To improve the anti-rollover capacity of a counterbalanced forklift, a two-stage rollover dynamic model is established on the basis of the forklift structure. Stable zones are divided according to the two-stage lateral load transfer rate: stable region, relatively stable region, dangerous zone and abnormal dangerous zone. An anti-rollover layered control strategy based on stable zone partition is proposed, and different anti-rollover control actuators are selected: dynamic balance weight, anti-rollover cylinder and steering cylinder. Anti-rollover controllers consist of the upper stable region identification controller, the middle-level controller based on model predictive control (MPC) and the lower layer executive controller. The upper stable region identification controller performs stable zone recognition based on the two-stage lateral load transfer rate. The middle-level MPC controller calculates the required control torque with the body’s lateral angle and yaw rate as the control objectives. The lower layer executive controller controls the balance weight, anti-rollover cylinder and the steering cylinder according to the improved chain incremental allocation method to meet the target control torque. Simulation and real vehicle tests based on MATLAB/Simulink show that the anti-rollover control based on stable zone partition can greatly reduce the risk of forklift rollover and improve the forklift safety.

为提高平衡重式叉车的抗侧翻能力，在叉车结构基础上建立了两级侧翻动力学模型。稳定区根据横向载荷传递速率分为两级：稳定区、相对稳定区、危险区和异常危险区。提出了一种基于稳定区划分的防侧翻分层控制策略，选择了不同的防侧翻控制执行器：动平衡重、防侧翻油缸和转向油缸。防侧翻控制器由上层稳定区域识别控制器、基于模型预测控制（MPC）的中层控制器和下层执行控制器组成。上稳定区识别控制器根据两阶段横向荷载传递率进行稳定区识别。中级MPC控制器以车身侧向角和横摆角速度为控制目标，计算出所需的控制力矩。下层执行控制器根据改进的链条增量分配方法控制平衡重、防侧翻油缸和转向油缸，以满足目标控制扭矩。基于MATLAB/Simulink的仿真和实车测试表明，基于稳定区划分的防侧翻控制可以大大降低叉车侧翻风险，提高叉车安全性。下层执行控制器根据改进的链条增量分配方法控制平衡重、防侧翻油缸和转向油缸，以满足目标控制扭矩。基于MATLAB/Simulink的仿真和实车测试表明，基于稳定区划分的防侧翻控制可以大大降低叉车侧翻风险，提高叉车安全性。下层执行控制器根据改进的链条增量分配方法控制平衡重、防侧翻油缸和转向油缸，以满足目标控制扭矩。基于MATLAB/Simulink的仿真和实车测试表明，基于稳定区划分的防侧翻控制可以大大降低叉车侧翻风险，提高叉车安全性。