as the frame itself. The carriage is lowered by its own weight.
The disadvantage of such a scheme of the forklift is the extension of the protruding part of the inner frame until the carriage is fully raised, which does not allow efficient use of loaders in cramped conditions in the holds of ships and covered wagons in height.
Rice. 1. Scheme of action of the load-lifting device of loaders: 1 - frame; 2- connection bracket with tilt mechanism; 3- stock; 4- hydrocn-lindr tilt; 5 - piston; 6 - mounting bracket to the chassis; 7 - guides of the cargo carriage; 8 - fork lift; 9 - piston; 10 - lifting hydraulic cylinder; 11 - stock; 12 - cross member; 13 - stars; 14 - internal racks (movable); 15 - fixed outer racks)
To work in cargo areas, a forklift with full free lifting of the carriage is required, without changing the height of the loader. Such forklifts are known on loaders of domestic and foreign production. However, their parameters do not fully satisfy the conditions of transshipment operations in the cargo spaces of old ships, and for modern ships the lifting height is insufficient. Developing package transportation requires forklift trucks with full free carriage lift, fork lifting height up to 5 m.
The outer frame of the forklift carriage and the crossbeams of the electric forklift are not suitable for the use of attachments. Such constructions require in each case a special solution for mounting the load grippers and do not allow unifying the binding of the load grippers to the carriages. These requirements are met by the design of the carriage by you - by installing instead of the existing four-spool switchgear R75-4-PG, assembled from two-spool distributors R75-B2 serially produced by the Melitopol plant, according to the scheme developed by the Moscow plant of hydraulic units.
The equipment of the R75-4-PG switchgear is carried out as follows:
- the “floating” position (spools of tractor design) is eliminated in P75-B2 by installing a special restrictive bushing on the spool or by installing a mechanical limiter for the spool stroke;
- the mechanism for fixing the spools is removed; the drain hole from the bypass valve control channel in both distributors is plugged;
- turns off bypass valve in the final distributor of the device by plugging the jet hole in the valve body and installing a restrictive sleeve to prevent the valve from lifting;
- liquidated safety valve final distributor of the device;
- a mechanism for switching on the electric motor of the loader pump is installed;
- the pressure and drain cavities of the distributors are connected in parallel.
Electric forklift models EBV-3002 and EB-732 manufactured by Balcancar (NRB), used in warehouse and ship handling operations. The hydraulic drive is being modernized by serially connecting two more similar or additional R75-P2 hydraulic distributors to the existing Bosch HySEVA / lD4 (Germany) hydraulic distributors.
Forklift models 400 3, 4 04 3, 4045 used in warehouse handling operations. Modernization of the hydraulic drive can be carried out in two ways, which are based on the replacement of existing distributors, since the industry does not produce spools of the corresponding parameters.
The first way is to install a switchgear R75-4-PG, completed from two-spool distributors R75-B2 of the Melitopol plant of hydraulic units (similar to KVZ electric loaders).
The second method is the installation of the switchgear R75-P6-PG (six-spool) of the Melitopol plant of hydraulic units. This method ensures the operation of a forklift truck with load gripping devices that perform more than two operations. However, the dimensions of this switchgear are large, and therefore its installation on a forklift can be done by installing one of them (the distributor consists of two three-spool R75-PZ) horizontally, the second vertically on a special bracket mounted on the frame cross member.
In addition to hydraulic valves, it is of fundamental importance for normal operation multi-operation hinged load-handling devices has the presence of control equipment in the hydraulic system. Modern load grippers require parameter adjustment working fluid(pressure, speed, flow).
The safety valve, which is available in each hydraulic distributor and is designed to protect the hydraulic system from overloads, cannot provide pressure regulation in the gripper hydraulic cylinders, since a decrease in the valve setting pressure will lead to a decrease in pressure in the forklift hydraulic cylinder. Therefore, pressure control in the gripper hydraulic cylinders, in order to ensure operation with different types of cargo (different compression force) while maintaining their quality and presentation, can be provided with an additional control valve included in the line for supplying the working fluid from the hydraulic distributor to the gripper hydraulic cylinders.
Depending on the design of the load grippers, the type of cargo being handled and the nature of the work performed, it becomes necessary to control the speed of movement of the working bodies. This regulation can be achieved with a throttle. The presence of a throttle limits the flow of fluid to the hydraulic cylinders and thereby reduces the speed of the piston.
During the operation of hinged load grippers with hydraulic drive there is a leakage of the working fluid in the hydraulic distributor and supply pipelines. Therefore, spontaneous movement of the hydraulic cylinder rods is possible, which can lead to a fall of the load. To prevent such cases, hydraulic locks must be included in the hydraulic system of the loader in parallel with the blocking hydraulic cylinder. They "lock" the liquid in the working cavities of the hydraulic cylinders with the spools in the neutral position, thereby disconnecting them from the hydraulic system.
The designs of the control valve and hydraulic lock were developed by the Baltic TsPKB.
When dismantling hinged load grippers, its hydraulic system is disconnected from the general one. This operation is associated with heavy losses working fluid flowing from open elements of the hydraulic system. To eliminate this phenomenon, the connected ends of detachable hoses must be equipped with automatic locking devices.
Of no small importance for the operation of attachments is the design of one-piece and detachable hose connections, which must be unified.
