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Showing results for tags 'dcg180-330'.
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Model of a Kalmar heavy forklift controlled using SBrick. Features drive, steering, fork elevation, pneumatic mast tilt, kissing forks, tilting cab, 6-cylinder engine, and lights. Functions/features: Drive Steering Fork elevation Mast tilt (pneumatic) Kissing forks (manual) Tilting cab 6-cylinder engine Lights It's been a while since I created a MOC featuring pneumatics, and even longer since I created one with remote-controlled pneumatics. My last MOC with fully remote-controlled pneumatics was from 2015, and that was before I had an SBrick. Ever since I obtained an SBrick I had made two MOCs with remote-controlled pneumatics - a front loader in 2016 and a Volvo EC350E excavator in 2019. However, both projects were cancelled before I finished them. I realized the mast tilting function on a forklift would be a good choice for pneumatics, especially the 7L cylinders. I originally just wanted to make a generic heavy forklift, but when I came across Kalmar's heavy forklifts I was really intrigued by their design so I decided to make the DCG180-330 by Kalmar. My model maximizes functionality while minimizing the amount of moving parts. Most functions have their motors connected directly to their inputs, thus minimizing moving parts and optimizing chassis space. The drive motor is placed directly behind the differential, and gear reduction is done via portal hubs placed horizontally. The servo motor for steering is placed vertically in the chassis, connected directly to the steering linkage without a rack-and-pinion mechanism. This allowed for a large steering lock which is commonplace among forklifts, but this also meant that the chassis around the axle has to be thin so the wheels don't bump into them - in fact, the chassis is only 3 studs wide in the rear but is reinforced well nevertheless. I limited the servo's range of movement in the SBrick profile designer as the steering input can only turn about 45 degrees each way. Even then I still had to add towballs as limiters to the steering mechanism to ensure the wheels don't rub against the rear body panel when turning. In the end, I wish the wheels could steer a little tighter, but the end result is impressive nonetheless. The mast is built with a PF L motor near the top, which drives a worm gear mechanism controlling fork elevation. The section that lifts up is essentially a frame with two sets of racks that contain the fork module sliding freely within it. A single rope pulls the fork up, and the range of movement is pretty impressive. The fork module contains two manually controlled linear actuators that allow the forks to move closer to each other - "kissing forks", as the PDF for the real-life counterpart calls it. The pneumatic system for the mast tilt function is comprised of a PF L motor driving the compressor and a PF M motor controlling the valve. The L motor for the compressor is geared up slightly to allow rapid pumping, and the valve mechanism is placed at the very front of the model to minimize the length of the hoses connecting the valve to the cylinders. Other features include a tilting cab, a 6-cylinder engine with mini pistons below the cab, and lights connected directly to the 8878 battery so the speed dial on it can be used to control their brightness. The 6-cylinder engine is accurate, as one of the engine options on the real Kalmar DCG180-330 is a Cummins B6.7. The fake engine is connected directly to the drivetrain and makes a pretty cool noise while driving. The functions overall worked pretty well - it had decent driving speed, a really good turning radius, the fork elevation had sufficient torque without being painfully slow and the pneumatic mast tilt had good precision. There were some issues - such as the fork elevation mechanism skipping at the racks when under load and the pneumatics not being able to tilt the mast back when the fork is fully raised and the mast is fully tilted in the forward direction. The fork mechanism also lacked a clutch, so it was really important to stop the motor precisely at the moment the fork reaches the bottom to prevent it from stalling. Still, given how well the functions worked overall and how realistic and detailed the bodywork is, I feel like this MOC was a great success. Video: Photos:
Hey guys, here's a new project I'm starting. It is a model of a Kalmar forklift. It will be controlled by SBrick, and it will feature drive, steering, pneumatically tilted mast and lifting fork. The wheels will be Unimog wheels (94.3x38 tires). https://www.kalmarusa.com/4ae438/globalassets/equipment/forklift-trucks/kalmar-forklifts-1852-ton-capacity/kalmar-dcg180-330-forklift-brochure-en-us.pdf So far I have the front axle and the rear portion of the chassis completed. The front axle is driven and is very compact - most of the gear reduction is done in the portal hubs so the drive motor is attached directly behind the frame holding the differential. As for the rear portion, it contains the steered rear axle. Note that the longitudinal beam supporting the chassis is only 3 studs wide directly below the rear axle - the steering lock is very large to ensure a minimal turning radius, and this avoids the wheels from rubbing the chassis when turning while also keeping the chassis sufficiently robust. I also have the compressor (driven by a PF L motor) and the SBrick installed. Note the vertical placement of the motors - I'm trying to make the model as compact as possible, and this avoids using too much longitudinal space. I was concerned that the servo motor might not have enough torque this way as it's driving the steering linkages directly rather than with rack and pinion (it will be limited to 45 degrees of rotation in the SBrick profile designer), but I've seen MOCs that use the servo like this and they work fine. If you have any suggestions for me, please let me know. Photos: