Patent Application
20190277311
This application claims priority under 35 U.S.C. § 119 to European Patent Application No. 18160925.6 filed Mar. 9, 2018, which the entirety thereof is incorporated herein by reference.
The present disclosure relates to a hydraulic system configured to generate hydraulic power for a hydraulic actuator of a mobile work machine and to control operation of the actuator. The disclosure further relates to a mobile mining machine and method of controlling the hydraulic actuator.
In mines and at other work sites different type of mobile work machines are used. The mobile work machines are provided with one or more working devices for executing designed work tasks at the work site. The mobile work machine may be a wheel loader, a transport vehicle or dumper, a rock drilling rig, an excavator or a lifting machine, for example. The machines are typically provided with hydraulic systems because hydraulics has several advantages, such as great power density and possibility to flexible power transfer. Further, hydraulic cylinders are great actuators for generating linear forces and movements. However, the present hydraulic systems contain some disadvantages regarding efficiency.
One object of the present disclosure is to provide a novel and improved hydraulic system and a mobile mining machine equipped with such hydraulic system. The present disclosure further relates to a novel and improved method of controlling hydraulic actuators.
An idea of the disclosed solution is that the hydraulic system is intended for a mobile work machine and it includes two hydraulic pumps, a first hydraulic pump and a second hydraulic pump for generating hydraulic fluid flow and pressure to a hydraulic circuit in order to actuate a hydraulic actuator of the mobile machine. One common electric motor is configured to rotate the mentioned two hydraulic pumps simultaneously. The first hydraulic pump is connected to a first working pressure space or volume of the hydraulic actuator by means of a first hydraulic line and the second hydraulic pump is connected to a second working pressure space of the hydraulic actuator by means of a second hydraulic line. Pressure of the hydraulic fluid prevailing in the first working pressure space or volume and the second pressure space or volume are configured to cause inversely directed forces for a moving element of the actuator, such as a piston of a hydraulic cylinder. Further, the first and second hydraulic pumps have inverse pumping characteristics so that when the first hydraulic pump generates pressure, the second hydraulic pump generates suction, and vice versa. In the disclosed solution movement speed and direction of the hydraulic actuator are controlled by controlling rotational speed and direction of the mentioned common electric motor. The controlling of the motor may be executed in various ways depending on type of the motor, for example.
The mentioned inverse pumping characteristics have the following meaning: the first hydraulic pump is configured to generate hydraulic pressure to the first hydraulic line when the electric motor is rotated in a first direction of rotation and correspondingly the second hydraulic pump is configured to generate suction to the second hydraulic line. Correspondingly, the first hydraulic pump is configured to generate suction to the first hydraulic line when the electric motor is rotated in a second direction of rotation and correspondingly the second hydraulic pump is configured to generate hydraulic pressure to the second hydraulic line. In other words, when one pump is pumping the other pump executes sucking action, and vice versa.
In the disclosed solution, the hydraulic actuator is controlled indirectly by means of the common electric motor. The speed and direction controlled electric motor serves as the controlling element for controlling operation of the actuator. Then, the entire hydraulic circuit may serve only as a kind of a power transmission system or a slave system without actively controlling the operation of the hydraulic actuator. In other words, the motor may be the only device that directly is controlled by means of control commands.
Further, it can be considered that the disclosed solution is a kind of a double pump—single motor-control system. The pumps, connected on opposite sides of a moving element of the actuator, are controlled simultaneously by the speed and direction controlled electric motor whereby the system may be without any separate flow and pressure adjusting elements arranged to pressure fluid channels.
According to the disclosed solution, advantages of hydraulics may be exploited without the disadvantages. The disclosed solution is simple and robust since it requires no hydraulic control elements for controlling the operation of the actuator. If any valves are included in the system, they may be passive valves or they may be simple ON/OFF type valves, which do not need complicated and accurate control. Control instructions and commands may be directed directly to the speed and direction controlled electric motor, since the system may be without any control valves requiring active control. Due to this, there is no need to arrange vulnerable electric control cables and similar control transmitting paths in harsh locations, but instead, only the electric motor needs to be controlled. Further, the operation of the disclosed solution is energy efficient since there is no need for different adjusting hydraulic elements arranged in hydraulic lines, which elements typically cause throttling and energy losses.
