The present invention relates to battery-powered utility vehicles, for example stand-on loaders, excavators, skid-loaders, forklifts, and the like, and more particularly to hydraulic systems used with such vehicles.
In one aspect, the invention provides a hydraulic system configured to provide a variable flow of hydraulic fluid to a first load circuit and a second load circuit. The hydraulic system includes a pump configured to pressurize and output hydraulic fluid, an electric motor selectively driving the pump, and a controller configured to selectively control a target speed of the electric motor based on input from an operator control. A first proportional directional control valve is in the first load circuit and communicates with the pump and the controller. The first proportional directional control valve controls a flow of hydraulic fluid to a first hydraulic actuator associated with the first load circuit such that the flow of hydraulic fluid to the first hydraulic actuator is proportional to a first signal provided by the controller. The first signal is a function of the input from the operator control. A second proportional directional control valve is in the second load circuit and communicates with the pump and the controller. The second proportional directional control valve controls a flow of hydraulic fluid to a second hydraulic actuator associated with the second load circuit such that the flow of hydraulic fluid to the second hydraulic actuator is proportional to a second signal provided by the controller. The second signal is a function of the input from the operator control.
In another aspect, the invention provides a hydraulic system configured to provide a variable flow of hydraulic fluid to a load circuit. The hydraulic system includes a pump configured to pressurize and output hydraulic fluid, an electric motor selectively driving the pump, and a controller configured to selectively control a target speed of the electric motor based on input from an operator control. A proportional directional control valve is in the load circuit and communicates with the pump and the controller. The proportional directional control valve controls a flow of hydraulic fluid to a hydraulic actuator associated with the load circuit such that the flow of hydraulic fluid to the hydraulic actuator is proportional to a signal provided by the controller. The signal is a function of the input from the operator control. Flow of hydraulic fluid to the hydraulic actuator through the proportional directional control valve is varied by the controller making a) variations of the target speed of the motor, and b) variations of the signal to the proportional directional control valve.
In yet another aspect, the invention provides a stand-on loader including a frame, the frame supporting a platform configured to support an operator of the loader, a boom configured to raise or lower a load; and a bucket coupled to the boom for supporting the load. The loader further includes a hydraulic system configured to provide a variable flow of hydraulic fluid to a boom raise/lower circuit and a bucket tilt circuit. The hydraulic system includes a pump configured to pressurize and output hydraulic fluid, an electric motor selectively driving the pump, and a controller configured to selectively control a target speed of the electric motor based on input from an operator control. A first proportional directional control valve is in the boom raise/lower circuit and communicates with the pump and the controller. The first proportional directional control valve controls a flow of hydraulic fluid to a first hydraulic cylinder associated with the boom such that the flow of hydraulic fluid to the first hydraulic cylinder is proportional to a first signal provided by the controller. The first signal is a function of the input from the operator control associated with raising or lowering the boom. A second proportional directional control valve is in the bucket tilt circuit and communicates with the pump and the controller. The second proportional directional control valve controls a flow of hydraulic fluid to a second hydraulic cylinder associated with the bucket such that the flow of hydraulic fluid to the second hydraulic cylinder is proportional to a second signal provided by the controller. The second signal being a function of the input from the operator control associated with tilting the bucket. The pump and the electric motor are positioned adjacent to the platform, and control of the target speed of the electric motor by the controller is open-loop control in which the target speed of the motor is proportional to a magnitude of the input from the operator control regardless of a pressure generated by the pump.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
The utility vehicle 10 further includes a lift system 26 including a bucket 30 supported by a boom 34. The bucket 30 can be raised and lowered by movement of the boom 34, and can also be tilted for dumping or carrying. An electric-powered hydraulic system 38 is schematically illustrated in
The main controller 54 is a microprocessor-based controller having hardware systems for accepting electrical input signals (e.g., from the operator controls 58), hardware systems for driving electrical outputs, and hardware systems for two-way communications. The main controller 54 may include one or more electronic processors and one or more memory devices. The controller 54 may be communicably connected to one or more sensors or other inputs, such as described herein. The electronic processor may be implemented as a programmable microprocessor, an application specific integrated circuit (ASIC), one or more field programmable gate arrays (FPGA), a group of processing components, or with other suitable electronic processing components. The memory device (for example, a non-transitory, computer-readable medium) includes one or more devices (for example, RAM, ROM, flash memory, hard disk storage, etc.) for storing data and/or computer code for completing the or facilitating the various processes, methods, layers, and/or modules described herein. The memory device may include database components, object code components, script components, or other types of code and information for supporting the various activities and information structure described in the present application. According to one example, the memory device is communicably connected to the electronic processor and may include computer code for executing one or more processes described herein. The controller 54 may further include an input-output (“I/O”) module. The I/O module may be configured to interface directly with one or more devices, such as a power supply, sensors, displays, etc. In one embodiment, the I/O module may utilize general purpose I/O (GPIO) ports, analog inputs/outputs, digital inputs/outputs, and the like.
