Patent Application
20170023149
The present disclosure relates generally to hydraulic systems and, more specifically, to controlling a hydraulic signal to synchronize actuation of valves in a hydraulic system.
Hydraulic systems may be used in various applications, such as within agricultural vehicles and implements. Typically, control valves are used in hydraulic systems to supply and/or drain hydraulic fluid from a work port and/or from hydraulic fluid reservoirs (e.g., tanks). For example, one or more hydraulic cylinders may be coupled to a work port and driven by the application and/or withdrawal of the hydraulic fluid through the valves. The valves generally used in hydraulic systems may include directional control valves, low-leak valves, and/or pilot stage check valves, among others. If there is leakage amongst the valves used in the hydraulic system, cavitation may occur. One way that leakage may occur is if the opening and/or closure timings of the valves in certain hydraulic systems are not synchronized. Cavitation may occur by gas bubbles forming in areas of the hydraulic system where pressure is low. For example, if the timing of the valves is not properly synchronized, one valve may open early and enable drainage of hydraulic fluid while another valve on the opposing side of the hydraulic system does not open. The difference in fluid pressure between the two sides may cause cavitation, which may lead to undesirable maintenance conditions and/or reduce the longevity of certain components within the hydraulic system.
In an embodiment, a tangible, non-transitory computer-readable media stores computer instruction. The computer instructions, when executed by a processor, are configured to increase a first signal pressure to a first actuating element of a directional control valve until the directional control valve is about to shift positions. The first signal pressure is greater than a second signal pressure to a second actuating element of the directional control valve by a signal pressure differential. The computer instructions are also configured to increase the first signal pressure and the second signal pressure equally while maintaining the signal pressure differential to cause a first pilot stage valve via the first signal pressure and a second pilot stage valve via the second signal pressure to shift positions, and, within a threshold time thereafter, increase the first signal pressure while maintaining the second signal pressure to increase the signal pressure differential to a value sufficient to cause the directional control valve to shift positions.
In an embodiment, a hydraulic system includes a directional control valve fluidly coupled to a pump, a hydraulic fluid reservoir, and a first and second vent-to-open check valve. The first vent-to-open check valve is fluidly coupled to the directional control valve, the hydraulic fluid reservoir, and a first work port. The second vent-to-open check valve is fluidly coupled to the directional control valve, the hydraulic fluid reservoir, and a second work port. The hydraulic system also includes a controller including a processor and a memory. The processor is configured to execute computer instructions stored on the memory. The computer instructions are configured to increase a first signal pressure to a first actuating element of the directional control valve until the directional control valve is about to shift positions. The first signal pressure is greater than a second signal pressure to a second actuating element of the directional control valve by a signal pressure differential. The computer instructions are also configured to increase the first signal pressure and the second signal pressure equally while maintaining the signal pressure differential to cause the first vent-to-open check valve via the first signal pressure and the second vent-to-open check valve via the second signal pressure to shift positions. Within a threshold time thereafter, the computer instructions are configured to increase the first signal pressure while maintaining the same second signal pressure to increase the signal pressure differential to a value sufficient to cause the directional control valve to shift positions.
In an embodiment, a hydraulic system includes a directional control valve fluidly coupled to a pump, a hydraulic fluid reservoir, and a first and second vent-to-open check valve. The first vent-to-open check valve is fluidly coupled to the directional control valve, the hydraulic fluid reservoir, and a first work port. The second vent-to-open check valve is fluidly coupled to the directional control valve, the hydraulic fluid reservoir, and a second work port. The hydraulic system also includes a controller comprising a processor and a memory. The processor is configured to execute computer instructions stored on the memory. The computer instructions are configured to increase a first signal pressure to a first actuating element of the directional control valve until the directional control valve is about to shift positions. The first signal pressure is greater than a second signal pressure to a second actuating element of the directional control valve by a signal pressure differential. The computer instructions are also configured to increase the first signal pressure and the second signal pressure equally while maintaining the signal pressure differential to cause the first vent-to-open check valve via the first signal pressure and the second vent-to-open check valve via the second signal pressure to shift positions. Within a threshold time thereafter, the computer instructions are configured to increase the first signal pressure while maintaining the same second signal pressure to increase the signal pressure differential to a value sufficient to cause the directional control valve to shift positions.