The disclosed solution makes it possible to design even a totally valveless speed and direction control system for a hydraulic actuator connected the hydraulic system. All in all, the disclosed solution utilized best features of the hydraulics and at the same time diminishes its typical disadvantages.
According to an embodiment, the disclosed hydraulic system includes one single hydraulic actuator. In this way, the entire hydraulic system is dedicated to operate with only one hydraulic actuator. An advantage is that the system may be simple in structure and it may be tailored for the specific requirements of the actuator.
According to an embodiment, the disclosed hydraulic system, which utilizes the above disclosed control principle, may be configured to actuate two or more actuators at separate times. In this way, the hydraulic system includes two or more alternative hydraulic actuators, which may be selectively connected to the disclosed hydraulic system one at a time. The system may include at least one distribution device for selecting which actuator is energized by the disclosed hydraulic system. The distribution device may implement an ON/OFF principle whereby it may have a simple design and control. Further, flow control elements and channels of the distribution device are dimensioned so wide such that throttling and power losses are minimized. The distribution device may have a valve block, which is designed only to direct the flow paths to the selected actuators and not to adjust flow or pressure of the directed flow paths in any way. As an alternative, one single valve block may be substituted with separate ON/OFF-valves with relatively large diameters.
According to an embodiment, the disclosed hydraulic system with one electric motor and double pump arrangement is configured to operate a primary hydraulic actuator, such as a lifting cylinder, steering cylinder or turning motor, which is configured to move an object or joint. The system is further configured to operate a hydraulic locking device, such as a locking cylinder, which is configured lock and release movement of the object or joint influenced by the primary hydraulic actuator. The primary hydraulic actuator and the hydraulic locking device are operationally connected whereby they both may be driven in accordance with the disclosed operating principle. In this embodiment the hydraulic system includes hydraulic actuators which are driven parallel and which differ from each other.
According to an embodiment, the hydraulic system provided with one electric motor and double pump arrangement includes several similar actuators operating parallel. The system may, for example, include two steering cylinders of a frame steered mobile work machine, two dump cylinders operating in tandem and designed for emptying a dump box of a hauling truck, two tandem operating lifting cylinders of a wheel loader or two lifting cylinders of a crane arranged to operate in tandem and configured to lift a boom.
According to an embodiment, the system may include two hydraulic actuators operating in tandem. In this way, the desired operation may be ensured by using duplicated actuator setting. Two hydraulic cylinders may operate simultaneously in the same direction of movement, or alternatively in opposite directions of movements, but still both cylinders having the same operational purpose and affecting to the same joint or object.
According to an embodiment, the common electric motor of the hydraulic system is an AC motor. In this way, the rotation speed and direction of the motor may be controlled by means of a variable-frequency drive (VFD) whereby the hydraulic actuator is controlled indirectly by means of the VFD controlled AC motor. In practice, the AC motor may be controlled by means of a frequency converter. In other words, the motor may have an inverter drive. In general, the VFD is a type of adjustable-speed drive used in electro-mechanical drive systems to control AC motor speed and torque by varying motor input frequency and voltage. It should be appreciated that other suitable means utilizing power electronics technology and allowing variable speed drive may also be used for achieving the same purpose.
According to an embodiment, the electric motor powering the double pump set is a DC motor, which is an alternative to the previous embodiment utilizing the AC motor. Since speed of the DC motor is directly proportional to armature voltage and inversely proportional to motor flux (which is a function of field current), either armature voltage or field current control may be used to control the speed. Thus, the DC motor may be provided with a DC drive or corresponding DC motor speed control system enabled by the modern power electronics.
According to an embodiment, movement speed and direction of the hydraulic actuator are configured to be proportional to rotation speed and direction of the common electric motor. The pumps are configured to generate for the actuator, which are controlled by the motor, only the needed fluid flow rate which corresponds to the desired movement speed of the controlled actuator. In practice, the operator gives a control command defining direction and speed of movement of the controlled actuator, and a control unit generates a speed request for a drive unit of the common electric motor. Since the movement speed and direction of the actuator are proportional to the rotation speed and direction of the common electric motor, controlling of the system is logical and easy to execute. The control unit may be provided with a processor and software for generating the control commands for the drive unit.
