Patent Application
20080053191
Frame 12 may include any structural unit that supports movement of machine 10. Frame 12 may be, for example, a stationary base frame connecting a power source (not shown) to a traction device 18, a movable frame member of a linkage system, or any other frame known in the art.
Implement 14 may include any device used in the performance of a task. For example, implement 14 may include a blade, a bucket, a shovel, a ripper, a dump bed, a propelling device, or any other task-performing device known in the art. Implement 14 may be connected to frame 12 via a direct pivot 20, via a linkage system with hydraulic cylinder 16 forming one member in the linkage system, or in any other appropriate manner. Implement 14 may be configured to pivot, rotate, slide, swing, or move relative to frame 12 in any other manner known in the art.
As illustrated in
Each of head-end and rod-end supply and drain valves 26, 28, 30, 32 may be an independent metering valve (IMV) that is independently operable to be in fluid communication with source 24, hydraulic cylinder 16, tank 34, and/or any other device present in hydraulic system 22. Each of head-end and rod-end supply and drain valves 26, 28, 30, 32 may be independently metered to control hydraulic flow in multiple hydraulic paths. Controller 70 controls each of the independently operable valves 26, 28, 30, 32.
Each of head-end and rod-end supply and drain valves 26, 28, 30, 32 includes a valve spool 26a, 28a, 30a, 32a and an actuator 26b, 28b, 30b, 32b to move respective valve spool 26a, 28a, 30a, 32a to a desired position to thereby control the hydraulic flow through valve 26, 28, 30, 32. The displacement of each valve spool 26a, 28a, 30a, 32a changes the flow rate of the hydraulic fluid through the associated valve 26, 28, 30, 32. Actuator 26b, 28b, 30b, 32b may be a solenoid actuator or any other actuator known to those skilled in the art.
Hydraulic cylinder 16 may include a tube 46 and a piston assembly 48 disposed within tube 46. One of tube 46 and piston assembly 48 may be pivotally connected to frame 12, while the other of tube 46 and piston assembly 48 may be pivotally connected to implement 14. It is contemplated that tube 46 and/or piston assembly 48 may alternately be fixedly connected to either frame 12 or implement 14. Hydraulic cylinder 16 may include a first chamber 50 and a second chamber 52 separated by piston assembly 48. In the exemplary embodiment shown in
Piston assembly 48 may include a piston 54 axially aligned with and disposed within tube 46, and a piston rod 56 connectable to one of frame 12 and implement 14 (referring to
Source 24 may be configured to produce a flow of pressurized fluid and may include a pump such as, for example, a variable displacement pump, a fixed displacement pump, or any other source of pressurized fluid known in the art. Source 24 may be drivably connected to a power source (not shown) of machine 10 by, for example, a countershaft (not shown), a belt (not shown), an electrical circuit (not shown), or in any other suitable manner. Source 24 may be dedicated to supplying pressurized fluid only to hydraulic system 22, or alternately may supply pressurized fluid to additional hydraulic systems (not shown) within machine 10.
A head-end valve section 40 includes head-end supply valve 26 and head-end drain valve 28. Head-end supply valve 26 may be disposed between source 24 and first chamber 50 and configured to regulate a flow of pressurized fluid to first chamber 50. Head-end supply valve 26 may include a two-position spring biased valve mechanism that is actuated by solenoid 26b and configured to move valve spool 26a between a first (open) position at which fluid is allowed to flow into first chamber 50 and a second (closed) position at which fluid flow is blocked from first chamber 50. Head-end drain valve 28 may be disposed between first chamber 50 and tank 34 and configured to regulate a flow of pressurized fluid from first chamber 50 to tank 34. Head-end drain valve 28 may include a two-position spring biased valve mechanism that is actuated by solenoid 28b and configured to move valve spool 28a between a first (open) position at which fluid is allowed to flow from first chamber 50 and a second (closed) position at which fluid is blocked from flowing from first chamber 50.
A rod-end valve section 42 includes rod-end supply valve 30 and rod-end drain valve 32. Rod-end supply valve 30 may be disposed between source 24 and second chamber 52 and configured to regulate a flow of pressurized fluid to second chamber 52. Rod-end supply valve 30 may include a two-position spring biased valve mechanism that is actuated by solenoid 30b and configured to move valve spool 30a between a first (open) position at which fluid is allowed to flow into second chamber 52 and a second (closed) position at which fluid is blocked from second chamber 52. Rod-end drain valve 32 may be disposed between second chamber 52 and tank 34 and configured to regulate a flow of pressurized fluid from second chamber 52 to tank 34. Rod-end drain valve 32 may include a two-position spring biased valve mechanism that is actuated by solenoid 32b and configured to move valve spool 32a between a first (open) position at which fluid is allowed to flow from second chamber 52 and a second (closed) position at which fluid is blocked from flowing from second chamber 52.