These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
One or more specific embodiments of the present disclosure will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters/conditions of the disclosed embodiments. It should be noted that the term “directional control valve” and “directional valve” may be used interchangeably herein. It should also be noted that a pressure source for a hydraulic system may be referred to as a “pump” herein.
Leakage from the work ports in a hydraulic system may reduce the efficiency of hydraulic components fluidly coupled to the work ports. As a result, a check valve may be employed to reduce work port leakage from a hydraulic system controlled by a directional control valve. In bidirectional systems, the check valve may be opened to enable reverse flow (e.g., to enable a single acting cylinder to retract or to control a double acting cylinder). As mentioned above, one type of check valve that may be used is a “vent-to-open” check valve. The vent-to-open check valve may vent one chamber of a hydraulic component to a low pressure return line.
One undesirable effect of this technique is the introduction of a second path for leakage. That is, hydraulic fluid may leak from the directional control valve into the low pressure return line while the directional control valve and the vent-to-open check valve are closed. To remedy the leakage, a second check valve, referred to as a “pilot stage check valve” or “pilot stage valve” is used. The pilot stage check valve blocks flow through the low pressure return line while closed. In addition, the pilot stage check valve is controlled by a signal pressure. When the signal pressure reaches an established threshold, the pilot stage check valve opens, which enables the vent-to-open check valve to open, thereby enabling reverse flow.
Oftentimes, the signal pressure may be provided from the same source that is used to control the directional control valve. Because the pressure sufficient to drive movement of each valve may be different, the directional control valve and the pilot stage check valve may not open at the same time. When the pilot stage check valve is opened before the directional control valve, a work port may drain hydraulic fluid through the low pressure return line without balancing the hydraulic fluid flow through the opposing line, which may lead to cavitation as described above. Additionally, if the pilot stage check valve is opened after the directional control valve, the directional control valve may not provide sufficient control over low flows of hydraulic fluid. Thus, it is desirable to open the pilot stage check valve and the directional control valve at the desired time (e.g., substantially the same time) so that the possibility of cavitation is substantially reduced or eliminated and flow of the hydraulic fluid may be controlled.
Accordingly, presently disclosed embodiments relate to a system and method for controlling the signal pressure in a hydraulic system such that the valves are substantially synchronously opened. In some embodiments, a calibration is performed to determine the exact pressure sufficient to cause the directional control valve to move. This calibration may be performed for each valve, and may be used to account for any variation in parts, such as parts made by different manufacturers, parts that are newer or older, and the like. One such calibration method is set forth in U.S. Pat. No. 6,571,190, entitled “Automatic Calibration of Remote Hydraulic Valve Flow,” filed on Apr. 30, 2001 by Hou et al., which is hereby incorporated into the present disclosure by reference.
In one embodiment, the hydraulic system may control the signal pressures by increasing a first signal pressure until the directional control valve shifts to a position just barely short of opening. Next, while keeping a pressure differential the same between the first signal pressure and a second signal pressure, both signal pressures are increased. The higher signal pressures cause the pilot stage check valves to open. Then, while maintaining, or increasing by a lesser amount, the lower second signal pressure, the higher first signal pressure may be increased to obtain a higher pressure differential to shift the directional control valve to an open position. Because increasing the higher first signal pressure to obtain a higher pressure differential is performed immediately after increasing both signal pressures while maintaining the pressure differential, the directional control valve and pilot stage check valves are opened at substantially the same time. As described below, additional embodiments may not use the pilot stage check valves to control the flow of hydraulic fluid. Additionally, as described below, some embodiments use electrical signals to control pressure control valves and/or flow control valves that use position feedback.
The hydraulic system included in the vehicle 10 may be controlled by manual inputs (e.g., by an operator using a lever) and/or by electrical control (e.g., by a controller activating solenoids coupled to control valves). Also, the hydraulic system may include a pump that distributes hydraulic fluid through fluid conduits (e.g., lines, chambers, etc.) to various work ports, one or more valves that control the flow of the hydraulic fluid and/or drainage of the hydraulic fluid, and hydraulic fluid reservoirs (e.g., tanks) where the hydraulic fluid is retained. In some embodiments, the hydraulic system includes a controller that is used to activate solenoids attached to certain valves that control the flow to the work ports and/or signal pressures.
