Patent Application
20140326039
The present invention relates to an apparatus and a method for assisting a hydraulic cylinder stroke initial calibration work.
An excavator, one of work machines, includes a traveling body, an upper swing body capable of swinging on the traveling body, and work equipment, above the upper swing body. The work equipment includes a boom having one end pivotably supported on a base body, an arm having one end pivotably supported at the other end of the boom, and an attachment pivotably supported at the other end of the arm. The boom, the arm, and the attachment are driven by hydraulic cylinders. A stroke of the hydraulic cylinder is measured to detect the position/posture of this work equipment.
For example, Patent Literature 1 discloses an excavator including a position sensor which detects, by rotation of a rotary roller on a cylinder rod, a piston stroke position of the hydraulic cylinder which drives the work equipment. Since minute slippage occurs between this rotary roller and the cylinder rod, an error may be generated between an actual stroke position and the stroke position obtained from a detection result of the position sensor. Therefore, a magnetic force sensor is provided, as a reset sensor, at a reference position on an outer surface of a cylinder tube of the hydraulic cylinder in order to calibrate the stroke position obtained from the detection result of the position sensor at the reference position. The stroke position detected by the position sensor is calibrated every time the piston passes the reference position while operating, thereby achieving accurate position measurement.
Patent Literature 1: Japanese Patent Application Laid-open No. 2006-258730
Patent. Literature 2: Japanese Patent Application Laid-open No. 2007-333628
Meanwhile, the above-described hydraulic cylinder includes the stroke sensor (position sensor), and the reset sensor to calibrate a measurement error of the stroke sensor so as to precisely obtain a stroke length of the hydraulic cylinder. Here, to calibrate this measurement error, it is necessary to carry out an initial calibration work in which a latest calibration reference position of the reset sensor is obtained, and stored.
However, this initial calibration work has been carried out with professional skills, in which a service man operates the work equipment in accordance with a prescribed procedure based on his/her own knowledge or some instruction manual. Accordingly, the service man had so many burdens to carry out the initial calibration work in the prior technique, and there was a problem in that it took a long time for an inexperienced service man to complete the initial calibration work due to failure and the like,
Meanwhile, Patent Literature 2 discloses a technique of displaying, on a monitor screen, changes of a cylinder stroke position which corresponds to a detent release position of detent function by which the work equipment operation lever is held at a predetermined operating stroke position.
The present invention has been achieved in consideration of the above-described circumstances. An object of the present invention is to provide an apparatus and a method for assisting the hydraulic cylinder stroke initial calibration work, whereby assistance for the hydraulic cylinder stroke initial calibration work may be easily carried out.
To overcome the problems and achieve the object, according to the present invention, an apparatus for assisting a hydraulic cylinder stroke initial calibration work, comprises: moving portions rotatably supported in series with respect to a vehicle body; a hydraulic cylinder configured to rotatably support the moving portion and arranged between the vehicle body and the moving portion, or between the moving portions; a stroke sensor mounted on the hydraulic cylinder and configured to measure a stroke length of the hydraulic cylinder; a reset sensor configured to measure a reset reference point to reset a value of the stroke length measured by the stroke sensor; a stroke end detection processing unit configured to detect a stroke end position of the hydraulic cylinder; a calibration processing unit configured to calibrate the measured value of the stroke length when the reset reference point and/or the stroke end position is detected; a monitor configured to display an entire work machine mounted with the hydraulic cylinder when an initial calibration work for the hydraulic cylinder is carried out; and a highlight display processing unit configured to highlight the mowing portion to drive a hydraulic cylinder to be calibrated along with an indication of a driving direction.
According to the present invention, completion of the calibration is displayed when calibration of a hydraulic cylinder to be configured is completed.
According to the present invention, the monitor issues a warning to call attention when an initial calibration work for a hydraulic cylinder is not completed.
According to the present invention, a method for assisting a hydraulic cylinder stroke initial calibration work, wherein when measuring a stroke length of the hydraulic cylinder by a stroke sensor mounted on the hydraulic cylinder, the initial calibration work to calibrate the stroke length is assisted by detecting a reset reference point by a reset sensor and/or a stroke end position of the hydraulic cylinder, and when the hydraulic cylinder initial calibration work is carried out, an entire work machine mounted with the hydraulic cylinder is displayed, and a moving portion to drive a hydraulic cylinder to be calibrated is highlighted along with an indication of a driving direction, and when the calibration of the hydraulic cylinder to be calibrated is completed, completion of the calibration is displayed.
According to the present invention, a warning to call attention is issued when an initial calibration work for a hydraulic cylinder is not completed.
According to the present invention, when the hydraulic cylinder initial calibration work is executed, the monitor is configured to display the entire work machine mounted with the hydraulic cylinder, and to highlight the moving portion to drive the hydraulic cylinder to be calibrated along with the indication of the driving direction. Therefore, the hydraulic cylinder stroke initial calibration work may be simply and easily assisted.
Hereinafter, embodiments of the present invention will be described with reference to the attached drawings. First, embodiments of the present invention will be described. In the following, a description will be given for an excavator, an example of the work machines, to which an idea of the present invention may be applied.