One or more head-end and rod-end supply and drain valves 26, 28, 30, 32 may include additional or different valve mechanisms such as, for example, a proportional valve element or any other valve mechanism known in the art. Furthermore, one or more head-end and rod-end supply and drain valves 26, 28, 30, 32 may alternately be hydraulically actuated, mechanically actuated, pneumatically actuated, or actuated in any other suitable manner. Hydraulic system 22 may include additional components to control fluid pressures and/or flows within hydraulic system 22 such as relief valves, makeup valves, shuttle valves, check valves, hydro-mechanically actuated proportional control valves, etc. For example, a bypass valve (not shown) may be provided for adjusting the pressure of the fluid. The bypass valve may allow flow from pump 24 to bypass into tank 34.
Head-end and rod-end supply and drain valves 26, 28, 30, 32 may be fluidly interconnected. In particular, head-end and rod-end supply valves 26, 30 may be connected in parallel to an upstream fluid passageway 60. Upstream common fluid passageway 60 may be connected to receive pressurized fluid from pump 24 via a supply passageway 62. Head-end and rod-end drain valves 28, 32 may be connected in parallel to a drain passageway 64. Head-end supply and return valves 26, 28 may be connected in parallel to a first chamber fluid passageway 61. Rod-end supply and return valves 30, 32 may be connected in parallel to a second chamber fluid passageway 63.
Tank 34 may constitute a reservoir configured to hold a supply of fluid. The fluid may include, for example, a dedicated hydraulic oil, an engine lubrication oil, a transmission lubrication oil, or any other fluid known in the art. One or more hydraulic systems within machine 10 may draw fluid from and return fluid to tank 34. It is also contemplated that hydraulic system 22 may be connected to multiple separate fluid tanks.
Hydraulic system 22 also includes one or more pressure sensors 36, 37, 38. For example, pressure sensor 36 monitoring an output pressure P of pump 24 may be provided in supply fluid passageway 62. When the fluid passes from pump 24 to hydraulic system 22, pressure sensor 36 in supply fluid passageway 62 monitors the output pressure P of the fluid supplied by pump 24 entering hydraulic system 22, and transmits an output signal reflecting the measured pressure to controller 70. The pressure sensor(s) 36, 37, 38 can be placed at any location suitable to determine a desired pressure of fluid supplied by pump 24. The exemplary calibration method described below determines output pressure P of pump 24 using pressure sensor 36. It is understood, however, that the calibration method may determine pressure P using pressure sensor(s) at other locations in hydraulic system 22, such as, for example, pressure sensors 37, 38. As shown in
Controller 70 may embody a single microprocessor or multiple microprocessors that include a means for controlling an operation of hydraulic system 22. Numerous commercially available microprocessors can be configured to perform the functions of controller 70. It should be appreciated that controller 70 could readily be embodied in a general machine microprocessor capable of controlling numerous machine functions. Controller 70 may include a memory, a secondary storage device, a processor, and any other components for running an application. Various other circuits may be associated with controller 70 such as power supply circuitry, signal conditioning circuitry, solenoid driver circuitry, and other types of circuitry. Controller 70 may be connected to at least one operator input device 68 that allows an operator to control the operation of one or more components of the hydraulic system 22 using one or more control devices known in the art, such as one or more pedals, switches, dials, paddles, joysticks, etc.
Controller 70 is electrically coupled to pressure sensors 36 and actuators 26b, 28b, 30b, 32b of the head-end and rod-end supply and drain valves 26, 28, 30, 32. Controller 70 receives pressure readings from pressure sensor 36 and may be configured to receive input from operator input device 68. Controller 70 sends one or more electrical command signals to actuators 26b, 28b, 30b, 32b. In response to the electrical command signal(s), one or more actuators 26b, 28b, 30b, 32b apply a varying force to controllably move one or more valve spools 26a, 28a, 30a, 32a to a desired displacement to control the hydraulic flow through the hydraulic system 22.
