The anti-rollover control actuator of a counterbalance forklift is determined by analysing its structural characteristics and roll-over mechanism. An anti-rollover control strategy for counterbalance forklifts based on extension decision is proposed, and the anti-rollover extension hierarchical controller, including the upper-layer extension and lower-layer execution controls, is designed. The upper-layer extension controller divides the forklift anti-rollover control domain into three types, namely, classical domain, extension domain and non-domain, and determines the weight coefficient of the lower-layer execution controller. The lower-layer execution controller receives the weight coefficient determined by the upper-layer extension controller, controls the weight distribution on the yaw rate and lateral acceleration controllers and executes the command to obtain the anti-rollover extension control of the counterbalance forklift. The European standard condition simulation and real vehicle test results show that the anti-rollover control strategy of the counterbalance forklift based on the extension decision can effectively reduce the forklift roll range under high-speed emergency steering conditions, prevent the forklift from rolling over and improve the stability and active safety of the counterbalance forklift.
This is a preview of subscription content, access via your institution.
Buy single article
Instant access to the full article PDF.
Price excludes VAT (USA)
Tax calculation will be finalised during checkout.
- a y :
lateral acceleration, m/s2
- ω r :
yaw rate, rad/s
- θ :
body roll angle
- » :
the weight coefficients of the lower yaw rate
- μ :
the weight coefficients of lateral acceleration
- F :
- S :
displacement of the steering cylinder link, m
- S(x, y) :
feature status of x and Y
- a i :
lateral acceleration of the classical domain boundary
- ω i :
yaw rate of the classical domain boundary
- P i :
- ρ(x, y):
classical or extension domain
- K (S):
the correlation function
- k i :
- K i :
- K p :
- K d :
Acarman, T. and Özgüner, Ü. (2006). Rollover prevention for heavy trucks using frequency shaped sliding mode control. Vehicle System Dynamics 44, 10, 737–762.
Alberding, M. B., Tjønnås, J. and Johansen, T. A. (2000). Integration of vehicle yaw stabilisation and rollover prevention through nonlinear hierarchical control allocation. Vehicle System Dynamics 52, 12, 1607–1621.
Chou, T. and Chu, T. W. (2014). An improvement in rollover detection of articulated vehicles using the grey system theory. Vehicle System Dynamics 52, 5, 679–703.
Chen, Z., Huang, Z., Li, D., Jing, S. and Tao, Z. (2019). Research on a rollover protective technique for a vibroseis truck based on reliability analysis. Int. J. Heavy Vehicle Systems 26, 1, 95–117.
Felez, J. and Bermejo, A. (2018). Design of a counterbalance forklift based on a predictive anti-tip-over controller. Integrated Computer-Aided Engineering 25, 3, 273–288.
Feng, S. L., Meng, G. W., Si, J. D., Tong, F. H. and Lin, S. (2012). Dynamic design method of engineering vehicle rollover protective structure. J. Jilin University (Engineering and Technology Edition) 42, 4, 828–833.
Gaspar, P., Szaszi, I. and Bokor, J. (2004). The design of a combined control structure to prevent the rollover of heavy vehicles. European J. Control 10, 2, 148–162.
Gáspár, P., Szaszi, I. and Bokor, J. (2005). Reconfigurable control structure to prevent the rollover of heavy vehicles. Control Engineering Practice 13, 6, 699–711.
Hrovat, D., Tseng, E. and Fodor, M. (2012). Tripped rollover mitigation and prevention systems and methods. U.S. Patent 8,108,104.
Huang, J. and Xiao, B. (2019). Variable steering ratio design and handling stability research for steer-by-wire forklift. Advances in Mechanical Engineering 11, 3, 1687814018822898.
Jalali, M., Hashemi, E., Khajepour, A., Chen, S. K. and Litkouhi, B. (2018). A combined-slip predictive control of vehicle stability with experimental verification. Vehicle System Dynamics 56, 2, 319–340.
Jin, Z., Zhang, L., Zhang, J. and Khajepour, A. (2016). Stability and optimised H∞ control of tripped and untripped vehicle rollover. Vehicle System Dynamics. 54, 10, 1405–1427.
