Patent Grant
7845169
The present disclosure relates generally to methods and apparatuses for controlling machines having hydraulic actuation systems, and relates more particularly to a method of compensating for actuator drift in a hydraulic system.
Hydraulic systems are used in a wide variety of machines, such as those used in construction, forestry and manufacturing. Over the years, a wide variety of sophisticated control systems and processes have been developed in an attempt to optimize the versatility, efficiency and overall operation of such hydraulic systems. Despite significant advances, a number of technical challenges continue to plague engineers when it comes to hydraulic system operation and control. One such challenge relates to a phenomenon known as “drift” in hydraulic actuation systems, particularly where the system is used to position and maintain a load at a specified position.
Drift may be understood as the tendency for an actuator, and hence a load positioned therewith, to unintentionally move from a commanded position over time due to leakage from or within the hydraulic system. Operators of certain machines such as loader machines, telehandlers, and similar devices will frequently be called upon to suspend a load at a desired height above the ground. Exemplary operations include accurately positioning a work implement, holding a load such as another machine at a lifted position for maintenance, or placing a load upon a structure. In many hydraulic systems, a certain degree of fluid leakage over time is well known to occur from one portion of the hydraulic system to another such as a fluid tank, or out of the hydraulic system all together. This sort of fluid leakage often results from internal component tolerances, typically necessary to allow freedom of movement. A certain amount of leakage may develop over time as the hydraulics are broken in, even in systems designed to exacting specifications.
A number of strategies addressing hydraulic actuator drift have developed over the years. One such approach utilizes a dedicated anti-drift valve. In one common anti-drift valve strategy, a pilot operated poppet valve is used to hydraulically lock a particular actuator such that fluid leakage is eliminated or at least reduced when the system is used to maintain a load at a specified position. While anti-drift valves have been relatively successful, they tend to have certain disadvantages, including slower cycle times and wasted energy due to pressure drop in the hydraulic system from valve actuation which must be compensated for by increasing hydraulic pressure and/or flow via the system pump. Anti-drift valves also tend to add cost and complexity to the overall system.
Other approaches have focused on tightening clearances of certain components within the hydraulic system to minimize fluid leakage. These strategies have also proven relatively successful, however, they are also accompanied by a number of disadvantages. For instance, tightening clearances on a main valve within a hydraulic system may result in valve sticking, where a valve component expands in response to temperature changes relatively faster than other components in the system. Using relatively tight clearances also tends to require relatively complex manufacturing processes, such as hard grinding, and matching a particular component such as a main valve to a particular hydraulic system. In other words, in systems machined to tight tolerances, it may be more difficult or impossible to random-fit the parts. There is thus a need for an improved means of compensating for leakage induced actuator drift in hydraulic systems.
A known approach to non-leakage induced perturbation of an actuator in a hydraulic system is known from United States Patent Application Publication No. 2005/0011190 A1 to Bitter (“Bitter”). Bitter provides a suspension system for the boom of a loading vehicle, having a hydraulic cylinder for raising and lowering the boom, which is controlled according to an active boom suspension process. Bitter utilizes a control valve to selectively route hydraulic oil to and from a chamber of the hydraulic cylinder. A position sensor is used to sense a position of the hydraulic piston rod, and sense when the rod is disturbed due to an inertial shock on the boom suspension system. A pressure-limiting unit separate from the main valve to the actuator is used to control fluid flow to and from the head-end chamber of the actuator such that the piston rod may be returned to an initial position following its shock-induced displacement. While Bitter may have applications in certain systems, the design is not well suited to remedying slower, undesired displacements of hydraulic cylinders, such as that induced by fluid leakage, and may not perform optimally, or at all, with certain hydraulic systems such as those having a pump with a margin control. Moreover, Bitter's use of a special pressure-limiting unit to achieve its goals increases cost, complexity and manufacturing practicability of the system.
The present disclosure is directed to one or more of the problems or shortcomings set forth above.
In one aspect, the present disclosure provides a method of controlling a machine having a linkage coupled with a hydraulic actuation system. The method includes suspending a load with the linkage, and lowering the load, including leaking hydraulic fluid from at least a portion of the hydraulic actuation system. The method may further include sensing an operating parameter value during lowering the load, and generating a drift compensation control signal responsive to leaking hydraulic fluid.
In another aspect, the present disclosure provides a method of compensating for actuator drift in a hydraulic system. The method includes changing a position of at least one hydraulic actuator of the hydraulic system at least in part by leaking hydraulic fluid from the at least one hydraulic actuator responsive to a load thereon. The method may further include sensing an operating parameter value during changing the position of the at least one hydraulic actuator, and generating a drift compensation control signal responsive to leaking hydraulic fluid.
