Among all types of warehouse transport the greatest demand W. russian companies Enjoy diesel. This trend is not accidental - the diesel engine has high power, suitable for heavy machines with a lifting capacity of more than 40 tons, retains performance in frost. In addition, the motors from leading manufacturers effectively purify exhaust gases, so the technique can be operated inside warehouse terminals.

Often the choice in favor of loaders working on diesel, is due to economic benefits - diesel equipment is cheaper than gasoline and electrical analogs, has relatively low cost possessions. The most important characteristic The "ownership prices" is fuel consumption - small consumption of diesel fuel significantly reduces the total costs of the production process. This indicator is calculated by the manufacturer and is specified in the Table of Technical Specifications as a specific fuel consumption. True, the calculated data obtained during the tests may be varied with practical indicators, because the loaders are operated in different conditions. To get real fuel consumption figures for any estimated period (shift, month, quarter, year), it is necessary to use a special technique.

The normalized fuel consumption of a forklift: mathematical calculation

After setting the equipment on the balance of the company's accounting, the calculated data for the write-off of fuel will be needed. You can get this data by the formula:

Q \u003d NQ / (1000RK 1)Where:

Q is the regulatory consumption of fuel in liter on Motochas;

N - engine power in horsepower;

q - specific fuel consumption of manufacturer's calculations;

R is the value of the density of the diesel fuel (0.85 kg / dm3),

k 1 - the ratio of the periods of the motor in the usual and maximum modes.

The K 1 coefficient is a specific workflow rate. In reality, the loader engine operates on maximum revolutions only part of the shift: during the acceleration of the machine, movement at the limiting speed, overcoming the loads with the load, lifting goods to the maximum possible height.

For example, if 60% of time operates in normal mode and 40% with a maximum load, then k 1 \u003d 1.5 (60/40). Calculate this indicator, determine the rate of fuel consumption will not be difficult. Take the Bull FD35 with a loading capacity of 3.5 tons with the Japanese ISUZUC240 motor with a capacity of 35.4 liters. with. and a specific fuel consumption of 202 g / kW * h, which a quarter of shifts is operated at maximum loads. We obtain: Q \u003d 35.4 * 202 / (1000 * 0.85 * 1.5) \u003d 5.6 l / Motochas.

It should be noted that the theory and practices may vary. In machines without running or with big mileage Fuel consumption increases in comparison with calculated indicators. In addition, the consumption of the diesel fuel rises if the technique is operated in the limit load mode.

Diesel loaders with optimized fuel consumption: manufacturers solutions

The main parameters affecting fuel consumption forklift- This is the power of the motor, the specific fuel consumption and actual loads during the shift. That is, it is possible to identify approximate costs at the stage of choosing the technique.

By the way, when buying a loader, it is important to take into account not only its efficiency, but also performance. The task of the buyer is the choice of equipment that quickly and accurately operates with cargo without unnecessary fuel costs. Such requirements are responsible for loaders with an improved hydraulic. For example, if you have hydraulic system high pressure The technique has an increased lifting speed / descent of loaded forks. If the hydraulics is equipped with dual pumps, lifting equipment and steering Machines work independently of each other. Also, an efficient engineering solution is a hydraulic pump with periodic oil supply to hydraulic.

Leading forklift manufacturers introduce innovations in every generation of technology, improving performance features its products. Recently, China has successfully compete with recognized world leaders. For example, on fuel consumption and performance, Chinese Bull forklifts manufactured at the Heli authoritative concern plants are comparable to European, American and Japanese classmates. At the same time, the cars are much cheaper, which attracts Russian consumers.

Calculation of fuel consumption standards for an hour, shift, for a month, etc.

O. Shevtsova

According to estimates russian market Forklifts with counterweight technology with engine internal combustion and electric drive is 68%: 32%. The predominance of auto-loader is due to the fact that industrialization processes (development of industry and construction) in our country are still a big stimulus for the market of loading equipment than the development of warehouse logistics. That is, at present, the main consumers of loaders in Russia are enterprises and companies of different industries, and not logistics, although the latter develops rather rapid pace.