Kim, J. B., Shin, W. and Park, J. H. (2015). Stability Analysis of Counterbalanced Forklift Trucks. J. Korean Society of Safety 30, 2, 1–8.
Larish, C., Piyabongkarn, D., Tsourapas, V. and Rajamani, R. (2013). A new predictive lateral load transfer ratio for rollover prevention systems. IEEE Trans. Vehicular Technology 62, 7, 2928–2936.
Marsh, S. M. and Fosbroke, D. E. (2015). Trends of occupational fatalities involving machines, United States, 1992–2010. J. Industrial Medicine 58, 11, 1160–1173.
Milanowicz, M., Budziszewski, P. and Kędzior, K. (2018). Numerical analysis of passive safety systems in forklift trucks. Safety Science, 101, 98–107.
Moshchuk, N. K., Chen, S. K. and Chen, C. F. (2010). Roll stability indicator for vehicle rollover control. U.S. Patent No. 7,788,007.
Pan, D. and Jin, Y. H. (1996). Exploration and research on extension control. Control Theory and Applications 13, 3, 305–311.
Sampson, D. J. M., McKevitt, G. and Cebon, D. (1999). The development of an active roll control system for heavy vehicles. Vehicle System Dynamics 33, Sup 1, 704–715.
Tao, P., Jin, X., Wu, H. and Wu, K. (2018) Research on Control Strategy of the Side Forklift Steering Movement Stability and it’s Simulation Analysis. In 2018 5th Int. Conf. Information Science and Control Engineering. Zhengzhou, China.
Wang, M., Zhang, Y., Ji, T. and Wang, X. (2016). Grey prediction control and extension assessment for turbine governing system. IET Generation, Transmission & Distribution 10, 11, 2601–2605.
Xia, G., Chen, W. W. and Zhao, L. F. (2015). Integrated control of counterbalanced forklift truck chassis based on wavelet network dynamic inverse internal model control. J. Mechanical Engineering 51, 18, 126–135.
Yakub, F. and Mori, Y. (2015). Enhancing rollover prevention and vehicle stability of heavy vehicle under disturbance effect. Applied Mechanics & Materials 695, 596–600.
Yim, S. (2012). Design of a robust controller for rollover prevention with active suspension and differential braking. J. Mechanical Science and Technology 26, 1, 213–222.
Yim, S. J., Yoon, J. Y., Cho, W. K. and Yi, K. S. (2011). An investigation on rollover prevention systems: unified chassis control versus electronic stability control with active anti-roll bar. Proc. Institution of Mechanical Engineers, Part D: J. Automobile Engineering 225, 1, 1–14.
Yoon, J., Cho, W., Kang, J., Koo, B. and Yi, K. (2010). Design and evaluation of a unified chassis control system for rollover prevention and vehicle stability improvement on a virtual test track. Control Engineering Practice 18, 6, 585–597.
Yoshihiro, S., Junhoi, H., Masahiko, A., Lin, S., Takahata, R. and Mukaide, N. (2013). Study on rollover prevention of heavy-duty vehicles by using flywheel energy storage systems. Proc. FISITA 2012 World Automotive Cong. Springer Science & Business Media. Berlin, Germany.
Zhang, Z. and Xiao, B. (2020). The Influence of Cargo Moving and Sliding Mode Control Strategy for Forklift. IEEE Access, 8, 16637–16646.
Zhao, W., Fan, M., Wang, C., Jin, Z. and Li, Y. (2019). H∞/extension stability control of automotive active front steering system. Mechanical Systems and Signal Processing, 115, 621–636.
This study was supported by the National Natural Science Foundation (51875151). The author would like to thank the state funding and all the participants for their assistance.
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
About this article
Cite this article
Xia, G., Li, J., Tang, X. et al. Study on Anti-Rollover of the Counterbalance Forklift Based on Extension Hierarchical Control. Int.J Automot. Technol. 22, 643–656 (2021). https://doi.org/10.1007/s12239-021-0060-0