In still another aspect, the present disclosure provides a machine including a hydraulic system having a valve and at least one hydraulic actuator. An electronic controller is in control communication with the valve, and configured to compensate for leakage induced drift of the at least one hydraulic actuator by selectively commanding adjusting of the valve if actuator drift criteria are satisfied.
Referring to
Hydraulic actuation system 16 will typically include at least one hydraulic actuator 18 such as a linkage lift/raise actuator, and may include at least one other hydraulic actuator 20 such as a bucket tilt/dump actuator. In other embodiments, a conventional linkage may not be used at all, and the present system and process could be configured to support a load coupled directly to an actuator, and compensate for leakage induced drift therein. Thus, descriptions herein of linkage 14 should not be understood to limit the present disclosure to linkages of the type associated with construction machines such as machine 10.
A sensor 22 may be coupled with actuator 18 such that a relative position of linkage 14, and hence a relative position of a load suspended therewith, may be determined. Additional position sensors (not shown) might be included and coupled with actuator 20, or other actuators if more than two actuators are used in system 16. Rather than position sensors associated with the individual hydraulic actuators, a different type of position sensor such as a rotary position sensor coupled between movable parts of linkage 14 might be used. In other embodiments, optical sensors might be used to detect a position of components of linkage 14 or system 16, and thus a load positioned or suspended thereby. In still other embodiments, a sensor configured to detect fluid leakage directly from actuator 18 or a velocity sensor might be used.
Sensor 22 may be coupled with an electronic controller 24 via a communication line 23. Electronic controller 24 may be configured via a drift compensation control algorithm, for example a closed loop control algorithm, to compensate for leakage induced drift in hydraulic system 16. To this end, electronic controller 24 may comprise a computer readable medium such as RAM or ROM or another medium whereupon the subject control algorithm is recorded. Rather than a pure software-based system, however, some or all of the control operations described herein might be carried out via dedicated hardware. Where a closed loop control algorithm is implemented, the algorithm may comprise an input term corresponding with position inputs from sensor 22. An operator input device 26 may also be coupled with electronic controller 24 via another communication line 25. Operator input device 26 may be configured to output a drift compensation routine activation signal to electronic controller 24, and may also be configured to output a corresponding deactivation signal. The drift compensation control process carried out by electronic controller 30 may also be activated in an autonomous manner, for example, where a series of similar or identical control commands, or a predetermined control command sequence, are received which indicate desired maintaining of a load at a specified position via linkage 14. In certain embodiments, drift compensation control may be deactivated where deactivation criteria such as receipt of further commands from input device 26 occurs, operator commands exceeding a deadband position, or where the control routine times out.
Turning to
The present disclosure contemplates any valve type for valve 32 which will allow fluid supply to be selectively initiated or increased to actuator 18 to compensate for drift thereof. In one embodiment, valve 32 may comprise a variable flow rate valve that is controlled via drift compensation control signals from electronic controller 24 to supply hydraulic fluid to actuator 18 at a selected pressure and/or flow rate. The pressure and/or flow rate to actuator 18 may be based at least in part on a difference between a specified, target position for actuator 18 and/or linkage 14 and/or a load suspended thereby and a sensed position. Thus, in one embodiment, sensor 22 may output signals associated with a position of actuator 18. Electronic controller 24 may be configured to compare the sensed position signals with signals expected for the target position, and responsively output a flow rate/pressure signal to valve 32.
Electronic controller 24 may further be configured to output a drift compensation control signal only when a difference between a sensed actuator, linkage or load position and the target position is greater than a predetermined amount. For instance, leaking of hydraulic fluid from actuator 18 past valve 32 may induce lowering of linkage 14, and hence lowering of bucket 15 and a load suspended therewith. In one contemplated embodiment, when bucket 15 is lowered a distance D, electronic controller 24 may output an appropriate drift compensation control signal to return linkage 14 toward the target position. The value of distance D may be varied based on operator or design preferences.
Following outputting of an initial drift compensation control signal, sensor 18 may continue to sense a position of actuator 18, and electronic controller 24 may continue to output subsequent drift compensation control signals to valve 32. The control signals may be flow rate/pressure control signals based on a comparison between the sensed position and the target position until a sensed position of actuator 18 is equal to or within an acceptable range of the target position. The target position for linkage 14, bucket 15, a load, etc. may be set by reading position signals from sensor 22, for example, responsive to activation of the drift compensation routine.