Play a certain role and features of the equipment: work a significant part of the year low temperatures on the open sites, far from the ideal state of the coating, and so on. The diesel engine requires smaller costs when buying, maintaining, work is reliable, easy to maintain, powerful and efficient energy source. In addition, such machines are produced in a wide range of lifting capacity (up to 43 tons) and with a large assortment hinged equipment To perform a variety of technological operations, and the exhaust gas purification system ( saw filters) used in recent models leading manufacturers reduce harmful emissions At 70 ... 98%, which allows you to work and indoors.

One of the characteristics of the "ownership price" diesel loader is fuel consumption. In the consolidated table of technical characteristics, the manufacturer often indicates the specific consumption of fuel in grams per unit of power measurement unit (hp or kW). Meanwhile, this parameter does not give an idea of \u200b\u200bhow much in practice will "eat" this engineWhat amount of fuel will be spent in an hour, shift, for a month, etc. It uses special techniques for this, with one of which we will introduce readers.

How to calculate fuel consumption rate

Suppose the loader is already purchased and put on the balance of the enterprise. Accounting requests from the employees of the official dealer service calculation data on the write-off of fuel.

Those in turn determine the rate of fuel consumption by the formula

Q \u003d n q / (1000 r k 1),

where Q. - specific fuel consumption (data from the power curve);

N. - Power, hp (data from the power curve);

R. - density of diesel fuel (0.85 kg / dm 3);

k 1. - The coefficient characterizing the percentage time of operation at the maximum speed of rotation of the engine crankshaft.

Engine power and specific fuel consumption are taken from the instructions for maintenance Engine that uses official dealerserving service. In it, the data is made in the form of a fuel consumption curve, which is built by engineers of the manufacturer's engineers based on the results of the engine testing in various modes, including at maximum turns.

In practice, in order to achieve the maximum engine speed, we squeeze the accelerator pedal until it stops, we blend it literally "to the floor". In this mode, the machine accelerates, rides to rise with the load or lifts the load to the maximum height with the maximum speed. It is clear that so the loader does not work all shift, but only some part of it. Hence the need to use the K1 coefficient. In fact, the coefficient characterizing the work on maximum revolutions is the indicator of the specifics of the enterprise technological cycle.

Consider two examples.

Example 1. With round-the-clock work of the enterprise, the shipment of products actually passes twice a day at 2 h, that is, only 4 h from the 24th. In these "peak hours", the entire fleet fleet is involved, all access roads are busy, under loading is maximum number trucks. The rest of the time the work shift loaders are operated with minimal or medium intensity.

Example 2. The rented loader operates on unloading wagons and loading the truck almost non-stop 8-hour shift, but it does not overcome the bias, does not use the maximum height of the lift, since the served sites are located at 1.5 ... 2 m from the floor. The maximum engine speed is used in this case, when the loader accelerates, overcoming the distance between the loading and unloading zones, which is about a third of its working time.

As you can see, the coefficient characterizing the percentage ratio of operation with the maximum and minimum load will in the second case there will be more. To accurately determine its magnitude, it is necessary to carry out measurements of time when the loader raises the maximum load when it moves, overcoming resistance road coat (overclocking, movement on the slope, etc.). By summing these temporary indicators, we get the time of operation during which the engine is experiencing maximum loads, and subtract it from the total duration of the work shift. The ratio of operation with minimal load (70%) by the time of operation with the maximum load (30%) is the required coefficient. So, if the time of operation with the maximum load amounted to 30% of the duration of the shift, the coefficient will be 2.3 (70%: 30%) \u003d 2.3.

For example, for the 4D92E engine with a capacity of 33.8 hp (Komatsu Loader of the AX50 series) operating at maximum revolutions for 1/3 of working time, the calculated indicators according to the formula will be 3.49 l / Moto-H:

Q \u003d 33.8 × 202 / (1000 × 0.85 × 2,3) \u003d 3.49 l / moto-h.

What in practice?

