Transcript Document

TMX
CLARK TMX
Service Overview
By: Mark Dyster
2005 National Sales Meeting
TMX
Recognizing the benefit of AC
technology, CLARK developed the
TMX with 100% AC MOTORS.
2005 National Sales Meeting
TMX
TMX Induction Motors
• No brushes to change or commutator to turn….ever
– Routine brush changes are eliminated.
– No need to pull the motor to turn and under-cut the
commutator.
– Much less likely to burn-out motor during a stall (Brushes
were hot spots on DC motors.)
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TMX Induction Motors- Continued
• All TMX Motors are Fully Enclosed
– Keeps out dust and contaminates.
– Wet environment is not an issue.
– Better suited for food processing or
outdoor use.
– Same motor in UL “E” and “EE”
models.
– But……………………
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Must avoid spray washing with high pressure hose.
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TMX Induction Motors- Continued
• Standard Thermistor
– All motors are equipped with a thermistor which constantly
monitors temperature. Should the temperature approach the
thermal limit, the control cuts back current.
– Once motor temperature decreases, full power is automatically
restored.
– Some competitors offer thermal switches. When activated,
truck performance decreases drastically. Operators typically
park the truck and wait for it to cool.
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TMX Induction Motors- Continued
• Pump Motor Thermal Cut-back
– Full control current up to ADJUSTMENT #4 temperature.
• ADJUSTMENT #4 is set at 130°C. DO NOT CHANGE.
– Proportional cutback from ADJUSTMENT #4 to MOTOR
SHUTDOWN temperature.
• MOTOR SHUTDOWN is set at 145°C. DO NOT CHANGE.
– Above MOTOR SHUTDOWN temperature you have steering
only.
– Icon on dash and fault code illuminate once ADJUSTMENT #4
temperature is reached.
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TMX Induction Motors- Continued
• Traction Motor Thermal Cut-back
– Full control current up to ADJUSTMENT #4 temperature.
• ADJUSTMENT #4 is set at 130°C. DO NOT CHANGE.
– Control current is reduced to ½ MAX from ADJUSTMENT #4 to
MOTOR SHUTDOWN temperature.
• MOTOR SHUTDOWN is set at 145°C. DO NOT CHANGE.
– Above MOTOR SHUTDOWN temperature traction is disabled.
– Icon on dash and fault code illuminate once ADJUSTMENT #4
temperature is reached.
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TMX Induction Motors- Continued
• Durable/Low Maintenance Design
– Only wear items are bearings and seals.
• Used high-temperature shaft seal.
• Used over-sized bearings for extended life.
– Change at 10,000 to avoid potential problems.
• Bearings filled with high-temp grease and
sealed on both sides.
– Clark will stock: Stator (includes temp senor),
Rotor, Drive-end shield, Non-drive end shield,
screws and other miscellaneous parts. These
items can not be rebuilt.
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Traction Control Features
• High travel speeds both loaded and unloaded.
– Top speed for TMX 12-20 set at 9.3 mph loaded and unloaded.
– Motor is not limiting factor. Control regulates speed.
• Ramp start Feature- Control boosts voltage to motor
producing higher starting torque.
– Allows operator to start loaded truck on ramp without rollback.
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Traction Control Features
• Anti-Roll Away Feature- If left unattended with the parking
brake not set, but the key on, truck will slowly (about 1
mph) descend ramp regardless of directional lever position
or truck orientation.
– Motor encoder knows which direction truck is rolling. Control
checks directional lever and accelerator input and applies
counter-torque as needed.
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Traction Control Features
• Three forms of regenerative braking are standard:
– Service brake (foot brake)
– Change of direction (Proportional to accelerator position)
– Accelerator release (Proportional to accelerator position)
• The Benefits are:
– Brakes are hardly used, prolonging brake life.
– Energy to stop truck goes back into battery, not into brakes.
– Drive train is always under load. No rattle during coasting.
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Traction Control Features
• Stall Protection
– Control reduces current by 50% after several
seconds of stall condition.
– If maximum temperature is exceeded then control
shuts down.
• Accurate speed control via encoder feedback.
– Can program lower travel speed.
– Truck travels at same speed loaded and unloaded
(not so without speed feedback).
– Can set different limits for forward and reverse.
• Consult factory if special speed reduction is
required for your application (ESQ/SQ available).
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Traction Control Features
• No delay during change of direction, as with DC systems.
– No contactor switching delay like series system.
– With brushed system the switching rate is limited to ensure
good brush-to-commutator surface contact is maintained.