Hydraulic cylinder 16 may be movable by fluid pressure in response to an operator input using operator input device 68. Fluid may be pressurized by source 24 and directed to head-end and rod-end supply valves 26 and 30. In response to an operator input to either extend or retract piston assembly 48, one of head-end and rod-end supply valves 26 and 30 may move to the open position to direct the pressurized fluid to the appropriate one of first and second chambers 50, 52. Substantially simultaneously, one of head-end and rod-end drain valves 28, 32 may move to the open position to direct fluid from the appropriate one of the first and second chambers 50, 52 to tank 34 to create a pressure differential across piston 54 that causes piston assembly 48 to move. For example, if an extension of hydraulic cylinder 16 is requested, head-end supply valve 26 may move to the open position to direct pressurized fluid from source 24 to first chamber 50. Substantially simultaneous to the directing of pressurized fluid to first chamber 50, rod-end drain valve 32 may move to the open position to allow fluid from second chamber 52 to drain to tank 34. If a retraction of hydraulic cylinder 16 is requested, rod-end supply valve 30 may move to the open position to direct pressurized fluid from source 24 to second chamber 52. Substantially simultaneous to the directing of pressurized fluid to second chamber 52, head-end drain valve 28 may move to the open position to allow fluid from first chamber 50 to drain to tank 34.
Current control system 80 transmits spool displacement command 82 to an actuator transform 84. Actuator transform 84 creates a nominal (or desired) current command 72 based on spool displacement command 82. Current control system 80 then transmits nominal current command 72 to a modifier 86 that outputs an actual current command 76 based on nominal current command 72. In the exemplary embodiment shown in
Calibration offset current command 74 is determined for each valve 26, 28, 30, 32 by a calibration method as described below. The calibration of valves 26, 28, 30, 32 includes determining the point at which flow begins through the valve being calibrated, and this point is commonly referred to as the cracking point. Calibration of one or more valves 26, 28, 30, 32 may occur once or multiple times, e.g., after assembling hydraulic system 22, periodically at the work site, after certain events, etc. In the exemplary embodiment, calibration offset current command 74 is based on a current command from controller 70 at the cracking point that is determined during the calibration of valve 26, 28, 30, 32. In the exemplary embodiment, calibration offset current command 74 equals the cracking point current command, i.e., the current command at the cracking point, determined using the calibration method described below, minus the expected (or desired) current command at the cracking point. The expected current command at the cracking point is a predetermined current command that is expected to open respective valve 26, 28, 30, 32. It is understood, however, that the calibration offset current command 74 may also depend on other factors associated with valves 26, 28, 30, 32, etc.
Controller 70 may close all valves 26, 28, 30, 32 by supplying zero or substantially zero current to all valves 26, 28, 30, 32 (step 102). Controller 70 then sends a command to pump 24 to raise its output pressure P to a predetermined level (step 104). In addition, controller 70 may send a command to a bypass valve (not shown) located downstream from pump 24 to raise the output pressure P from pump 24. The fluid from pump 24 is supplied at the predetermined pressure level at least to valve section 40 (i.e., the valve section that includes the valve being calibrated). In the exemplary embodiment, pump 24 supplies fluid to both valve sections 40, 42.
Controller 70 then increases a current to actuator 26b of head-end supply valve 26 (i.e., the actuator of the valve being calibrated), and substantially simultaneously, controller 70 also directs a full current to actuator 28b of head-end drain valve 28 (i.e., the actuator of the opposite valve in the same valve section as the valve being calibrated) (step 106). As a result, the full current to actuator 28b fully opens head-end drain valve 28. As controller 70 increases the current directed to actuator 26b of head-end supply valve 26, the output pressure P of pump 24 is measured by pressure sensor 36. The pressure sensor 36 transmits an output signal reflecting the measured output pressure P to controller 70 (step 108).
Controller 70 also calculates a derivative dP/dt of the measured output pressure P of pump 24 with respect to time, i.e., a rate of pressure change. The derivative dP/dt of the measured output pressure P of pump 24 is zero as controller 70 increases the current to actuator 26b of head-end supply valve 26 and while head-end supply valve 26 is closed. When head-end supply valve 26 opens and allows flow to pass, the output pressure P of pump 24 decreases, and the derivative dP/dt of the output pressure P of pump 24 changes rapidly. Controller 70 monitors the derivative dP/dt and determines when the derivative dP/dt is greater than a predetermined threshold and remains above the threshold for a predetermined period of time (step 110). For example, controller 70 may determine when the derivative dP/dt of the measured output pressure P of pump 24 is greater than the predetermined threshold and continues to remain over the predetermined threshold for a predetermined time interval (e.g., 0.5 second, 1 second, etc.). If the derivative dP/dt is not greater than the predetermined threshold or the derivative dP/dt does not remain greater than the predetermined threshold before the predetermined time interval has elapsed (step 110; no), then the process returns to step 106. Controller 70 then continues to increase the current to actuator 26b of head-end supply valve 26 and to compute the derivative dP/dt of the output pressure P of pump 24 until the derivative dP/dt is greater than the predetermined threshold for the predetermined period of time (steps 106-110).