As illustrated, a carrier frame 36 is rotatably coupled to the hitch assembly 28 by a pivot joint 38. Ground engaging wheels 40 are coupled to the carrier frame 36 to support the weight of the implement 24 during both operation and transport. In addition, a support frame 42 is coupled to the hitch assembly 28, and configured to support the carrier frame 36. Specifically, main lift cylinders 44 extend between the support frame 42 and the carrier frame 36. In the illustrated working position, the hydraulic system caused the main lift cylinders 44 to be in a retracted position such that the hitch assembly 28 is lowered relative to the carrier frame 36, thereby inducing the row units 34 to engage the soil. Additionally, the hydraulic system may cause the main lift cylinders 44 to extend to raise the row units 20 above the ground, thereby transitioning the implement into a transport position.
In the illustrated embodiment, the directional control valve 52 is fluidly coupled to the pump 58 and to the hydraulic fluid reservoir 60 via fluid conduits 57 on one side, and the directional control valve 52 is fluidly coupled to the vent-to-open check valves 62 and 64 via fluid conduits 57 on the other side. In the illustrated embodiment, the directional control valve 52 is a three position/four way valve. The first position 66 is configured to block hydraulic fluid flow between the vent-to-open valves 62, 64, and the pump 58 and the hydraulic fluid reservoir 60. The second position 68 is configured to facilitate hydraulic fluid flow to work port B through the first vent-to-open check valve 62, and to facilitate hydraulic fluid flow to the hydraulic fluid reservoir 60 through the first pilot stage check valve 54. The second position is also configured to facilitate draining of hydraulic fluid from work port A through the second vent-to-open check valve 64 to the hydraulic fluid reservoir 60. The third position 70 is configured to facilitate hydraulic fluid flow to work port A through the second vent-to-open check valve 64 and to facilitate hydraulic fluid flow to the hydraulic fluid reservoir 60 through the second pilot stage check valve 56. The third position 70 is also configured to facilitate draining of hydraulic fluid from work port B through the first vent-to-open check valve 62 to the hydraulic fluid reservoir 60. The second and third positions of the directional control valve 52 may be referred to as “open” positions throughout the disclosure.
The directional control valve 52 also includes two actuating elements 76 and 78 configured to adjust the position of the valve 52. In the present embodiment, the first actuating element 76 is driven by signal pressure B, and the second actuating element 78 is driven by signal pressure A. Also, the first actuating element 76 includes a spring configured to urge the directional control valve 52 toward the second position 68, and the second actuating element 78 includes a spring configured to urge the valve 52 toward the third position 70.
The first and second vent-to-open check valves 62 and 64 include two positions. The first vent-to-open check valve 62 includes a first position 80 configured to block flow of hydraulic fluid between the work port B and the directional control valve 52. The valve 62 also includes a second position 82 configured to enable the flow of hydraulic fluid between work port B and the directional control valve 52. The second vent-to-open check valve 64 includes a first position 84 configured to block the flow of hydraulic fluid between work port A and the directional control valve 52. The valve 64 also includes a second position 86 configured to enable the flow of hydraulic fluid between work port A and the directional control valve 52. It should be noted that the first and second vent-to-open check valves 62 and 64 may be any suitable type of vent-to-open check valves. For example, in some embodiments, a poppet or ball type check valve may be used.
In addition, each vent-to-open check valve 62 and 64 includes an actuating element. For example, the first vent-to-open check valve 62 includes an actuating element 88, which includes a spring configured to urge the valve 62 toward the first position 80. The second vent-to-open check valve 64 includes an actuating element 90, which includes a spring configured to urge the valve 64 toward the first position 84. The actuating elements 88 and 90 actuate the valves 62 and 64 when the force applied by the actuating elements 88 and 90 is greater than the force exerted on the other side of the valve by the hydraulic fluid. Further, each vent-to-open valve 62 and 64 includes a choke 92 and 94. The chokes 92 and 94 are configured to reduce the flow of hydraulic fluid to the actuating elements 88 and 90 so the first and second vent-to-open check valves 62 and 64 are not moved to the respective first positions 80 and 84 while providing hydraulic fluid to, and draining hydraulic fluid from, the work ports.