Turning to
From step 125, process 100 may proceed to step 127 wherein linkage 14 may be lowered via leaking hydraulic fluid from at least a portion of system 16. As contemplated herein, “lowering” of the load will take place apart from any operator command. In other words, in most embodiments, the present drift compensation strategy will be applicable where a load is lowered via unintended leaking of hydraulic fluid, not where lowering is commanded. The present disclosure is not thereby limited, however. Fluid may leak past valve 32 to tank 40, for example, or may leak from actuator 18 via a different pathway. From step 127, process 100 may proceed to step 130 to again sense linkage/actuator position, and thenceforth to step 135 wherein electronic controller 24 will compare the position sensed in step 130 with the target position determined in step 125. From step 135, process 100 may proceed to step 140 wherein electronic controller 24 may query whether the sensed position is indicative of a drift condition of actuator 18. Determining the existence of a drift condition may occur, for example, by determining if a sensed position of actuator 18 indicates that bucket 15 has been lowered distance D. If at step 140, the sensed position is not indicative of an actuator drift condition, then process 100 may return to step 127 to continue to sense actuator position until a drift condition is detected, or until the drift compensation routine is deactivated. If at step 140, sensed position of actuator 18 is indicative of a drift condition, process 100 may proceed to step 145.
At step 145, electronic controller 24 may determine a fluid flow rate for actuator 18 responsive to the comparison of sensed position with target position in step 135. In other words, electronic controller 24 may determine the fluid flow rate based on a difference between the position sensed in step 135 and the target position determined in step 125. Where the sensed position differs from the target position by a relatively greater degree, the commanded fluid flow rate may be relatively larger, whereas the fluid flow rate may be relatively lesser for a relatively smaller difference between the sensed and target positions. From step 145, process 100 may proceed to step 150 wherein electronic controller 24 may output a drift compensation control signal to fluid supply valve 32, e.g. a flow rate signal, to begin returning actuator 18 toward a position corresponding with the target position.
From step 150, process 100 may proceed to step 155 to once again sense linkage/actuator position. From step 155, process 100 may proceed to step 160 wherein electronic controller 24 may query whether the linkage/actuator is at the target position. If no, process 100 may return to step 145 to again determine a fluid flow rate to actuator 18 based on the difference between a sensed linkage/actuator position and the target position, and will thenceforth output a subsequent drift compensation control signal. The subsequent drift compensation control signal may correspond to a flow rate at valve 32 that is less than the flow rate commanded via the control signal output the first time the routine executes step 150, given an expected relatively lesser difference between the sensed actuator position and the target position. In this manner, process 100 may comprise a closed loop control process whereby progressively lesser flow rates at valve 32 are commanded as actuator 18 approaches a position corresponding with the target position. If in step 160, the linkage/actuator position is determined to be at a position corresponding to the target position, or within an acceptable tolerance thereof, process 100 may proceed to step 165 to FINISH.
The present disclosure thus provides significant advantages over known drift compensation strategies. Rather than a dedicated, separate anti-drift valve, adding complexity and expense to the overall hydraulic system, existing components may be used, albeit via a new control strategy. The present disclosure further provides a system and method superior to an approach wherein components of the hydraulic system are machined to exacting specifications, and must be matched to specifically corresponding systems, rather than random fit in mass production.
The present description suggests suspending a load with linkage 14 at a specified position, however, it should be appreciated that only one actuator or set of actuators in a hydraulic system might be controlled as described herein, while other actuators are allowed to freely adjust. For instance, in machine 10 of
The present description is for illustrative purposes only, and should not be construed to narrow the breadth of the present disclosure in any way. Thus, those skilled in the art will appreciate that various modifications might be made to the presently disclosed embodiments without departing from the intended spirit and scope of the present disclosure. For example, while hydraulic system 16 is shown in a context of a variable discharge hydraulic pump 30, the disclosure is not limited thereby. A fixed displacement pump, possibly coupled with a return line to tank 40 might be used. In still other embodiments, rather than a linkage coupled with a mobile machine such as machine 10, a stationary system such as a machine maintenance jack might be designed and controlled as taught herein. Other aspects, features and advantages will be apparent for an examination of the attached drawings and appended claims.
| Number | Name | Date | Kind |
|---|---|---|---|
| 3938669 | Vinton | Feb 1976 | A |
| 4951549 | Olsen et al. | Aug 1990 | A |
| 5230272 | Schmitz | Jul 1993 | A |
| 5743165 | Tanaka et al. | Apr 1998 | A |
| 20050011190 | Bitter | Jan 2005 | A1 |
| 20060064971 | Reedy et al. | Mar 2006 | A1 |
| Number | Date | Country | |
|---|---|---|---|
| 20080087163 A1 | Apr 2008 | US |