[Entire Structure of Excavator]
As illustrated in
A vehicle body 1a is mainly formed of the lower traveling body 2 and the upper swing body 3. The upper swing body 3 includes a cab 5 on the front left side (vehicle front side), and includes, on the rear side (vehicle rear side) , an engine room 6 for housing an engine, and a counterweight 7. Inside the cab 5, a driver's seat 8 is placed for an operator to be seated. Further, a plurality of antennas 9 is set on both right and left sides of a rear upper surface of the upper swing body 3. Meanwhile, according to this first embodiment, note that front, back, right and left of the vehicle are determined based on the operator who is seated on the driver's seat 8 placed inside the cab 5.
The boom 4a, the arm 4b, and the bucket 4c are rotatably supported in series with respect to the vehicle body 1a. The boom 4a, the arm 4b, and the bucket 4c are moving portions of the vehicle body 1a, the boom 4a, and the arm 4b respectively.
A rotary encoder 20 is mounted on the boom 4a. As described later, the rotary encoder 20 is also mounted on the vehicle body. Rotation of the arm 4b with respect to the boom 4a is transmitted to the rotary encoder 20 mounted on the boom 4a via a lever pivotably supported at the arm 4b. The rotary encoder 20 outputs a pulse signal corresponding to a rotation angle of the arm 4b. Rotation of the boom 4a with respect to the vehicle body 1a is transmitted to the rotary encoder 20 mounted on the vehicle body 1a via the lever pivotably supported at the boom 4a. The rotary encoder 20 outputs a pulse signal corresponding to a rotation angle of the boom 4a.
[Circuit Configuration of Excavator'
A description will be given for a hydraulic circuit of the excavator 1 with reference to
As illustrated in
The boom cylinder 4f is driven, for example, by a variable displacement hydraulic pump 103 as a drive source. The hydraulic pump 103 is driven by an engine 3a. A swash plate 103a of the hydraulic pump 103 is driven by a servo mechanism 104. The servo mechanism 104 operates in accordance with a control signal (electric signal) output from the main controller 32, and the position of the swash plate 103a of the hydraulic pump 103 is changed in accordance with the control signal. Also, an engine driving mechanism 105 of the engine 3a operates in accordance with a control signal (electric signal) output from the main controller 32, and the engine 3a runs at an engine speed according to the control signal.
A discharge port of the hydraulic pump 103 is in communication with the control valve 102 via a discharge oil passage 106. The control valve 102 is in communication with a cap-side oil chamber 40B and a rod-side oil chamber 40H of the boom cylinder 4f via oil passages 107 and 108. The hydraulic oil discharged from the hydraulic pump 103 is supplied to the control valve 102 via the discharge oil passage 106. The hydraulic oil having passed the control valve 102 is supplied to the cap-side oil chamber 40B or the rod-side oil chamber 40H of the boom cylinder 4f via the oil passage 107 or the oil passage 108.
A stroke sensor 10 is mounted on the boom cylinder 4f. The stroke sensor 10 measures a piston stroke. The rotary encoder 20 that functions as a reset sensor is mounted on a portion where one end of the boom 4a of the vehicle body 1a is pivotably supported. The rotary encoder 20 detects a rotation angle of the boom 4a, and outputs a pulse signal according to the rotation angle. The stroke sensor 10 and the rotary encoder 20 are each connected to a measurement controller 30.
A battery 109 is a power source which activates the main controller 32. The measurement controller 30, a standard monitor 31, and an HMI (Human Machine Interface) monitor 33 as an information-oriented construction guidance monitor are electrically connected to the battery 109. The main controller 32 is electrically connected to the battery 109 via an engine key switch 110.
When the engine key switch 110 is turned on, the battery 109 is electrically connected to a start-up motor (not illustrated) of the engine 3a to start the engine 3a, and also the battery 109 is electrically connected to the main controller 32 to activate the main controller 32. When the engine key switch 110 is turned off, the electrical connection between the main controller 32 and the battery 109 is cut off, the engine 3a is stopped, and further the activated main controller 32 is stopped.
The main controller 32, the measurement controller 30, the standard monitor 31, the HMI monitor 33, and a position information detector 19 are mutually connected via a network N inside the vehicle. A switch state signal indicating the switch state (ON/OFF) of the engine key switch 110 is input from the main controller 32 to the measurement controller 30, the standard monitor 31, and the HMI monitor 33 via the network N. In the case where the switch state signal input to the measurement controller 30, the standard monitor 31, and the HMI monitor 33 is ON, the measurement controller 30, the standard monitor 31, and the HMI monitor 33 are activated. In the case where the switch state signal turns to OFF, the measurement controller 30, the standard monitor 31, and the HMI monitor 33 are inactivated.
Operation lever devices 101R and 101L include, for example, operation levers 101Ra and 101La each provided inside the cab 5, and detectors 101Rb and 101Lb. The detectors 101Rb and 101Lb detect operation signals indicating operating directions and operating amounts of the operation levers 101Ra and 101La. The operation signals detected by the detectors 101Rb and 101Lb are input to the main controller 32. The control valve 102 is connected to the main controller 32 via the electric signal line. Here, the operation lever devices 101R and 101L, are a pair of right and left levers. The operation lever device 101R is adapted to operate the boom 4a and the bucket 4c, and the operation lever device 101L is adapted to operate the arm 4b and to swing the upper swing body 3. Note that a swing actuator of the upper swing body 3 is not illustrated.