In the depicted embodiment, the first pilot stage check valve 54 and the second pilot stage check valve 56 include two positions. For example, the first pilot stage check valve 54 includes a first position 96 configured to block flow of hydraulic fluid between from a vent of the first vent-to-open check valve 62 to the hydraulic fluid reservoir 60. In some embodiments, the first position 96 is configured to block flow of hydraulic fluid from work port B to the hydraulic reservoir. The first pilot stage check valve 54 also includes a second position 98 configured to enable flow of hydraulic fluid from the vent of the first vent-to-open check valve 62 to the hydraulic fluid reservoir 60. In some embodiments, the second position 98 is configured is enable flow of hydraulic fluid from the work port B to the hydraulic fluid reservoir. Likewise, the second pilot stage check valve 56 includes a first position 100 configured to block flow of hydraulic fluid from a vent of the second vent-to-open check valve 64 to the hydraulic fluid reservoir 60. In some embodiments, the first position 100 is configured to block flow of hydraulic fluid from work port A to the hydraulic reservoir. The valve 56 also includes a second position 102 configured to enable flow of hydraulic fluid from the vent of the second vent-to-open check valve 64 to the hydraulic fluid reservoir 60. In some embodiments, the second position 102 is configured is enable flow of hydraulic fluid from the work port A to the hydraulic fluid reservoir.
In addition, each pilot stage check valve 54 and 56 includes an actuating element. For example, the first pilot stage check valve 54 includes an actuating element 104, which includes a spring configured to urge the valve 54 toward the first position 96. The second pilot stage check valve 56 includes an actuating element 106 which includes a spring configured to urge the valve 56 toward the first position 100. In some embodiments, the pilot stage check valves may include independent vent or return lines.
As depicted, the first pilot stage check valve 54 is driven by signal pressure B. Thus, signal pressure B controls the movement of the first pilot stage check valve 54 and the directional control valve 52. Likewise, the second pilot stage check valve 56 is driven by signal pressure A. Thus, signal pressure A controls the movement of the second pilot stage check valve 56 and the directional control valve 52. In some embodiments, to move the directional control valve 52, the pressure differential between signal pressure A and signal pressure B reaches a threshold amount. It should be noted that, in some embodiments, the hydraulic system 50 may be configured so that the signal pressure that causes the pilot stage check valves 54 and 56 to open is higher than the signal pressure sufficient to drive the directional control valve 52 to the second or third position. This configuration may be used in the systems and methods disclosed herein to properly synchronize the opening of the valves, as discussed below.
For example, a signal pressure may be applied to the directional control valve 52, and movement of the valve 52 may be monitored. If the valve 52 does not move, incrementally higher signal pressures may be applied until the valve 52 transitions to a new position (e.g., to the second position or to the third position). The difference between the signal pressure on one side of the directional control valve 52 and the pressure on the other side creates a force on the valve 52. The force acts upon the valve 52 to drive the valve 52 away from the first position 66. To shift the differential control valve 52 to a certain position (e.g., first position 66, second position 68, or third position 70), a certain signal pressure differential is applied. Once the valve 52 shifts, the signal pressure differential and/or each signal pressure A and B may be determined and recorded as a calibration pressure for valve 52. Likewise, calibration is performed for the first pilot stage check valve 54 and the first vent-to-open check valve 62 to determine the respective calibration pressures (e.g., the pressure of signal pressure B sufficient to drive the valve to move). Also, calibration is performed for the second pilot stage check valve 56 and the second vent-to-open check valve 64 to determine the respective calibration pressures (e.g., the pressure of signal pressure A that causes the valve to move). It should be noted that, in some embodiments, the calibration pressures may be affected by work port pressure. For example, if the work port pressure is high, then a higher signal pressure may be applied to move the valves, which may influence the calibration pressures. Thus, in some embodiments, it may be desirable to minimize the influence of work port pressure by draining the work ports prior to calibration. In another example, the positions of the valves may be read by the position feedback device and the directional control valve may be moved to a position barely short of opening.
The process 110 includes the signal pressure control system 65 increasing a first signal pressure until the directional control valve 52 shifts to a position barely short of opening (process block 114). In some embodiments, the calibration pressure for the valve 52 may be used in process block 114. Then, the signal pressure control system 65 increases first and second signal pressures equally while keeping the signal pressure differential the same (process block 118). As long as the signal pressure differential is the same, the directional control valve 52 does not move. The higher signal pressures will cause the pilot stage check valves 54 and 56 to open. While maintaining, or increasing by a lesser amount, the lower second signal pressure, the signal pressure control system 65 increases the first signal pressure to obtain a higher signal pressure differential sufficient to shift positions of the directional control valve 52 (process block 120). It should be understood that process block 120 is performed substantially simultaneously with process block 118. It should be noted that performing the steps in process block 120 and 118 substantially simultaneously refers to performing the steps within 10 milliseconds (ms) to 100 ms.