While
The operator controls 58 provide the input from the operator for the desired action to be taken by the lift system 26 (as well as other inputs for other vehicle actions not discussed herein). These controls can take any suitable form (e.g., buttons, switches, levers, joysticks, dials, knobs, wheels, handlebars, combinations thereof, and the like). In the illustrated embodiment, a transducer converts the position of one or more control levers for the lift system 26 into respective electrical signals. For example, when a control lever is in a neutral/centered position, the transducer will generate a predetermined voltage signal indicative of the neutral/centered position. The voltage signal will then change when the lever is moved out of its neutral/centered position to provide the desired signal(s) to the main controller 54. Additional inputs, such as a main on/off control are also provided on the operator controls 58. Only when the main on/off control is in the on position will the main controller 54 activate the contactor 62 to permit the battery 66 and its battery controller 70 to power the motor controller 50 and the motor 46.
With reference to
The portion of the hydraulic system 38 associated with the raising/lowering functionality of the boom 34 (i.e., the raise/lowering hydraulic circuit or the first load circuit) will now be described with respect to
The hydraulic system 38 further includes a raise/lower proportional directional flow control valve 94 communicating with output and return lines 82, 90. The raise/lower directional flow control valve 94 is a proportional spool valve that is operated to shift between the three illustrated positions by a lower proportional solenoid 98 and a raise proportional solenoid 102. More specifically, when the main controller 54 observes the predetermined neutral/centered position input signal from the operator controls 58 associated with the raise/lower functionality (e.g., the control lever is in the neutral/centered position), neither proportional solenoid 98, 102 is actuated, and thus, the valve 94 remains in the centered position shown in
When the operator moves the operator controls 58 out of the neutral/centered position for a desired raising or lowering operation, the corresponding signal is sent to the main controller 54 and the logic programming of the main controller 54 controls the output signals to the proportional solenoids 98, 102. The signals to the solenoids 98, 102 will be variable, such as a variable voltage or variable resistance. The magnitude of the signal will vary as a function of how far the operator moves the control away from the neutral/centered position. The control can be moved in a first direction to control lowering of the boom 34 and can be moved in an opposite second direction to control raising of the boom 34.
When the main controller 54 receives this input signal from the operator control 58, it will first send a signal to the motor controller 50 to drive the motor 46 to rotate the pump 42 at a target speed that is a function of the magnitude of the input signal received from the operator control 58. In other words, the further the operator moves the control lever away from the neutral/centered position, the faster the target speed for the motor 46, and hence the faster the rotation of the pump 42. This control is open-loop in regards to the control signal from the main controller 54 to the motor controller 50 because the target speed of the motor 46 is set as a function of the operator control signal regardless of a pressure generated by the pump 42.
This open-loop control system for controlling the motor 46 and pump 42 is not an obvious solution. Commonly a closed-loop control system would be used, in which hydraulic pressure generated by the pump would be used as feedback so that the speed of the motor driving the pump could be reduced when an adequate pressure was generated. This closed-loop technique reduces the occurrences of when the motor drives the pump to generate excessive flow—more flow than is required for the demanded action. This closed-loop technique reduces parasitic loads, thereby improving efficiency. However, with the utility vehicle 10, the closed-loop control resulted in noticeable distracting noise from the resulting frequent speed variation of the motor 46 and pump 42. Notice in
The motor controller 50 will receive this target signal and appropriately control the voltage/current provided to the permanent magnet AC motor 46 to achieve the desired target speed. The motor controller 50 will receive feedback from the motor 46, thereby forming a closed-loop control of the motor speed by the motor controller 50, enabling the motor controller 50 to adjust the electric current provided to the motor 46 to maintain the target speed even as load on the motor 46 varies. This system thereby reduces noise fluctuations at the motor 46, improving the operating experience for the user.
The main controller 54 will also send a signal to the appropriate proportional solenoid 98, 102 so that pressurized hydraulic fluid will be properly directed by the flow control valve 94. Specifically, should the operator controls 58 indicate that a boom lowering action is desired, the main controller 54 will send the appropriate signal to the lower solenoid 98, thereby shifting the valve 94 proportionally to the right in the arrangement shown in
The illustrated hydraulic system 38 can include additional components located between the directional control valve 94 and the hydraulic cylinders 74. For example, a priority valve 106 is shown communicating with the valve 94. As will be discussed in greater detail below, this priority valve 106 is operable to prioritize the flow of hydraulic fluid to the hydraulic cylinders 74 associated with the raise/lower functionality, and the flow of hydraulic fluid to the hydraulic cylinder 110 associated with the bucket tilt functionality. The priority valve 106 cooperates with the directional control valve 94 so that the appropriate amount of hydraulic fluid is ultimately output from the valve 94 to the cylinders 74.