Here, for example, when the operation lever 101Ra is operated, an operation signal of the operation lever 101Ra is input to the main controller 32, and a control signal to operate the control valve 102 is generated at the main controller 32. This control signal is supplied to the control valve 102 from the main controller 32 via the electric signal line, and the position of the control valve 102 is changed.
[Configuration of Apparatus for Assisting Hydraulic Cylinder Stroke Operation Diagnosis]
Next, a description will be given for an apparatus that assists the hydraulic cylinder stroke operation diagnosis. This apparatus for assisting the hydraulic cylinder stroke operation diagnosis includes the hydraulic cylinders (bucket cylinder 4d, arm cylinder 4e, boom cylinder 4f) , the measurement controller 30, the standard monitor 31, the HMI monitor 33, and the main controller 32.
The stroke sensor 10, which detects a stroke amount of the hydraulic cylinder as a rotation amount, is mounted on each of the arm cylinder 4e and the boom cylinder 4f. Further, the stroke sensor 10 and a magnetic force sensor 20a are mounted on the bucket cylinder 4d.
The rotary encoders 20 are mounted on portions supporting rotary shafts of the arm 4b and the boom 4a. The rotary encoder 20 outputs pulse signals in accordance with rotation amounts (angles) of the arm 4b and the boom 4a. This pulse signal is a square-wave signal.
The stroke sensor 10, the rotary encoder 20, and the magnetic force sensor 20a are electrically connected to the measurement controller 30. The measurement controller 30 includes a calibration processing unit 30b. The calibration processing unit 30b calibrates stroke lengths measured by the respective stroke sensors 10 of the bucket cylinder 4d, the are cylinder 4e, and the boom cylinder 4f, based on the detection signals of the stroke sensor 10, the rotary encoder 20, and the magnetic force sensor 20a. In other words, the stroke lengths measured by the stroke sensors 10 of the bucket cylinder 4d and the arm cylinder 4e are calibrated respectively based on the measurement results of the corresponding rotary encoders 20. Further, the stroke length measured by the stroke sensor 10 of the bucket cylinder 4d is calibrated based on the measurement result of the magnetic force sensor 20a that functions as a reset sensor. Meanwhile, the measurement controller 30 computes the position and posture of the bucket 4c based on the measured stroke lengths of the respective hydraulic cylinders.
Additionally, the measurement controller 30 includes a stroke end detection processing unit 30a. The stroke end detection processing unit 30a detects whether the piston has reached a stroke end, namely, a maximum stroke position or a minimum stroke position. This stroke end detection processing unit 30a determines that the piston has reached the stroke end when the following three conditions are fulfilled: the operation levers 101Ra and 101La are being operated; the stroke position measured by the stroke sensor 10 is, for example, within 3 mm from the stroke end position; and a moving velocity of the piston is minute, such as ±3 mm/sec or less. Note that the moving velocity of the piston is obtained by differentiating the stroke position detected by the stroke sensor 10 by time. Further, whether the piston has reached the stroke end may be also determined by a following condition: an acquired discharge pressure of the hydraulic pump 103 exceeds a predetermined pressure, which is a relief state. Additionally, the calibration processing unit 30b is configured to reset the stroke length in the case where the piston has reached the stroke end as well as in the case where the stroke length is reset by the above-described rotary encoder 20 and the magnetic force sensor 20a which are the reset sensors.
Moreover, the measurement controller 30 includes a malfunction detection processing unit 30c. The malfunction detection processing unit 30c outputs an error indicating a stroke malfunction in the case where a measured stroke length exceeds a predetermined value which is larger than a stroke range defined by the minimum stroke end position and the maximum stroke end position.
The standard monitor 31 includes a calculation unit 31a, a display unit 31b, an operation unit 31c, a notification unit 31d, and a calibration invalidity setting unit 31e. The calculation unit 31a acquires various information by communicating with the main controller 32 and the measurement controller 30, and displays the acquired various information on a display screen of the display unit 31b. Further, the calculation unit 31a outputs various instruction information received from the operation unit 31c to the display unit 31b, other controllers, etc. Additionally, the notification unit 31d is formed of, for example, a buzzer, and outputs a sound and the like in the case where a warning such as an error warning is necessary. The calibration invalidity setting unit 31e sets validity/invalidity of the reset processing executed by the reset sensor which will be described later. The display unit 31b may be a touch panel used also as the operation unit 31c.
The HMI monitor 33 includes a calculation unit 33a, a display unit 33b, an operation unit 33c, a notification unit 33d, and a highlight display processing unit 33e. The calculation unit 33a acquires various information by communicating with the main controller 32 and the measurement controller 30, and displays the acquired various information on a display screen of the display unit 33b. Further, the calculation unit 33a outputs various instruction information received from the operation unit 33c to the display unit 33b, other controllers, etc. Additionally, the notification unit 33d is formed of, for example, a buzzer, and outputs a sound and the like in the case where a warning such as an error warning is necessary. Meanwhile, the display unit 33b of the HMI monitor 33 is formed of a touch panel that is also used as the operation unit 33c, but the display unit 33b and the operation unit 33c may be also formed separately. Further, the HMI monitor 33 assists the initial calibration work by changing the screen for assisting the stroke initial work which, will be described later. Meanwhile, the position information detector 19 computes the position and orientation of the excavator 1 based on position information acquired via the antennas 9, and transmits a computing result to the main controller 32 and the HMI monitor 33, thereby achieving information-oriented construction processing.