For example, when it is desired to provide hydraulic fluid to work port A and drain hydraulic fluid from work port B, signal pressure A is increased so the actuating element 78 drives the directional control valve 52 to a position just barely short of the third position 70 (process block 114). That is, the valve 52 is driven nearly to an open position but remains closed. For example, the calibration pressure differential for the directional control valve 52 may be 3 bar. Thus, signal pressure A may be increased to 3 bar while signal pressure B is 0 bar.
Then, both signal pressures A and B are equally increased to cause the pilot stage check valves 54 and 56 to open, while still maintaining the same signal pressure differential so the directional control valve 52 does not move (e.g., signal pressure A increases to 7 bar and signal pressure B increases to 4 bar, thereby maintaining the signal pressure differential at 3 bar, but providing the 4 bar signal pressure sufficient to shift the pilot stage check valves 54 and 56) (process block 118). It should be noted that opening the pilot stage check valves 54 and 56 (transitioning to the second positions 98 and 102) causes the vent-to-open check valves 62 and 64 to open (transition to positions 82 and 86). Then, process block 120 is executed substantially simultaneously with process block 118 by increasing signal pressure A (e.g., to 15 bar) while maintaining the lower signal pressure B (e.g., 4 bar) to obtain a pressure differential of 11 bar that shifts the directional control valve 52 to the third position 70. In this way, the pilot stage check valves 54 and 56 and the directional control valve 52 are opened at substantially the same time (e.g., within 10-100 ms). As a result, hydraulic fluid flows through the directional control valve 52, which is in the third position 70, and through the second vent-to-open check valve 64, which is in the second position 86, to work port A (arrow 72). Also, hydraulic fluid flows through the directional control valve 52, which is in the third position 70, through the second vent-to-open check valve 64, which is in the second position 86, and through the second pilot stage check valve 56, which is in the second position 102, to the hydraulic fluid reservoir 60. Additionally, hydraulic fluid is drained from work port B (arrow 74) through the first vent-to-open check valve 62, which is in the second position 82, and through the directional control valve 52, which is in the third position 70, to the hydraulic fluid reservoir 60. Also, hydraulic fluid is drained through the first pilot stage check valve 54, which is in the second position 98, to the hydraulic fluid reservoir 60.
For example, when it is desired to provide hydraulic fluid to work port A and drain hydraulic fluid from work port B using the hydraulic system 130, the calibration pressures, i.e., for signal pressures that are sufficient to open each valve, or the positions of the valves, are determined (process block 112). Next, signal pressure A is increased so the actuating element 78 drives the directional control valve 52 to a position just barely short of opening (process block 114). For example, the calibration pressure differential for the directional control valve may be 3 bar. Thus, signal pressure A may be increased to 3 bar while signal pressure B is 0 bar.
Then, both signal pressures A and B are equally increased to causes the pilot-to-open check valves 54 and 56 to open, while still maintaining the same signal pressure differential, so that the directional control valve 52 does not move (e.g., signal pressure A increases to 7 bar, and signal pressure B increases to 4 bar, thereby maintaining the signal pressure differential at 3 bar, and providing the 4 bar signal pressure sufficient to shift the pilot-to-open check valves 54 and 56 to the open position) (process block 118). Then, process block 120 is executed substantially simultaneously with process block 118, i.e., by increasing signal pressure A (e.g., to 15 bar) while maintaining the lower signal pressure B (e.g., 4 bar) or increasing signal pressure B by a lesser amount than signal pressure A, to obtain a signal pressure differential of 11 bar that shifts the directional control valve 52 to the third position 70. In this way, the pilot-to-open check valves 54 and 56 and the directional control valve 52 are opened at substantially the same time (e.g., within 10-100 ms of one another).