The illustrated hydraulic system 38 further includes solenoids and valving operable to provide a float functionality for the boom 34 and bucket 30. The float functionality, when selected by the operator controls 58, allows the boom 34 and bucket 30 to float or follow the contours of the terrain. If the operator selects/activates the float functionality with the operator controls 58, appropriate signals are sent to associated float solenoids 114, which control respective float valves 118. These valves 118 selectively communicate with associated load holding valves 122 to provide the float functionality within the hydraulic system 38 for the hydraulic cylinders 74.
The portion of the hydraulic system 38 associated with the tilt functionality of the bucket 30 (i.e., the tilting hydraulic circuit or the second load circuit) will now be described with respect to
When the operator moves the operator controls 58 out of the neutral/centered position for a desired bucket tilting operation, the corresponding signal is sent to the main controller 54 and the logic programming of the main controller 54 controls the output signals to the proportional solenoids 130, 134. The signals to the solenoids 130, 134 will be variable, such as a variable voltage or variable resistance. The magnitude of the signal will vary as a function of how far the operator moves the control away from the neutral/centered position. The control can be moved in a first direction to control tilt up of the bucket 30 and can be moved in an opposite second direction to control tilt down of the bucket 30.
When the main controller 54 receives this input signal from the operator control 58 for tilting, it will first send a signal to the motor controller 50 to drive the motor 46 to rotate the pump 42 at a target speed that is a function of the magnitude of the input signal received from the operator control 58. The main controller 54 will coordinate the target speed of the motor 46 based on both the input relating to bucket tilting and the input relating to boom raising/lowering. The logic could set the target speed as a maximum flow rate associated with the two separate controls, or as a combined target flow rate associated with the two separate controls. The motor control for the tilting functionality is the same open-loop control as that described above with respect to the raise/lower functionality and will not be described again.
When the operator controls 58 indicate that a bucket tilt up action is desired, the main controller 54 will send the appropriate signal to the tilt up solenoid 130, thereby shifting the valve 126 proportionally to the right in the arrangement shown in
The illustrated hydraulic system 38 can include additional components located between the directional control valve 126 and the hydraulic cylinder 110. For example, a priority valve 138 is shown communicating with the valve 126. This priority valve 138 is operable to prioritize the flow of hydraulic fluid to the hydraulic cylinder 110 associated with the bucket tilt functionality, and the flow of hydraulic fluid to the hydraulic cylinders 74 associated with the boom raise/lower functionality. The priority valve 138 cooperates with the directional control valve 126 so that the appropriate amount of hydraulic fluid is ultimately output from the valve 126 to the cylinder 110.
The priority valve 138 associated with the bucket tilting functionality communicates with the priority valve 106 associated with the boom raise/lower functionality through a pilot pressure signal line 142. This signal line 142 communicates the pressure demands or load signal between the boom raise/lower portion of the hydraulic system 38 and the bucket tilting portion of the hydraulic system 38 to balance a bias of the priority valves 106 and 108 toward a maximum flow restriction position. Each priority valve 106, 138 further has its own respective pilot signal line 146, 150 biasing the respective valve 106, 138 toward a minimum flow restriction position based on the flow to the valves 94 and 126 generated by the pump 42. Together, the pilot pressure signal lines 142, 146, 150 cooperate to control how much hydraulic fluid will be output through each directional control valve 94, 126 based on the load demands on the hydraulic system 38. The two directional control valves 94, 126 provide the ability to separately control the speed and direction of movement of the boom raise/lower system and the bucket tilting system. The priority valves 106, 138 coordinate the flow so that separate, independent control capabilities for raise/lower and tilt functionalities are provided.
For example, an operator could want to raise a load while at the same time tilt the bucket 30 down to maintain a level of the bucket 30. In this situation there may be a relatively high pressure necessary on a butt-end of the lift cylinder to raise the boom 34 by extending the lift cylinders 74. There could also be a very low pressure needed on the rod-end of the tilt cylinder 110. The two directional control valves 94, 126 provide the ability to separately control the speed and direction of movement of these separate systems. The capability for separate, independent control is provided by the system having separate controls sending signals to the main controller 54, and the main controller 54 sending separate signals to the appropriate proportional control solenoids 98, 102, 130, 134 in coordination with sending a target speed signal to the motor controller 50 to control the speed of the motor 46 and the speed of rotation of the pump 42.
The illustrated hydraulic system 38 further includes a load holding valve 154 that holds the tilt angle of the bucket 30. No float functionality for bucket tilt is provided in the illustrated embodiment.
Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described.
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