[Arrangement and Operation of Stroke Sensor]
Next, a description will be given for the stroke sensor 10 with reference to
As illustrated in
The cylinder rod 4Y contracts as the hydraulic oil is supplied to the rod-side oil chamber 40H and discharged from the cap-side oil chamber 403. Also, the cylinder rod 4Y extends as the hydraulic oil is discharged from the rod-side of chamber 40H and supplied to the cap-side oil chamber 40B. In other words, the cylinder rod 4Y linearly moves in the horizontal direction in the drawing.
A case 14, which covers the stroke sensor 10 and houses the stroke sensor 10 inside thereof, is provided outside the rod-side oil chamber 40H and adjacent to the cylinder head 4W. The case 14 is fastened to the cylinder head 4W, for example, with a bolt, and fixed to the cylinder head 4W.
The stroke sensor 10 includes a rotary roller 11, a rotary central shaft 12, and a rotation sensing portion 13. A surface of the rotary roller 11 contacts a surface of the cylinder rod 4Y, and is arranged so as to freely rotate in accordance with the linear movement of the cylinder rod 4Y. In other words, the linear movement of the cylinder rod 4Y is converted to the rotary movement by the rotary roller 11. The rotary central shaft 12 is arranged so as to be orthogonal to the direction of the linear movement of the cylinder rod 4Y.
The rotation sensing portion 13 is configured to detect a rotation amount (rotation angle) of the rotary roller 11 as an electric signal. The signal indicating the rotation amount (rotation angle) of the rotary roller 11 detected by the rotation sensing portion 13 is transmitted to the measurement controller 30 via the electric signal line, and is converted to a position (stroke position) of the cylinder rod 4Y of the boom cylinder 4f at the measurement controller 30.
As illustrated in
The Hall IC 13b is a magnetic force sensor that detects the magnetic force (magnetic flux density) generated by the magnet 13a as an electric signal. The Hall IC 13b is arranged at a position distant from the magnet 13a by a predetermined distance along the axial direction of the rotary central shaft 12.
The electric signal detected by the Hall IC 13b is transmitted to the measurement controller 30, and the electric signal from the Hall IC 13b is converted, at the measurement controller 30, to the rotation amount of the rotary roller 11, namely a displacement amount (stroke length) of the cylinder rod 4Y of the boom cylinder 4f. More specifically, the displacement amount of the linear movement of the cylinder rod 4Y when the rotary roller 11 makes one rotation is calculated as 2nd, using a rotation radius d of the rotary roller 11.
Here, a relation between the rotation angle of the rotary roller 11 and the electric signal (voltage) detected at the Hall IC 13b is described with reference to
Further, the number of rotations of the rotary roller 11 may be measured by counting the repeated number of a cycle of the electric signal (voltage) output from the Hall IC 13b. Then, the displacement amount (stroke length) of the cylinder rod 4Y of the boom cylinder 4f is measured based on the rotation angle of the rotary roller 11 and the number of rotations of the rotary roller 11.
[Rotary Encoder Operation]
As illustrated in
The disc portion 25 rotates in synchronization with the rotation of the boom 4a with respect to the vehicle body 1a. The four light receiving elements 27a respectively output electric signals in accordance with the amounts of light passing through the first light transmitting portions 25a and the second light transmitting portion 25b by the rotation of the disc portion 25. In accordance with the amounts of light which has passed through the first light transmitting portions 25a and the second light transmitting portion 25b, the light receiving portion 27 converts, to pulse signals, the electric signals output from the first and third light receiving elements 27a mutually spaced apart, and the electric signals output from the second and fourth light receiving elements 27a mutually spaced apart, out of the light receiving elements 27a continuously arranged in series. Subsequently, the light receiving portion 27 outputs the converted pulse signals to the measurement controller 30. The reason why the electric signals from the two light receiving elements 27a are used to generate one pulse signal is to improve robustness of the sensor against the external light, etc.
Also, after the light receiving element 27a outputs the electric signal obtained by the light which has passed through the light transmitting portion 25b, the light receiving portion 27 outputs a corresponding pulse signal. That is to say, the light receiving portion 27 outputs three pulse signals generated in accordance with the rotation angle of the disc portion 25. The pulse signal is output in accordance with the rotation angle of the boom cylinder 4f because the rotation angle of the disc portion 25 is identical to the rotation angle of the boom 4a.