The first flow control valve 142 includes two positions. A first position 152 is configured to block flow of hydraulic fluid from the pump 58 to the directional control valve 52 and to the first pilot stage check valve 54, while enabling flow of hydraulic fluid to the hydraulic fluid reservoir 60 from the actuating element 76 of the directional control valve 52 and the actuating element 104 of the first pilot stage check valve 54. Also, a second position 154 is configured to enable the pump 58 to provide hydraulic fluid via fluid conduit 57 to the actuating element 76 of the directional control valve 52 and the first pilot stage check valve 54. When the controller 146 activates the first solenoid 148, the first flow control valve 142 is driven to the second position 154. With the valve 142 in the second position 154, hydraulic fluid flows through the valve 142 and fluid conduit 57 to the actuating element 76 until a desired pressure (e.g., calibration pressure) is achieved.
Similarly, the second flow control valve 144 includes two positions. A first position 156 is configured to block flow of hydraulic fluid from the pump 58 to the actuating element 78 of the directional control valve 52 and to the second pilot stage check valve 56, while enabling the flow of hydraulic fluid to the hydraulic fluid reservoir 60 from the actuating element 78 directional control valve 52 and the actuating element 106 of the second pilot stage check valve 56. Also, a second position 158 is configured to enable the pump 58 to provide hydraulic fluid to the actuating element 78 of the directional control valve 52 and the second pilot stage check valve 56 via fluid conduit 57. When the controller 146 activates the first solenoid 148, the first flow control valve 142 is driven to the second position 154. With the valve 144 in the second position 158, hydraulic fluid flows through the valve 144 and fluid conduit 57 to the actuating element 78 until a desired pressure (e.g., calibration pressure) is achieved.
Further, to control the first and second flow control valves 142 and 144, the controller 146 uses position feedback obtained from a position measurement device (e.g., linear variable differential transformer (LVDT)) 160 coupled to the directional control valve 52 and communicatively coupled to the controller 146. In some embodiments, the position measurement device 160 is in direct or wireless communication with the controller 146. The position measurement device 160 provides positional information of the valve 52 to the controller 146. The controller 146 uses the positional information of the valve 52 to activate the appropriate solenoid 148 and 150 to drive the flow control valves 142 and 144 to a desired position. The determination of whether to open or close the flow control valves 142 and 144 is made solely by the controller 146. The opening and closing of the flow control valves 142 and 144 affects the signal pressures exerted on the actuating elements 76 and 78, thereby controlling the opening and closing of the directional control valve 52.
The controller 146 may include one or more processors 162 and one or more tangible, non-transitory processor-readable media (e.g., memory device 164). The processor 162 may include multiple microprocessors, one or more “general-purpose” microprocessors, one or more special-purpose microprocessors, and/or one or more application specific integrated circuits (ASICS), or some combination thereof. For example, the processor 162 may include one or more reduced instruction set (RISC) processors. The memory device 164 may include a volatile memory, such as random access memory (RAM), and/or a nonvolatile memory, such as ROM. The memory device 164 may store a variety of information and may be used for various purposes. For example, the memory device 164 may store processor-executable instructions (e.g., firmware or software) for the processor 162 to execute, such as instructions for controlling the flow control valves 142 and 144. In addition, the controller 146 may include a storage device(s) (e.g., nonvolatile storage), which may include read-only memory (ROM), flash memory, a hard drive, or any other suitable optical, magnetic, or solid-state storage medium, or a combination thereof. The storage device(s) may store data (e.g., calibration pressure data, position feedback data, etc.), instructions (e.g., software or firmware for controlling the hydraulic system 140, including flow control valves 142 and 144, etc.), and any other suitable data.
The process 170 includes using the controller 146 to determine calibration points (e.g., pressures or position) for each of the valves (process block 172). In some embodiments, process block 172 includes obtaining the position of the directional control valve 52 via the position measurement device 160. Next, the process 170 includes using the controller 146 to obtain position feedback of the directional control valve 52 from the position measurement device 160 (process block 174). The controller 146 then controls the first flow control valve 142 to open to a pressure source (e.g., pump 58) and the second flow control valve 144 to the hydraulic fluid reservoir 60 until the directional control valve 52 shifts to a position just barely short of opening using (process block 176).