It is understandable and visuality is such an indicator as the amount of fuel in liters spent in the hour of operation of technicians by exploiting enterprises and organizations. It should also be noted here that theoretical calculations of fuel consumption at the loader will always be somewhat higher than in practice, since in real conditions the load on the engine is less than in test conditions. Therefore, it is necessary to conduct control measurements to determine the fuel consumption.

A kind of timing was performed for the Komatsu diesel 3-tonner of the VX50 series (FD30T-16), operating from 12 to 21 h, i.e. 9 hours daily. Technological operations: unloading trucks, moving goods into wagons. The readings of the fuel consumption for the engine on the FD30T-16 Komatsu 4D94LE loader were 2.5 l / h.

For a number of other companies, we obtained the following fuel consumption data by loader Komatsu:

• 1.7 l / h - loader with a carrying capacity (g / n) 1.5 ... 1.8 T (4D92E engine), change 24 hours;
• 2.5 l / h - Loader g / n 2 ... 2.5 t (engine 4D94e), change 24 hours;
• 2.2 l / h - Loader g / n 1,5 t (4D92E engine), shift 8 hours;
• 2.9 ... 2.95 l / h - Loader g / n 1.8 tons (4D92E engine), shift 8 h or more.

Thus, the fuel consumption indicators are influenced by such parameters such as power and specific engine fuel consumption, the duration of working time when it works on maximum speed. Machines with great mileage or, on the contrary, new, but not yet passed running, show a greater fuel consumption than those on which the engine is adjusted. Fuel consumption is higher than usual shown machines during special testing when working with a maximum load (for example, with a 1,5-ton loader, a 1,5-ton loader can show flow to 5 ... 6 l / h during test.

What makes manufacturers of technology to reduce fuel consumption

By the way, low fuel consumption is not an end in itself, it is important in a high performance complex, the dynamics of the machine, i.e., when evaluating, how good and quickly the machine will respond when performing working operations, how confidently overcomes the rise and so on. What makes manufacturers make to increase the speed of technological operations, leaving at the same level fuel consumption? For example, equip the machines with a hydraulic high-pressure system, and this allows you to increase the rate of lifting. True, increasing the rate of transmission of dynamic impact, it is necessary to ensure the tightness of the contour (high pressure hoses, hoses, etc.) due to the use of high-quality materials. In order for the fork loaders of one of the grades of the economy class by this indicator to compete with more expensive machinesManufacturer will have to apply a better transmitting device. Accordingly, this will lead to the rise in the cost of the machine, and that will lose its main competitive advantage - price availability.

Another engineering reception is the separation of the hydraulic flow on the steering and on the lifting equipment. In the last series of forklifts Komatsu VKH50 (g / n 2 ... 3 t), a hydraulic system of the Super System is used: dual pumps ensure the operation of the steering and the lifting mechanism independently of each other. The result is a steady rise on idling At maximum load, low fuel consumption.

New diesel loader Still GmbH RX70 is equipped with a hybrid drive, consumes 2.5 liters of fuel per hour (measurements were carried out on the basis of the model of g / n 2,5 t according to the new criteria of VDI 2198, i.e. after 60 working cycles per hour). The technology of a hybrid drive involves the installation of diesel or gas engine and electric motor. In this model of the loader, a hydraulic pump was applied, which supplies oil into the hydraulic system as needed, and not constantly, which also contributes to fuel economy.

Creators of the DFG / TFG 316-320 series of the DFG / TFG 316-320 series of 1,6 ... 2 ton, speaking of the advantages of the engine, emphasize that the industrial engine of the large volume (2.5-liter diesel engine of 28 kW) is already on low revolutions Develops the maximum torque, which also allows you to provide low fuel consumption. For engine PERKINS 404C.22 DFG 16 AS models Manufacturer Indicates fuel consumption 3.1 l / h along VDI cycle.

Due to the use of a high torque engine and a steering system with a hydrostatic transmission in the Linde H16D diesel loader (VVV / ADG engine), fuel consumption is 2.3 l / h along the VDI cycle.