More specifically, the rotary encoder 20 is an incremental encoder, and configured to output a pulse signal of an A-phase, a pulse signal of a B-phase that differs from the A-phase by 90 degrees, and a pulse signal (reference pulse signal) of a Z-phase. The pulse signal of the Z-phase is generated when the light passes through the light transmitting portion 25b at every rotation of the disc portion 25. The measurement controller 30 counts changes of rise and fall of the pulse signals of the A-phase and the B-phase. A count value is proportional to the rotation amount of the boom cylinder 4f. The measurement controller 30 determines a rotation direction of the boom 4a based on a phase difference between the A-phase and the B-phase. Further, a reference position of rotation of the boom 4a is measured by the pulse signal of the Z-phase, and the count value is cleared. An approximate center of an angle range within which the boom 4a may rotate is set as the reference position. The measurement controller 30 monitors a count value of the rotary encoder 20, and stores an arbitrary number of strokes per predetermined count value, and then stores an average value thereof as a reset reference point (intermediate reset position), namely a setting reference position. The pulse signal of the Z-phase is output when the emitted light that has passed through the light transmitting portion 25a corresponding to the Z-phase is shielded by the disc portion 25. That is, the pulse signal of the Z-phase is detected when the pulse signal falls.
The rotary encoder 20 outputs the pulse signal of the Z-phase at an angle substantially in the middle of the angle range within which the boom 4a may rotate. In other words, the rotary encoder 20 outputs the pulse signal of the Z-phase at an approximate center of a stroke range of the boom cylinder 4f. According to the first embodiment, the intermediate reset position of the rotary encoder 20 is as described above, but an arbitrary position except for the stroke end of the hydraulic cylinder may be set as the intermediate reset position.
[Measurement and Calibration of Stroke Length by Measurement Controller]
Next, a description will be given for measurement and calibration of a stroke length by the measurement controller 30. Here, the description will be given with an example of measurement and calibration of a stroke length in the case where the boom 4a moves up and down. As illustrated in
Here, it is not possible to avoid minute slippage occurring between the rotary roller 11 at the stroke sensor 10 and the cylinder rod 4Y. Particularly, a large slippage may occur in the event of the piston 4V colliding against the cylinder tube 4X at the stroke end position, or in the event of any impact given to the cylinder rod 4Y during operation. Due to this slippage, an error (accumulated error due to slippage) is generated between an actual position of the cylinder rod 4Y and a stroke measurement position of the cylinder rod 4Y obtained by a detection result of the stroke sensor 10. Accordingly, the rotary encoder 20 is provided, as the reset sensor, to calibrate the stroke measurement value obtained by the detection result of the stroke sensor 10. The rotary roller 11 and the rotary encoder 20 are connected to the measurement controller 30, and the measurement controller 30 calibrates the stroke length measured by the stroke sensor 10 based on the pulse signal output from the rotary encoder 20.
As illustrated in
Here, note that a reference stroke length L2 is stored in the measurement controller 30 at the time of initial calibration as illustrated in
On the other hand, the measurement controller 30 detects growths of the stroke lengths L1-1 to L1-3 of the boom cylinder 4f corresponding to the count values of the predetermined integral number of times (here, every multiple of 2, three times) of the rotary encoder 20 at the time of detecting the pulse signal of the Z-phase in course of the normal operation of the boom cylinder 4f. The measurement controller 30 stores the stroke lengths L1-1 to L1-3 measured the predetermined number of times, and then stores an average value thereof as a measured stroke length L1.
As described above, the reference stroke length L2 for the count values of the predetermined integral number of times of the rotary encoder 20, which have been calculated and stored by the initial calibration, is stored in the measurement controller 30. The measurement controller 30 calculates a difference L3 between the measured stroke length L1 detected at the time of the normal operation other than the initial calibration, and the reference stroke length L2 detected at the time of the initial calibration.
Subsequently, the measurement controller 30 calibrates the measured value of the stroke sensor 10, using the difference L3 when the boom cylinder 4f stops after the pulse signal of the Z-phase is detected and the measurement is carried out through the normal operation of the boom cylinder 4f.
In other words, the measurement controller 30 detects, by the fall of the Z-phase of the rotary encoder 20, that the boom 4a has reached a reference rotation angle, and further detects rotation of a predetermined angle from the reference rotation angle, and then stores the stroke lengths of the boom cylinder 4f the predetermined number of times during this time, and subsequently stores the average value thereof (measured stroke length L1). Further, the measurement controller compares the measured stroke length L1 with the reference stroke length L2 stored in advance at the time of the initial calibration, and calculates a deviation (difference L3). Then, when the boom 4a stops, the measurement controller executes calibration whereby the deviation is incorporated into the measured value.
[Calibration of Magnetic Force Sensor and Calibration of Stroke Length]
The rotary encoder 20 may not be mounted on the bucket cylinder 4d because the bucket cylinder 4d often comes in contact with water and sediment in comparison with the boom cylinder 4f and the arm cylinder 4e. For this reason, as for the bucket cylinder 4d, the magnetic force sensor 20a is mounted on an outer periphery of the cylinder tube 4X as the reset sensor as described above, and calibration is carried out so as to reset the stroke position obtained from the detection result of the stroke sensor 10 to the intermediate reset position (origin position).