• High acceleration rates = greater throughput.
– Again, the TMX AC system is not limited by the need to
maintain good commutation.
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Power Reversing Drive Control
• Steer potentiometer relays steer tire position to control.
• Control regulates speed and direction of both motors.
– 0 to 8 degrees- Equal power to both motors
– 8 to 71 degrees- Decrease speed of both wheels in proportion
to steer angle.
– 71 to 75 degrees- Inside wheel coasts
– 75 to 90 degrees- Inside wheel powered in reverse
• Pivot point is centered between drive tires.
– Provides the tightest possible turning radius.
• 2-wheel drive (versus only one)
– Provides added traction, especially on wet or uneven surfaces.
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AC Pump Control is standard
on every TMX……not a
high priced option.
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Pump Control Features
• One AC motor for lifting and steering operation.
– Flow control valve ensures steering has priority.
• Linear potentiometer on lift handle provides fully
proportional lift.
– Motor only runs as fast as needed, conserving energy.
• Closing Tilt, Aux1 or Aux2 switches causes pump motor to
spin at preset speed.
– Motor speed can be adjusted to meet attachment needs.
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Pump Control Features
• Low Noise Operation
– Pump motor spins at 500 RPM to
reduce steering noise.
– Speed ramps up for all hydraulic
functions.
– Use “silent” pump to further
reduce steering/lift noise.
– On-demand steering option no
longer needed.
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TMX Control Features
• Thermal Protection
– Standard on traction and pump controls.
– Controls equipped with thermistors.
– Thermal cut-back is gradual, not on/off.
– Reduces current sent to motor.
• Reduces control power output so it
can start to cool.
– Control will shutdown before exceeding
maximum temperature.
– Icon on dash lights to signify condition.
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TMX Control Features
• Higher Efficiency-Longer Runtime
– Overall the AC system is more efficient than equivalent DC
system.
– 13% longer run time per battery charge than equivalent DC
system.
• Higher Throughput
– High lift and travel speeds, along with quick acceleration, mean
faster throughput.
– 12% more cycles per hour than equivalent DC system.
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TMX Control Features
• Overall life cycle cost less than DC systems.
– No FWD/RVS/1-A contactors to service.
– No motor brushes to change.
– Motor commutator does not need to be turned.
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TMX Control Features
• Hand-Set service tool
– Can change top speed (forward AND
reverse), acceleration, plugging (all 3
forms), etc.
– Use to check switches for proper
operation.
– Use to check wiring for proper
connection.
– Use to view status of any value that
control measures.
– Control has learning mode to set steer pot
and accelerator end points. No need to
fine tune by hand.
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TMX Control Features
• Laptop service tool
– Can do all that the handset can plus………
– Can update control software/firmware by flashing processes.
– Can data log any value that control measures.
– Can export alarm (fault) codes to file which can be emailed to
Clark.
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Disadvantages of AC Technology
• Control produces twice the amount of heat.
– Clark uses a finned heat sink on all models.
– Three fans used to help prevent control from
overheating, even in demanding operations.
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Disadvantages of AC Technology
• Some competitors claim to have a performance retention
feature that maintains performance levels as the battery
discharges. Such a feature could cause additional motor
heating as voltage drops.
– Same power required if same amount of work is performed.
– Power equals volts times amps (P=V*I).
– Therefore, lower voltage (at end of the shift) means higher
current.
– Higher current means considerably more heating.
• Therefore- battery capacity is still important to maintain
voltage.
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TMX Reliability
• Proven Drive Axle
– Same as TMG axle, except new
pinion carrier because of new
motor mounting flange.
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TMX Reliability
• Proven Steer Axle
– Same as on TMG.
– Added grease zerk to trunnion
housing.
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TMX Ruggedness
• Rugged Frame
– 3/8” thick steel frame side plates.
• Rugged Carriage
– 6 load roller design, whereas
most competitors use only 4.
– Massive high-strength steel fork
bars.
– Standard side thrust rollers.
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Side-Thrust Rollers
• TMX has external sidethrust rollers.
• More effective control of
carriage under off-set
loading conditions.
• Mounted on eccentric
shaft that adjusts and
locks into place.
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Hydraulics
• 3 spool valve standard.
• Kits available to add 4th
section in the field.
• Use Allen-wrench to adjust
flow rate. No need to change
cartridge.
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Hydraulics
• Adjustable aux relief setting.
• Wiper seal cleans spool as it
enters the valve body.
• Pressure test ports for main
and aux circuits.
– No need to break into lines
to check system pressure.