In a number of design developments, almost all leading manufacturers of loaders have models designed to work on hydrogen fuel. It is clear that high-tech models are worth 20 ... 30% more expensive than basic. And yet this area is given serious attention as a peculiar intellectual contribution to the development of the brand.

Diesel forklifts - the most popular type of warehouse equipment among russian buyers. It is easily explained. Engines operating on diesel fuel are easily fit at minus temperatures, differ in power and suitable for equipment with a carrying capacity of over 4 thousand kg. Market leaders are introduced into their equipment innovative technologies Cleaning from exhaust gases. This allows you to use their diesel loaders including indoors.

Another argument in favor of diesel engineering is economy. It is significantly cheaper than the loaders on the gasoline engine and warehouse electrical equipment and is distinguished by a low cost of ownership. The last diesel loaders are obliged low flow Fuel. The manufacturer calculates this parameter and indicates it in the documentation attached to the equipment, as a specific fuel consumption. Of course, these are averaged data, and they may differ from the actual consumption of fuel - because the conditions of operation of the equipment are different. Calculate an objective fuel consumption indicator for a certain period (working shift, month, quarter, etc.) helps a special technique.

How the normized fuel consumption of the loader is calculated

The company's accountants below are used to obtain data necessary to write off the fuel when the technique is listed on the organization's balance sheet.

Q \u003d NQ / (1000RK 1), where:

Q is the regulatory consumption of fuel (calculated in l in motochas).

N - engine power in l. with.

q - specific fuel consumption (according to the manufacturer);

R is the value of the density of the diesel fuel (0.85 kg / dm3),

k 1 - the ratio of periods of operation of the motor in the standard and maximum modes.

The K 1 coefficient is a specific workflow rate. In practice, the forklift motor operates on the limit revolutions only part of the work shift: when overclocking, movement on maximum speed, lifting cargo for the maximum height, movement up the slope with the load. Suppose 60 percent of the shift duration loader works in standard mode. 40 percent - with maximum load. In this case, the K 1 coefficient is calculated as the ratio of the first indicator to the second: 60/40 \u003d 1.5. After that, it is already easy to calculate the rate of fuel consumption.

Consider the calculation methodology on the example of the Chinese forklift BullFD35. Its carrying capacity is 3500 kg. Loader is equipped japanese engine ISUZUC240 with a capacity of 35.4 liters. with. Manufactured by the manufacturer Specific fuel consumption is 202 g / kW per hour. 25 percent of the working time, the engine works on limiting turnover. The real fuel consumption indicator is calculated as:

Q \u003d 35.4 * 202 / (1000 * 0.85 * 1.5) \u003d 5.6 l / motochas.

However, the calculated data may not coincide with the actual. Loaders without a return or after long-term operation in practice, fuel consumption will be higher. The flow rate of diesel fuel and in the operation of warehouse equipment in the avral mode.

How manufacturers optimize diesel fuel consumption

So, the diesel power is primarily affected by the power of the engine, the specific indicator declared by the manufacturer, and the intensity of the loader operation during the shift. Therefore, the buyer has already at the stage of acquiring equipment can roughly calculate this parameter.

Of course, the choice is determined not only by the engineering of the model, but also its productivity. The ultimate goal of the acquisition of the loader is the organization of operational and accurate loading and unloading works with minimal financial costs. In solving such a task, loaders with an updated hydraulic system help. Thus, high pressure hydraulics increases the speed of the water with a cargo. The dual pump of the hydraulic system allows you to autonomously work the lifting mechanism and steering loader. Another progressive technology is a hydraulic pump with periodic oil supply to the system.

The world's largest manufacturers of warehouse equipment update every generation of their products by improving it. performance With the help of advanced engineering solutions. In recent years, the Chinese warehouse technique has been actively conquering in the global market. For example, the Chinese diesel loaders of the company BULL, manufactured in production famous company Heli, the consumption of fuel and productivity is confidently competed with Japanese, European and American brethren. At the same time, their cost is significantly lower, which, of course, adds points to them in the eyes of Russian consumers.