The process 170 also includes using the controller 146 to open the first flow control valve 142 to provide a pilot signal pressure to the directional control valve 52, and to close the second flow control valve 144 to block fluid from escaping to the hydraulic fluid reservoir 60, thereby increasing the second signal pressure equally to maintain the signal pressure differential and prevent the directional control valve 52 from moving (process block 178). Blocking fluid from escaping is achieved by moving the second flow control valve 144 to the second position 154 by activating solenoid 154. The higher signal pressures will cause the pilot stage check valves 54 and 56 to be driven to the second positions 98 and 102 (e.g., open). Then, the controller 146 continues to open the first flow control valve 142 fully at pilot signal pressure and controls the second flow control valve 144 to allow fluid to escape to the hydraulic fluid reservoir 60, which reduces the second signal pressure and increases the signal pressure differential, thereby achieving the desired directional control valve 52 shift (process block 180). To allow fluid to escape, the second flow control valve is shifted to the first position 152 by activating solenoid 152. It should be noted that, in some embodiments, the hydraulic system 140 is damped or over-damped so that a directional control valve 52 overshoot is inhibited. If overshoot does occur, a correction may be made by dropping the signal pressure below the threshold needed to keep the first and second pilot stage check valves 54 and 56 open. That is, the controller 146 may instruct the flow control valves 142 and 144 to move to the first positions 154 and 158 so fluid can flow from the pilot stage check valves 54 and 56 to the hydraulic fluid reservoir 60, thereby reducing signal pressure and enabling the valves 54 and 56 to close.
To illustrate, when it is desired to provide hydraulic fluid to work port A and drain hydraulic fluid from work port B, the controller 146 activates the solenoid 150 to drive the second flow control valve 144 to the second position 158, thereby opening the second flow control valve 144 to the pump 58, and maintains the first flow control valve 144 in the first position 152 to enable fluid to flow to the hydraulic fluid reservoir 60. The first and second fluid control valves 142 and 144 are kept in these positions until the directional control valve 52 shifts to a position barely short of the third position 70 based on position feedback obtained from the position measurement device 160.
The controller 146 obtains positional feedback from the position measurement device 160 relating to the directional control valve 52, so that the controller 146 ascertains when the valve 52 has reached a position just short of the third position 70 (process block 176). The second flow control valve 144 is then opened fully by completely transitioning the valve to the second position 158, such that signal pressure A increases to the full pilot pressure (e.g., 18 bar). At the same time/substantially the same time, the controller 146 instructs the first flow control valve 142 to close (e.g., transition to the second position 154) by activating solenoid 148, thereby increasing signal pressure B (e.g., to 15 bar) concurrently with signal pressure A (process block 178). In this way, the signal pressure differential between signal pressures A and B is maintained (e.g., 3 bar). The increased signal pressure A and signal pressure B cause the first and second pilot stage check valves 54 and 56 to move to the respective second positions 98 and 102. However, since the signal pressure differential is maintained, the directional control valve 52 substantially does not move. Then, the controller 146 executes process block 180 substantially simultaneously with process block 178 (e.g., within 10-100 ms of process block 178). Process block 180 includes the controller 146 maintaining the second flow control valve 144 in the fully open position (e.g., the second position 158), which maintains the signal pressure A (e.g., at 18 bar), and enabling fluid to flow to the hydraulic fluid reservoir 60 by instructing the solenoid 148 to move the flow control valve 142 toward the first position 152, thereby reducing signal pressure B (e.g., to 7 bar). As a result, the signal pressure differential increases to 11 bar, which causes the directional control valve 52 to shift to the third position 70. In this way, the pilot stage check valves 54 and 56 and the directional control valve 52 are opened at substantially the same time (e.g., within 10-100 ms of one another).
As depicted, the first pressure control valve 192 includes two positions. A first position 200 is configured to block flow of hydraulic fluid from the pump 58 to the directional control valve 52 and to the first pilot stage check valve 54, while enabling flow of hydraulic fluid to the hydraulic fluid reservoir 60 from the actuating element 76 of the directional control valve 52 and the actuating element 104 of the first pilot stage check valve 54. Also, a second position 202 is configured to enable the pump 58 to provide hydraulic fluid to the actuating element 76 of the directional control valve 52 and to the first pilot stage check valve 54 through the fluid conduit 57, while blocking hydraulic fluid flow to the hydraulic fluid reservoir 60 from the actuating element 76 of the directional control valve 52 and the first pilot stage check valve 54. When the controller 146 activates the first solenoid 196, the first pressure control valve 192 is driven to the second position 202 when the force applied by the solenoid outweighs the force applied by the fluid at the output (bar 204). In addition, an actuating element 206 (e.g., including a spring) urges the valve 192 to the first position 200. When the valve 192 is in the second position 202, hydraulic fluid flows through the valve 192 and fluid conduit 57 to the actuating element 76.