As illustrated in
[Control of Calibration Inhibition Processing at the Time of Starting Power Supply to Device]
Meanwhile, in the case where the work equipment is not in a stable posture under the state of power supply loss in the device in which no stroke length is detected (a state in which no power is supplied to the main controller 30), the stroke length may change due to the dead weight of he work equipment itself. In this case, a deviation occurs between an actual stroke length of the hydraulic cylinder and the stroke length measured immediately after the power supply loss in the device. Here, in the case where there is any deviation between the actual stroke length and the latest measured stroke length at the time of starting power supply to device, the malfunction detection processing unit 30c issues an error warning, for example, with a buzzer, thereby interfering with progress of the work equipment operation.
For this reason, at the time of starting power supply to the device, the measurement controller 30 executes control whereby calibration processing for the stroke length is inhibited until the cylinder rod passes the intermediate reset position of the reset sensor and the reset is executed. In other words, the deviation between the actual stroke length and the latest measured stroke length is allowed until the cylinder rod passes the intermediate reset position of the reset sensor so that no error warning may be issued.
Now, a description will be given for the control procedure for the above-described calibration inhibition processing at the time of starting power supply with reference to
(Initial Value Setting for Rotary Encoder at the Time of Starting Power Supply to Device]
In the above-described measurement controller 30, the strokes are stored a predetermined number of times based on the count values by the A-phase, the B-phase, and the Z-phase of the rotary encoder 20, and the reference stroke length L2 and the measured stroke length L1 are calculated from the average value of the stored values. However, whether the count value immediately after starting the power supply to the measurement controller 30 is correct or not is uncertain until passing the Z-phase and the count value is cleared to zero. Therefore, immediately after starting the power supply to a measurement controller 30, stroke calibration needs to be executed using the count value of the rotary encoder 20 after passing the Z-phase. More specifically, the initial count value of the rotary encoder 20 at the time of starting the power supply to the device is stored in advance in the measurement controller 30. This initial count value may be set to a large value, such as 9000, in the case where the count value of the rotary encoder 20 in the measurement range is ±3000.
As a result, no error warning is issued because the above-described control of the calibration inhibition processing is executed at the time of starting the power supply to the device although the initial count value of the rotary encoder 20 is large at the time of starting the power supply to the device and the deviation between the actual stroke length and the measured stroke length corresponding to the initial count value is large until the cylinder rod passes the reset reference point of the rotary encoder 20.
[Rotary Encoder Reset Invalidation Setting]
In the case where “OFF”, which indicates reset is set invalid, is displayed by the calibration invalidity setting unit 31e, the calibration processing unit 30b does not reset the rotary encoder 20, determining that the calibration processing is invalid.
[Screen for Assisting Stroke Operation Diagnosis by Standard Monitor]
The display unit 31b of the standard monitor 31 is configured to display, on a screen, the values of stroke lengths measured by the stroke sensor 10 and the state of stroke length calibration executed by the calibration processing unit 30b.
In an area E1 on the screen for assisting the boom cylinder stroke operation diagnosis illustrated in
In areas E2 and E3 below the area E1, correction values calibrated at the time of the rotary encoder 20 resetting are displayed. For instance, the difference L3 illustrated in
Further, in an area E4 below the area E3, whether the reset by the rotary encoder 20 is valid or invalid is displayed according to the setting by the calibration invalidity setting unit 31e. When “ON” is displayed, the reset is valid, and when “OFF” is displayed, the reset is invalid. Note that the default display is “ON”. Switching between these “ON” and “OFF” is executed by toggle-operation of a function key F2 provided at the lower portion of the screen corresponding to an area E22. In this case, the function key F2 functions as the calibration invalidity setting unit 31e. Meanwhile, the operation unit 31c is arranged below the display unit 31b and includes six function keys F1 to F6. Conversely, function icons are displayed at the lower portion of the screen corresponding to these six function keys F1 to F6. For example, in this screen, an icon indicating a backward function is displayed in an area E25 at the lower portion of the screen corresponding to the function key F5. Meanwhile, the operation unit 31c includes other special function keys and ten keys. Also, the operation unit 31c may include some keys independent of the standard monitor 31.
Further, in an area E5 below the area E4, the count value of the rotary encoder 20 is displayed in real time. Additionally, in an area E6 below the area E5, the reference stroke length L2 detected at the time of initial calibration is displayed.
Moreover, in an area E7 below the area E6, characters “OK” are highlighted, for example, in red in the case where the rotary encoder 20 could normally calculate a measured stroke length at a time other than the initial calibration. Note that the characters “OK” are lit off when the stroke starts in the reverse direction.
Further, a bar-shaped area E8 stretching sideways is provided below the area E7. The left end of the bar indicates the minimum stroke end position, and the right end of the bar indicates the maximum stroke end position. Further, the stroke length corresponding to the value in the area E1 is transformed to a bar length and displayed. That is, the value of the stroke length measured by the stroke sensor 10 is displayed in a bar graph, and the stroke changes with continuous time are graphically displayed in the area E8. Also, the reference stroke length L2 at the time of initial calibration is indicated at a position E5-1, and an allowable stroke deviation range from this position E5-1 is indicated at positions E5-2 on the bar graph.
Further, in an area E10 on the left side below the area E8, the characters “OK” are highlighted, for example, in red same as the area E7 in the case where the reset is executed at the minimum stroke end. Also, in an area E12 on the right side below the area E8, the characters “OK” are highlighted, for example, in red same as the area E7 in the case where the reset is executed at the maximum stroke end. The highlighted indications in the areas E10 and E12 are lit off in the case where a stroke end state is gotten rid of. Further, when the reset is executed along with the highlighted indications in the areas E7, E10, and E12, the notification unit 31d outputs a sound.