Gasoline Loaders - Reliable Equipment for Open Warehouse

A wide variety of warehouse equipment makes it possible to flexibly optimize the production process of almost any warehouse, taking into account all the characteristics of the cargo and the cost of its unloading and loading. This article is written to help those who would like to better figure out the features of gasoline loaders, in particular, regarding the sphere of their application, advantages and costs associated with their operation.

Using Loaders S. gasoline engine most justified if the work is performed outside the premises, or if we are talking about warehouses big size With high ceilings and a good ventilation system. Gasoline loaders are rather unpretentious and reliably cope with work in a polluted, dusty and even chemically aggressive environment.

If we take into account the climatic factors in the field of operation of technology, thanks to the built-in ability to increase the temperature of the cylinders before starting the engine by heating them, the loaders with a gasoline engine are excellent even for areas with fairly cold winters.

The following marks are currently the most popular: Toyota, Nissan, Mitsubishi, TCM, Komatsu, Clark.

Assessment of any loader includes, in addition to the lifting capacity and other characteristics, finding out the type of engine installed on the special equipment. The fact is that it is from the drive to a large extent that much depends, including the applicability of equipment in certain conditions, as well as the cost of operation and service.

Gasoline loader engine

The key difference between the gasoline engine from the diesel is in the method of fuel ignition. In the case of gasoline, it is a mixture with air electric ignition. In the diesel engine, the fuel is self-proposal due to a strong compression of the air mixture. To date, the leaders of the production of high-quality and reliable gasoline engines for loaders are toyota company, Nissan, Mitsubishi.

For the most part and the advantages, and the disadvantages of a model of the loader are largely associated with the type of actuator, and gasoline loaders are no exception.

Benefits of the loaders with a gasoline engine

Give below a number of moments that are usually crucial when choosing a gasoline loader:

• The cost of loaders with a gasoline engine is on average lower than diesel or electrical equipment.
• Possibility additional installation gas equipment Expands the scope of application of gasoline loaders to work with food, medical and other industries in the territory of closed warehouses.
• Easier in operation and maintenance (compared to diesel loaders).
• The gasoline loader engine produces less noise when working than diesel.
• The widespread availability of fuel (in contrast to gas loaders).
• Long-term uninterrupted operation (in contrast to electric loaders in need of periodic recharging).
• Lower demand for fuel quality (compared to diesel).
• High dynamism, the ability to work confidently at high revolutions (Especially important for use conditions when speed is needed more than a uniform thrust).

Loads for loaders with a gasoline engine

Perfect technology does not happen, but knowing the "narrow" places of loaders can provide the best performance in certain conditions. As a rule, special equipment with gasoline drive It has the following disadvantages:

• Increased cost of fuel.
• Fuel consumption is higher than in diesel engineering.
• Little engine motor test than diesel.
• The presence of harmful exhausts.

The environmental safety of gasoline loaders increases by setting a different kind of neutralizing equipment, catalysts and soot trap, allowing to largely reduce the concentration of harmful components in the exhaust gases. It should be remembered that such an additional equipment serves as long as the higher the quality of the gasoline poured into the tank.

Gasoline loader fuel consumption

Of course, know how much gasoline loader requires fuel needed, especially choosing technique when buying. But, of course, data on fuel consumption will be used and later during the entire operational period. We give below two methods of calculations.

Simplified calculation of fuel consumption

It is often quite a completely small amount of data to navigate in the whole in terms of the indicators for different loaders.

Q \u003d n q,

• N is the regulatory power of the gasoline engine, l. with. (Horse power);
• q - Specific fuel consumption, g / l. with. h (the number of grams of gasoline, spent on one horsepower per hour of work).

Both parameters (power and specific consumption) can be found in the documentation for the loader. If you want to translate kW in " horsepower»You can use the ratio: 1 l. with. \u003d 0.736 kW.

The results of the calculations can be used for an approximate comparison of fuel need different models Gasoline loaders when choosing. In practice, the consumption of gasoline depends on the set of moments complicating calculations.