Similarly, the second pressure control valve 194 includes two positions. A first position 208 is configured to block flow of hydraulic fluid from the pump 58 to the directional control valve 52 and to the second pilot stage check valve 56, while enabling flow of hydraulic fluid to the hydraulic fluid reservoir 60 from the actuating element 76 of the directional control valve 52 and the actuating element 104 of the second pilot stage check valve 56. Also, a second position 210 is configured to enable the pump 58 to provide hydraulic fluid to the actuating element 76 of the directional control valve 52 and to the second pilot stage check valve 56, while blocking hydraulic fluid flow to the hydraulic fluid reservoir 60 from the actuating element 76 of the directional control valve 52 and the second pilot stage check valve 56. When the controller 146 activates the second solenoid 198, the second pressure control valve 194 is driven to the second position 208 when the force applied by the solenoid outweighs the force applied by the fluid at the output (bar 212). In addition, an actuating element 214 (e.g., including a spring) urges the valve 194 to the first position 208. When the valve 194 is in the second position 210, hydraulic fluid flows through the valve 194 and fluid conduit 57 to the actuating element 78.
The process 220 also includes using the controller 146 to send a signal to the solenoid 196 to fully open the first pressure control valve 192 to provide a pilot signal pressure to the directional control valve 52 (process block 226). It should be noted that, in some embodiments, the first pressure control valve 192 may compare the force applied by the solenoid 196 and the force of the fluid output when opening. Process block 226 also includes preventing hydraulic fluid from flowing to the hydraulic fluid reservoir 60 by activating the solenoid 198 of the second pressure control valve 194 so that the valve moves to the second position 210, which increases a second signal pressure equal to the first signal pressure to maintain the signal pressure differential.
Then, process block 228 is executed at substantially the same time as process block 228 (e.g., within 10-100 ms of process block 226). Process 230 includes the controller 146 opening the first pressure control valve 192 fully, thereby providing full pilot signal pressure. Step 228 also includes using the second pressure control valve to enable fluid to escape from the opposite spring chamber by activating the solenoid of the second pressure control valve 194 via the controller 146, which moves the valve to the first position 200 or 208, thereby reducing the second signal pressure to achieve the desired directional control valve 52 shift. By keeping the first signal pressure at the full pilot signal pressure and lowering the second signal pressure, a sufficient signal pressure differential is obtained to shift the directional control valve 52 to the open position (e.g., the second position or the third position). It should be noted that, in some embodiments, the hydraulic system 190 is damped or over-damped so that the possibility of directional control valve overshoot is substantially reduced or eliminated.
As depicted, in this embodiment, the hydraulic system 230 is similar to the hydraulic system 130 of in
The process 240 includes determining calibration points for each of the valves (process block 242). It should be noted that, in some embodiments, the calibration points may include a pressure or a position of the valve obtained from a position feedback device. The process 240 also includes the signal pressure control system 65 increasing a first signal pressure (e.g., signal pressure B) until the directional control valve 52 shifts to a position barely short of opening (process block 244). In some embodiments, the calibration pressure for the valve 52 may be used in process block 244. Then, the signal pressure control system 65 increases the first and a second signal pressure (e.g., signal pressure B and signal pressure A) until the signal pressure (e.g., signal pressure A) that is controlling the pilot-to-open check valves 54 and 56 goes above a threshold pressure (process block 246). As long as the signal pressure differential is the same, the directional control valve 52 does not move. The higher signal pressure (e.g., signal pressure A) will cause the pilot stage check valves 54 and 56 to open. While maintaining the same lower second signal pressure, or increasing the second signal pressure by a lesser amount, the signal pressure control system 65 increases the first signal pressure to obtain a higher signal pressure differential sufficient to shift positions of the directional control valve 52 (process block 248). It should be understood that process block 248 is performed substantially simultaneously with process block 246. It should be noted that performing the steps in process block 248 and 246 substantially simultaneously refers to performing the steps within 10 milliseconds (ms) to 100 ms.
While only certain features of the present disclosure have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure.