Moreover, the distance between the cylinder pins at the minimum stroke end and the distance between the cylinder pins at the maximum stroke end, which are obtained in advance, are displayed in areas E11 and E13 below the areas E10 and area E12, respectively.
Now, referring to the flowchart illustrated in
After that, it is determined whether the stroke end reset has been normally executed (step S207). In the case where the stroke end reset has been normally executed (step S207, Yes), “OK” is displayed in the corresponding area E10 or E12 (step S208), and the process moves to step S201. In the case where the stroke end reset has not been normally executed (step S207, No), the process moves to step S201.
Additionally, a description will be given specifically regarding the diagnosis using the screen for assisting the stroke operation diagnosis in the case of moving up/down the boom cylinder 4a. Note that in this case, only the boom cylinder 4a is moved up and down as illustrated in
<Stroke Sensor Malfunction Check>
First, since a default indication in the area E4 is “ON”, the function key F2 is pressed and held to switch to “OFF“. Then, the reset by the rotary encoder 20 is set invalid. Subsequently, the boom 4a is moved up with the bucket 4c mounted on.
In this case, the stroke length reaches the maximum stroke end by moving up the boom 4a, and during that time, the distance between the cylinder pins is displayed in real time in the area E1. Further, when the stroke length reaches the maximum stroke end, the stroke end reset is executed, thereby displaying a correction value in the area E2. For example, in the case where this correction value is not several millimeters, it is diagnosed that slippage may have occurred at the stroke sensor 10. Also, since the stroke length change is continuously and graphically displayed with the bar graph in the area E8, the operating condition of the stroke sensor 10 may be diagnosed based on whether the bar graph display movement is smooth or not. Meanwhile, the reset by the rotary encoder 20 may be kept valid instead of being set invalid. However, since the reset by the rotary encoder 20 becomes invalid by the invalidity setting, the diagnosis may be given by a long stroke length graphically displayed in the area E8. This eliminates some extra work, such as disconnection of a connector of the rotary encoder 20, and may provide effective diagnosis.
<Rotary Encoder Malfunction Check>
Additionally, malfunction of the rotary encoder 20 may be diagnosed by checking whether the count value of the rotary encoder 20 displayed in the area E5 has changed, or whether the Z-phase has been input in the area indicated between the positions E5-1 and E5-2 and then the count value of the rotary encoder 20 has been cleared to zero.
<Reset Operation Check: Reset Operation by Stroke End>
In addition, since the reset is executed at the maximum stroke end, “OK” is highlighted in the area E12 with issuance of a reset completion report. As a result, it is diagnosed that the reset at the maximum stroke end is normally executed. In the case where there is neither “OK” highlight indication nor any reset completion report, it may be diagnosed that the reset processing at the stroke end has not been executed.
<Reset Operation Check: Reset Operation by Reset Sensor>
Next, the boom 4a is moved down from the maximum stroke end. In this case, it is diagnosed that the reset processing by the rotary encoder 20 is normally executed by confirming that “OK” is highlighted in the area E7 and the reset completion report is issued at the time of resetting by the rotary encoder 20. In the case where there is neither “OK” highlight indication nor any reset completion report, it may be diagnosed that the reset processing by the rotary encoder 20 is not executed and the rotary encoder 20 is malfunctioning.
With the above-described structure, the stroke operation diagnosis may be easily and simply carried out because at least the value of the stroke length measured by the stroke sensor 10 and the calibration state by the calibration processing unit 30b are displayed on the screen for assisting the stroke operation diagnosis.
Particularly, the changes of the value of stroke length measured by the stroke sensor 10 are graphically displayed with the bar for a continuous time. Therefore, diagnosis for the slippage of the stroke sensor may be carried out in detail.
Also, first reset processing may be executed smoothly without any error warning and the like because the reset is inhibited until the stroke length passes the reset reference point at the time of starting power supply to the device.
Moreover, the initial stroke value of the rotary encoder 20 at the time of starting power supply to the device is set to the value outside the measurement range of the stroke length measured by the stroke sensor 10. Therefore, occurrence of erroneous reset processing due to noise and the like before the first reset processing may be prevented, and the first reset processing may be normally executed.
According to the above-described first embodiment, the stroke operation diagnosis may be simply and easily carried out by outputting the displays of the measured values of the stroke lengths and the calibration state on the screen for assisting the hydraulic cylinder stroke operation diagnosis. According to this second embodiment, an initial calibration work may be easily carried out by displaying a screen for assisting hydraulic cylinder stroke initial operation calibration work on a display unit 33b of an HMI monitor 33.
This initial calibration work is, as described above, to obtain and store a reference stroke length L2 at the time of factory shipment, or at the time of replacement of a reset sensor. When operating work equipment afterward, calibration processing, such as reset of a stroke length, is executed based on the reference stroke length L2 at the time of the initial calibration work. This initial calibration work has been previously executed based on, for example, a service man's own check list.