Calculation of fuel consumption taking into account the operational regime and the mass of cargo

Loading equipment works with quite a variety of operations. And the use of maximum power is carried out not all the time. Moreover, most of the work shift engine of the loader works with small efficiency, on small revolutions. It is too difficult to clearly define, as a prevailing, some kind of standard mode of operation, which specifies the use of the drive capabilities.

Fuel consumption depends mostly precisely from the required power at the output. And the task is significantly complicated by the fact that the efficiency of the engine is not at all permanent - gasoline is consumed not proportionately issued power.

Everything else, fuel consumption is in meaningful dependence on the quality of fuel and lubricants, drive wear and adjustment, as well as from weather and other conditions.

Therefore, in practice, for more accurate calculations, it is desirable to use a formula that takes into account more factors, in particular the intensity of the mode of operation and the nature of the lifting goods. And the results of calculating the number of gasoline per hour of the loader work is much more practical in liters than in grams.

Quite exactly the required volume of gasoline consumption can be calculated according to the following formula:

Q \u003d n q m e / (1000 g),

• N is the regulatory power of the gasoline engine, l. with.;
• q - Specific fuel consumption, g / l. with. h;
• M is a coefficient that takes into account the mass of the cargo (is 0.3 - for light cargo; 0.4 - for cargo of medium mass; 0.5 - for heavy);
• E is a coefficient depending on the nature of the operation of the gasoline loader (0.6 - with light operations; 0.75 - with medium loads; 0.9 - in heavy operation);
• G is the average gasoline density at 20 ° C (for AI-92 - 0.76 kg / dm 3, for AI-93 - 0.745 kg / dm 3; for AI-95 - 0.75 kg / dm 3).

Naturally, the most accurate data on fuel consumption by a gasoline loader is obtained at periodic control measurements during operation.

The table below demonstrates data on fuel consumption on the example of equipped Nissan various models of TCM gasoline loaders depending on the drive power and lifting capacity:

When choosing used loaders, buyers often have difficulties with the definition of real wear. The fact is that after the entire complex of repair and restoration work, characteristic of pre-sale preparation, is very difficult to determine the actual degree of wornity with sufficient accuracy, since the loaders are no longer too different from new machines. It confuses and significantly complicates the choice. Nevertheless, some guidelines in the selection of special equipment are still possible.

It is known that most of the assemblies of loaders equipped with internal combustion engines are usually wear out quite evenly. In any case, this is how it happens when properly organized and regular service. Accordingly, inspecting the equipment of the gasoline loader on the wear of the main systems, you can still be confident in your impressions.

Another nuance, able to help when choosing, concerns the ratio of engine motor and price, if we are talking about comparing diesel and gasoline loaders. It would seem that the Diesel resource is higher, and with equal wear, it is more preferable than the loader with a gasoline engine, however, the resource supply is not always a decisive factor, especially on the background of a clearly greater cost of diesel engineering.

And on the basis of the uniform wear of most nodes, in addition to the purchase price, it is necessary to take into account the cost of future service, repairs. Which, for diesel loaders, they are seriously different in the big face.

For example, change or repaired the TNLD ( fuel pump High pressure) diesel engine will cost about $ 1000. While replacing the benoline drive carburetor, is usually worth $ 50. And even if you have to buy a new carburetor, most likely, it will be possible to meet in the amount of up to $ 500.

In addition, good specialist For maintenance diesel engines - Sufficient rarity. Plus not every driver has the necessary experience for properly operation diesel loader. And these reasons may well change the balance to prefer technique with gasoline drive.

I would also like to pay attention to that if the gasoline drive loader was initially equipped with gas-filled equipment, its actual motor is most likely higher than that of technique without such a modification.

With all unpretentiousness, the gasoline loader is still a high-precision technique, and although its design is considered simpler than that of a diesel engine, only the organization of the right service and timely technical inspections will help to do without sudden serious repairs and increase the service life to the highest possible values.