According to an embodiment, the first and second hydraulic pump are connected to the same rotating axle rotated by the common electric motor. In other words, the pumps may have direct mechanical drive. This way, mechanical structure of the rotating arrangement may be very simple, durable, maintenance free, inexpensive and it requires only little space.
According to an embodiment, the first and second hydraulic pump both have a physical mechanical connection to the common electric motor. The mechanical connection may be the above disclosed common rotating axle, but at least in some cases there may be other mechanical arrangements for transmitting the rotation from the common motor to the pumps. For example, there may be a gear box or corresponding force transmitting device for connecting the common motor and the two pumps. This embodiment allows variations for positioning the motor and pumps on the carrier of the mobile work machine, whereby layout of the machine is more flexible.
According to an embodiment, the first hydraulic pump has a first nominal rotation direction and the second hydraulic pump has a second nominal rotation direction. The mentioned first and second nominal directions are in opposite direction relative to each other. In other words, the pumps have inverse pressure effect.
According to an embodiment, the nominal size of the first working pressure space of the hydraulic actuator is greater than the nominal size of the second working pressure space. In this way, the first hydraulic pump may have a first volume flow rate per revolution and the second hydraulic pump may have a second volume flow rate per revolution. The second volume flow rate may be less than the first volume flow rate per revolution. It should be appreciated that the term “volume flow rate per revolution” is also widely known as “displacement volume per revolution,” and also in an even simpler format “displacement per revolution.” In this embodiment the pumps may be dimensioned according to the controlled actuator when the actuator has different volumes on opposite sides of a movable element of the actuator. This is the case in a hydraulic cylinder, wherein volume on a piston rod side is smaller than on the opposite side. However, in a hydraulic motor the volumes of the pressure spaces are typically equal in size.
According to an embodiment, the first and second volume flow rates per revolution are dimensioned proportional to relative nominal sizes of the first and second working pressure space, whereby the capacities of the hydraulic pumps match with the nominal size of the dedicated working pressure spaces.
According to an embodiment, the hydraulic actuator is a hydraulic cylinder, wherein the first working pressure space with a greater nominal size is located on a piston side of the cylinder, and the second working pressure space with a smaller nominal size is located on a piston rod side of the cylinder.
According to an embodiment, the hydraulic actuator is a hydraulic motor and nominal sizes of the first and second working pressure spaces are the same. In this way, volume flow rates per revolution of the pumps may have the same magnitude.
According to an embodiment, the hydraulic circuit is an open circuit system, wherein feed ports of the first and second pump are connected to a reservoir or hydraulic fluid tank. In a closed loop circuit the feed ports of the pumps are connected to receive returning hydraulic fluid directly from the actuator. Also, in the closed loop circuit a charge pump is needed in the loop for maintaining the pressure. Advantages of the open circuit system compared to the closed loop circuit are that the charge pump may be omitted and that simpler commercially available hydraulic components may be used in the system. Thus, the system may be inexpensive and durable.
According to an embodiment, the hydraulic fluid of the first and second working pressure spaces of the hydraulic actuator are configured to be discharged through the dedicated first and second hydraulic pump to a reservoir.
According to an embodiment, the hydraulic system is provided with an energy recovery feature. The system is configured to convert kinetic energy at first into hydraulic energy, and is secondly configured to convert the hydraulic energy into kinetic rotational energy, and further, is finally configured to convert the kinetic rotational energy into electric energy. In the disclosed system, at least one of the mentioned hydraulic pumps is configured to serve as a hydraulic motor when discharged hydraulic fluid flow is flowing through the pump to the reservoir, whereby rotation of the hydraulic pump is generated. The hydraulic pump is then configured to rotate the common electric motor, which is configured to serve as a generator when being de-energized. The rotation of the common electric motor is configured to generate the electric energy. The disclosed energy recovery feature is advantageous for electrically operable mobile work machines especially when they are not connected to an external electric power supply or network. Thereby, the embodiment is well suited for battery operated work machines. Further, the energy recover feature does not require any special components but the feature may be implemented using the basic components of the system. A further advantage is that the recovered energy is transformed into electric energy which is relatively easy to store, or alternatively to direct it for other electrically operated devices.
According to an embodiment, the hydraulic circuit of the hydraulic system is without any energy storage. Thus, the hydraulic system is without any hydraulic energy storage, such as pressure accumulators. Because there is no hydraulic storage elements in the system, the system may be simple in structure and it requires less space and maintenance.
