Forklift Controller: Structure and Function
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Forklift Controller: Structure and Function
Below is an overview of the forklift controller, including its structure and main functions.
🔧 WHAT IS A FORKLIFT CONTROLLER?
A forklift controller is the “central brain” that coordinates all operations of an electric forklift such as moving, lifting, steering, accelerating, or braking. It controls the electrical current and processes signals from other components (throttle, sensors, pedals, switches…) to ensure the vehicle operates smoothly and safely.
⚙️ STRUCTURE OF A FORKLIFT CONTROLLER
Depending on the type of forklift and manufacturer (Curtis, ZAPI, Inmotion, SME…), the controller may vary, but it generally includes the following components:
| Component | Description |
|---|---|
| Central Processing Unit (CPU) | Processes all input signals and issues control commands for the vehicle functions. |
| Printed Circuit Board (PCB) | Holds electronic components: capacitors, resistors, transistors, power ICs, etc. |
| Connector Ports | Receive signals from throttle, lift/lower switches, and sensors. |
| Power Module | Controls high-power current sent to the lift motor and drive motor. |
| Protection Circuit | Detects overheat, overload, short-circuit, and cuts off power to protect the system. |
| Heatsink | Cools high-power components. |
| Protective Housing | Shields from dust, moisture, and mechanical impact in the working environment. |
⚡ FUNCTIONS OF A FORKLIFT CONTROLLER
Movement Control
➤ Receives signals from the throttle to control forward/reverse motion at desired speed.
Lift/Lower Control
➤ Processes signals from the lift/lower switches and powers the hydraulic motor or pump.
Electric Brake / Regenerative Braking
➤ Controls braking and regenerates energy back to the battery (in modern forklifts).
Speed Limiting and Safety Monitoring
➤ Adjusts maximum speed, limits current, monitors overheating, etc.
Fault Diagnosis
➤ Displays error codes via indicators or interfaces with diagnostic software for maintenance.
Sensor Integration
➤ Some advanced models integrate tilt sensors, position sensors, and brake sensors for more comprehensive control.