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Steer Potentiometer
• Original lasted 2000-7000 hours.
• Old design was difficult to
properly align unless
counterweight removed.
• If not in alignment would only
last 500-2000 hours.
• New design is much more
forgiving and pot has better
sealing (IP65). Proven unit.
• Field kit can be purchased to
update trucks (P/N 8450019).
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TMX Features
• Lower Step Height
– Left side is 17” (430 mm)
– Right side is 19” (480 mm)
• Steel step plate
– Removable, should cleaning be
needed.
• Rounded “GEN2” looking OHG.
– Less likely to catch on hanging
curtains.
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TMX- Competitive Comparison
Comparing 4000 LB models
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Motor/Control Technology Comparison
• CLARK– Standard: AC traction, AC Lift/Steer using priority valve.
– Option: None Needed.
• Hyster– Standard: AC traction, DC contactor lift, On demand power
steering with DC brushless motor.
– Option: DC pump control ($1185 list, $687 D-net).
• Komatsu– Standard: AC traction, DC contactor lift, DC steering.
– Option: None
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Motor/Control Technology Comparison
• Crown– Standard: DC SEM traction, DC contactor lift, On demand
power steering with DC motor.
– Option: None
• Toyota– Standard: AC traction, AC Lift/Steer using priority valve very
similar to the TMX arrangement.
– Option: None Needed.
• Daewoo
– Standard: DC traction, DC Pump control for lift and steer.
– Option: None
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Motor/Control Technology Comparison
• CAT/Mitsubishi– Standard: DC traction, DC pump control, DC Contactor
steering.
– Option: None
• Nissan
– Standard: DC traction, DC contactor lift, DC on-demand
steering.
– Option: None
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LIFT SPEEDS- 36V with 189" TSU
Mfg.
Model
Loaded
(fpm)
Mfg.
Model
Unloaded
(fpm)
CLARK TMX 20
61
CLARK
TMX 20
104
Crown
4040-40
58
Crown
4040-40
90
Toyota
7FBEU20
57
Hyster
J40ZT
90
Cat
EP20KT
55
Cat
EP20KT
89
Hyster
J40ZT
55
Toyota
7FBEU20
89
2005 National Sales Meeting
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TRAVEL SPEEDS- 36V-189" TSU
Mfg.
Model
Loaded
(mph)
Mfg.
Model
Unloaded
(mph)
CLARK
TMX 20
9.3
CLARK
TMX 20
9.3
Hyster
J40ZT
8.6
Cat
EP20KT
9.3
Cat
EP20KT
8.1
Hyster
J40ZT
8.8
Toyota
7FBEU20
7.8
Toyota
7FBEU20
8.4
Crown
4040-40
7.1
Crown
4040-40
8.2
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Maximum Amp-Hr Battery Capacity- 36V
Mfg.
Model
Standard
Compartment
(Amp-Hr)
Optional
Compartment
(Amp-Hr)
CLARK
TMX 20
1240
1550
Hyster
J40ZT
1100
NA
Cat
EP20KT
868
NA
Crown
4040-40
850
NA
Toyota
7FBEU20
765
1100
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Basic Right Angle Stack Dimension
Mfg.
Model
RAS (in)
CLARK
TMX 20
74.2
Hyster
J40ZT
75.4
Crown
4040-40
77.2
Toyota
7FBEU20
77.2
Cat
EP20KT
80.0
Note: Add load length and clearance for isle width.
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Gross Truck Weight- with Minimum Battery Weight
Mfg.
Model
Weight (LB)
CLARK
TMX 20
8964
Crown
4040-40
8510
Cat
EP20KT
7700
Hyster
J40ZT
7250
Toyota
7FBEU20
7230
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Draw Bar Pull Ratings-36V Loaded Truck
Mfg.
Model
S2-5 minute (LB)
S2-60 minute (LB)
CLARK
TMX 20
4325
1790
Toyota*
7FBEU20
1760
????
Cat
EP20KT
1320
560
Crown
4040-40
????
????
Hyster
J40ZT
????
????
*Toyota only list the 3-minute rating, not the 5-minute rating.
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Maximum Gradeability at 1 MPH-Loaded
Mfg.
Model
Grade (%)
CLARK
TMX 20
32.7
Toyota
7FBEU20
16.0
Cat
EP20KT
11.0
Crown
4040-40
????
Hyster
J40ZT
????
Note: Values listed for TMX 20 are an indication of motor performance. Actual gradeability may be limited by grade clearance.
2005 National Sales Meeting
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THE END…....
2005 National Sales Meeting