According to an embodiment, the system includes one or more energy storages for storing the generated electrical energy. The mentioned electric energy storages are the only energy storages of the hydraulic system. The mobile work machine may include a battery package or corresponding electric storage device.
According to an embodiment, the system does not include either hydraulic or electric energy storages for storing the recovered energy. Rather, the recovered electric is led away from the system and is utilized immediately for other purposes, such as for driving other electric motors or devices of the mobile work machine.
According to an embodiment, the hydraulic system is configured to recover potential energy and to convert it into electricity when lowering mass. The potential energy recovery may take place when lowering a boom, bucket or dump box, for example.
According to an embodiment, the hydraulic system is configured to recover kinetic energy and to convert it into electricity when stopping of movement of load or mass. The kinetic energy recovery may take place when braking the mobile work machine or its movable components and parts.
According to an embodiment, the first and second hydraulic lines of the hydraulic system are both without any actively controlled valves. This way, the hydraulic system may be simple and power losses caused by the valves may be avoided.
According to an embodiment, the first and second hydraulic lines of the hydraulic system are both without any fluid control elements, such as valves. As it is disclosed already above, operational speed of the actuators are adjusted by the speed controlled electric motor of the hydraulic system.
According to an embodiment, the first and second hydraulic lines of the hydraulic system are both without any directional valves configured to control movement direction of the hydraulic actuator. As it is disclosed already above, operational speed of the actuators are adjusted by the speed controlled electric motor of the hydraulic system.
According to an embodiment, the first hydraulic line includes a first load holding valve for preventing discharge of hydraulic fluid from the actuator when the hydraulic system is non-pressurized, and correspondingly, the second hydraulic line includes a second load holding valve for preventing discharge of hydraulic fluid from the actuator. Due to the load holding valves the actuator is configured to hold its position when no hydraulic power is generated by the first and second hydraulic pumps. In other words, the load holding valves close the hydraulic lines when the hydraulic system is non-pressurized, whereby the actuator is stopped and locked hydraulically to be in immovable state. The load holding valves operate automatically and independently without any external control.
According to an embodiment, the hydraulic lines may only include passive valves, which are not controlled by any control command or signal external to the valve.
According to an embodiment, the hydraulic lines may include passive check valves serving as anti-cavitation valves. The check valves operate independently and automatically without any external control.
According to an embodiment, the system may be provided with at least one pressure setting device connected to at least one pressure line. However, the purpose of such device is to protect the hydraulic system and not to control operation of the connected actuator. The pressure setting device is meant for special situations and needs.
According to an embodiment, the above mentioned mobile work machine is a mobile mining machine. The mining machine includes a movable carrier and one or more mine work devices for executing mining work at an underground or surface mine work site. The mining machine includes a hydraulic system for moving the mine work device and the hydraulic system is in accordance with the previously disclosed embodiments. The mining machine may be a rock drilling rig, a hauling truck, a wheel loader, a bolting rig, a shotcrete vehicle or a charging vehicle.
According to an embodiment, the mining machine is a rock drilling rig including at least one drilling boom provided with a drilling unit. The drilling boom includes at least one hydraulic boom cylinder for moving the drilling boom. Movement speed and direction of the mentioned boom cylinder connected to the dedicated hydraulic system is configured to be controlled by the speed controlled electric motor.
According to an embodiment, the mining machine is a frame steered machine such as a wheel loader, hauling truck or rock drilling rig including two frame parts and a steering joint between the frame parts. The frame parts are turned during steering relative to each other by at least one hydraulic steering cylinder connected to the dedicated hydraulic system. Further, movement speed and direction of the at least one steering cylinder is configured to be controlled by the speed controlled electric motor. The machine may include a doubled steering actuator system including two steering cylinders operating parallel or in opposite directions. Cylinders are accurate and powerful hydraulic actuators which can be easily controlled by the disclosed system.
According to an embodiment, the mining machine is a wheel loader including a bucket which is connected to the carrier by at least one lifting arm. The lifting arm is movable relative to the carrier by at least one hydraulic lifting cylinder connected to the dedicated hydraulic system. Further, movement speed and direction of the at least one lifting cylinder is configured to be controlled by the speed controlled electric motor. The system may include one single lifting cylinder or two cylinders that operate in tandem.