Here, a description will be given for assisting the initial calibration work carried out based on a flowchart illustrated in
On the screen for assisting the stroke initial calibration work illustrated in
On the screens illustrated in
In the case where the screen
On the screen illustrated in
On the screen Illustrated in
On the screen illustrated in
On the screen illustrated in
On the screen illustrated in
On the screen illustrated in
On the screen illustrated in
Meanwhile, the above-described initial calibration work procedure has been carried out in the following order: the bucket, the arm, and the boom, but the order is not limited thereto. For example, in the case where the initial calibration work is carried out for the arm, the initial calibration work for the arm is completed. Then, the screen illustrated in
Further, in the case where the calibration for the calibration target is not successful (step S306, No), the screen is changed to the screen illustrated in
Further, in the case where the initial calibration work for the hydraulic cylinders has not been completed, the calculation unit 33a issues a warning to call attention via a notification unit 33d. The calculation unit 33a determines whether the initial calibration work has been completed based on whether all of the reference stroke lengths L2 have been written in the measurement controller 30.
Additionally, in the case where the HMI monitor 33 is capable of receiving information from a communication satellite via a position information detector 19 and an antenna 9, the position information detector 19 calculates the position and orientation of the excavator 1 based on the received position information, and outputs the calculated position and orientation as vehicle position information to a main controller 32 and the HMI monitor 33. On the other hand, work position information regarding the horizontal and vertical positions of a cutting edge of the work equipment 4 is acquired at the measurement controller 30, and is output to the main controller 32 and to the HMI monitor 33. The main controller 32 and the HMI monitor 33 may automatically control the cutting edge of the work equipment 4 based on the vehicle position information, the work position information, and further three-dimensional work information. In the event of communication error between the main controller 32 and the HMI monitor 33 during the initial calibration work, a pop-up error screen is displayed on the screen. In this case, the initial calibration is stopped by pressing a button corresponding to “backward” in the pop-up screen, and then the screen returns to the menu screen. In such a case, the initial calibration work using the screen for assisting the stroke initial calibration work is to be carried out again after the error is recovered.
According to this second embodiment, the calculation unit 33a of the HMI monitor 33 changes the screen for assisting the stroke initial calibration work based on detection of the work equipment operating status as well as the input from the operation unit 33c. Further, the calculation unit 33a controls the stroke length L2, i.e., the calibration result, to be written, and also the error screen to be displayed. As a result, the service man operates the work equipment in accordance with the screen for assisting the stroke initial calibration work, and may complete the initial calibration work only by making the simple input from the operation unit 33c.
Meanwhile, according to the above-described first and second embodiments, it is preferable that the reset by the reset sensor or the reset at the stroke end be executed by reset processing for only one-direction stroke, not for bi-directional stroke. This is because the reset processing itself is complicated since the reset position has directivity and the reset processing needs to be executed per direction. For instance, the reset processing for the bucket cylinder 4d and the arm cylinder 4e is to be executed only in a direction the cylinder extends, and the reset processing for the boom cylinder 4f is to be executed only in a direction the cylinder contracts. The reason why the reset processing for the boom cylinder 4f is to be executed in the direction the cylinder contracts is that, since the work equipment position is lower than the ground level, normally the stroke end on the contracting side of the boom cylinder 4f may not be used. Additionally, the screen for assisting an initial configuration work may be displayed on the standard monitor 31 although the screen for assisting the initial calibration work is displayed on the HMI monitor 33 according to the second embodiment.
1 excavator
la vehicle body
2 lower traveling body
2
a crawler
3 upper swing body
3
a engine
4 work equipment
4
a boom
4
b arm
4
c bucket
4
d bucket cylinder
4
e arm cylinder
4
f boom cylinder
4X cylinder tube
4W cylinder head
4Y cylinder rod
4V piston
5 cab
6 engine room
7 counterweight
8 driver's seat
9 antenna
10 stroke sensor
11 rotary roller
12 rotary central shaft
13 rotation sensing portion
13
a magnet
13
b Hall IC
14 case
19 position information detector
20 rotary encoder
20
a magnetic force sensor
25 disc portion
25
a, 25b light transmitting portion
26 light emitting portion
27 light receiving portion
27
a light receiving element
30 measurement controller
30
a stroke end detection processing unit
30
b calibration processing unit
30
c malfunction detection processing unit
31 standard monitor
31
a, 33a calculation unit
31
b, 33b display unit
31
c, 33c operation unit
31
d, 33d notification unit
31
e calibration invalidity setting unit
32 main controller
33 HMI monitor
33
e highlight display processing unit
40H rod-side oil chamber
40B cap-side oil chamber
61 magnetic force sensor
63 magnet
101, 101R, 101L operation lever device
101Ra, 101Rb operation lever
101Rb, 101Lb detector
102 control valve
103 hydraulic pump
103
a swash plate
104 servo mechanism
105 engine driving mechanism
106 discharge oil passage
107, 108 oil passage
109, battery
110 engine key switch
d rotation radius
E1 to E8, E10, E12, E22, E30 to E34 area
F1, F2, F5 function key
L stroke length
measured stroke length
L2 reference stroke length
L3 difference
N network
PA, PB fixing pin
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2013/061120 | 4/12/2013 | WO | 00 | 7/24/2014 |
