Real-time simulation model for dynamic analysis of three-wheel counterbalance forklift

Modern multibody simulation techniques enable the explicit description of complex mechanical systems such as mobile and industrial machinery into relevant equations of motion. The subsequent solution of the equations of motion can lead to simulation in real-time. Presently, real-time simulation models based on multibody dynamics can account for a large number of rigid and flexible bodies as well as contact descriptions. It enables the inclusion of physical phenomena and user feelings associated with multibody systems in the real-time simulation. These specifications can be used in a number of product processes including user training and product development. The present study applies real-time multibody simulation to a three-wheel, two-ton counterbalance forklift. The forklift simulation model includes rigid bodies, joints, a contact model, friction forces, power transmission, and a steering mechanism. The study reports aspects associated with forklift performance such as speed, speed reduction around a curved path, mast wobbling, maximum lifting capacity, and vibrations during the lift. The simulation model is verified by comparing the speed, acceleration, mast lift and tilt speeds with the measurements of a reference forklift.