According to an embodiment, the mining machine is a wheel loader including a bucket which is connected to the carrier by at least one lifting arm. The lifting arm is movable relative to the carrier by at least one hydraulic lifting cylinder connected to the dedicated hydraulic system. Further, the bucket may be tilted relative to a distal end of the lifting arm, i.e., the bucket may be turned by one or more hydraulic tilting cylinders relative to the lifting arm. Movement speed and direction of the at least one tilting cylinder is configured to be controlled by the speed controlled electric motor. The system may include one single tilting cylinder or two cylinders may operate in tandem.
According to an embodiment, the mining machine is a frame steered wheel loader including one or more steering cylinders, and a bucket which is connected to the carrier by at least one lifting arm. The machine further includes one or more lifting cylinders and one or more tilting cylinders for moving the bucket. The above-mentioned steering cylinders, lifting cylinders and tilting cylinders may be controlled as described herein.
According to an embodiment, the mining machine is a hauling truck including a dump box for receiving rock material. The dump box is movable relative to the carrier by at least one hydraulic dump cylinder connected to the dedicated hydraulic system. Further, movement speed and direction of the at least one dump cylinder is configured to be controlled by the speed controlled electric motor. The system may include one single dump cylinder or two cylinders that operate in tandem.
According to an embodiment, control features of the speed controlled motor may be software controlled, whereby the control features may be adjusted by a software program and input parameters. The motor may be controlled by a control unit including a processor for executing the software program. In this way, the control principles of the motor and the directly affected actuator may be easily changed by adjusting the input parameters or by reprogramming the software, or both.
According to an embodiment, the mobile work machine is a forest machine such as a harvester, forwarder or other forest tractor. The forest machines are typically frame steered vehicles and may thereby include steering cylinders. The forest machines may also include booms which may be lifted and turned by means of hydraulic cylinders or motors. Alternatively, the mobile work machine may be an excavator or earth moving machine including a hydraulic rotating motor for turning its upper frame relative to a lower frame provided with wheels or crawler tracks. The excavators also includes a boom, which may be lifted by a cylinder. Further, the mobile work machine may be a pile driving rig, a mobile crane or a person lifter, which all may include one or more lifting cylinders, which may be connected to the disclosed hydraulic system with a one motor, two pumps arrangement.
The above disclosed embodiments may be combined in order to form suitable solutions having those of the above features that are needed.
The foregoing summary, as well as the following detailed description of the embodiments, will be better understood when read in conjunction with the appended drawings. It should be understood that the embodiments depicted are not limited to the precise arrangements and instrumentalities shown.
Some embodiments are described in more detail in the accompanying drawings, in which:
For the sake of clarity, the figures show some embodiments of the disclosed solution in a simplified manner. In the figures, like reference numerals identify like elements.
The machine 2 includes at least one hydraulic system 11 or circuit for generating hydraulic power for the hydraulic actuators. For clarity reasons the hydraulic system 11 is shown in a simplified manner. The machine 2 may include one or more improved hydraulic systems disclosed herein for powering and controlling dedicated hydraulic actuators, such as the steering cylinders 7 and the lifting cylinders 9. The above disclosed solutions and embodiments may be applied in all type of rigs being implemented in mine operations. The same applies to both surface and underground machines.
As can be noted, operation of the hydraulic actuator HA is controlled by controlling the motor since there are no control valves in the fluid lines 19a, 19b. When the motor M receives speed and direction request from the control unit CU, it begins to rotate in direction R1, whereby the first pump P1 generated pressure P+ to the pressure port 18b of the hydraulic actuator HA. Thereafter, the moving member of the hydraulic actuator initiates its movement in the direction A and hydraulic fluid is discharged from the actuator HA through the pressure port 18b. Simultaneously, the second pump P2 is rotated by the motor M and the pump P2 causes suction P- to the pressure line 19b. When the actuator HA is moved in the opposite direction, then direction of the motor M is changed and rotational speed of the motor M is adjusted in accordance with the desired movement speed of the actuator HA. This way, movement control of the actuator HA is controlled indirectly by the electric motor M without a need for any directional control valves.
Although the present embodiment(s) has been described in relation to particular aspects thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred therefore, that the present embodiment(s) be limited not by the specific disclosure herein, but only by the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 18160925.6 | Mar 2018 | EP | regional |