When controller 70 determines that the derivative dP/dt is greater than the predetermined threshold for the predetermined period of time (step 110; yes), then controller 70 determines and stores the current command sent to actuator 26b of head-end supply valve 26 when the derivative dP/dt of output pressure P of pump 24 begins to be greater than the predetermined threshold, i.e., the start of the predetermined period of time that the derivative dP/dt continued to remain above the predetermined threshold (step 112). As shown in
After the predetermined number of current commands have been stored (step 114; yes), then controller 70 calculates an average of the stored current commands, and a maximum deviation from the calculated average. The maximum deviation is the largest difference between the predetermined number of stored current commands and the calculated average. Controller 70 then determines if the maximum deviation is less than a predetermined threshold (step 116).
If the maximum deviation is less than a predetermined threshold (step 116; yes), then controller 70 computes the calibration offset current command 74 for head-end supply valve 26 by subtracting the calculated average of the stored current commands minus the expected cracking point current command (step 118). Controller 70 stores the computed calibration offset current command 74 (step 120), and then the calibration of head-end supply valve 26 is complete. The process shown in
If, at step 116, the maximum deviation is not less than the predetermined threshold (step 116; no), then controller 70 determines if a predetermined maximum number of attempts (e.g., eight) to determine the cracking point current command has been reached (step 122). If the predetermined maximum number of attempts has not been reached (step 122; no), then the process returns to step 102 so that controller 70 may determine another cracking point current command by repeating steps 102 to 116, removing the oldest cracking point current command and computing another maximum deviation with the newest cracking point current command. However, if the predetermined maximum number of attempts has been reached (step 122; yes), then the calibration of head-end supply valve 26 is incomplete, and the calibration offset current command 74 may be, e.g., zero or a previously determined calibration offset current command. The process may return to step 102 at a later time to determine the cracking point current command and compute the calibration offset current command 74.
The disclosed calibration method may be applicable to any valve arrangement, such as an arrangement of IMVs, for controlling a fluid actuator where balancing of pressures and/or flows of fluid supplied to the actuator is desired. The disclosed calibration method may provide consistent actuator performance in a low cost simple configuration and may achieve precise positioning of valves of the valve arrangement.
The method of calibrating any of head-end and rod-end supply and drain valves 26, 28, 30, 32 includes determining the cracking point current command, i.e., the current command at which the valve being calibrated begins to allow fluid to pass. In the exemplary embodiment, calibration offset current command 74 is the cracking point current command minus the expected current command at the cracking point. Calibration offset current command 74 is added to nominal current command 72 to determine actual current command 76. Therefore, actual valve behavior may be predicted based on the cracking point current command determined using the exemplary disclosed calibration method. Actual current command 76 is transmitted from controller 70 to actuator 26b, 28b, 30b, 32b of valve 26, 28, 30, 32 to control the respective valve 26, 28, 30, 32, and is determined by summing nominal current command 72 and calibration offset current command 74.
Calibration offset current command 74 is used to shift nominal control curve 90 so that performance of valve 26, 28, 30, 32 becomes actual control curve 92. This shift compensates for variations in the actual valve behavior compared to the nominal (or desired) valve position due to, for example, variations in an individual component's design and/or assembly.
During the calibration of head-end supply valve 26, zero current is first applied to actuators 26b, 28b, 30b, 32b of valves 26, 28, 30, 32 as the pump output pressure P is raised to a predetermined level. As a result, fluid begins to flow to valves 26, 28, 30, 32. Current is applied to actuator 26b of head-end supply valve 26, and the current applied to actuator 26b is ramped up from zero while a full current at a predetermined level is applied to actuator 28b of head-end drain valve 28. Meanwhile, the pump output pressure P is monitored. Since the pump output pressure P is monitored during the calibration of valves 26, 28, 30, 32, calibration may be performed for each of valves 26, 28, 30, 32 with a single pressure sensor 36 disposed near the outlet of pump 24. Therefore, fewer pressure sensors may be required, thereby simplifying the valve calibration method and reducing any discrepancies that may occur when using multiple pressure sensors.
The derivative dP/dt of the pump output pressure P is calculated and compared against a predetermined threshold. If the derivative dP/dt remains greater than the predetermined threshold over a predetermined time interval, then the current command applied to actuator 26b at the start of the time interval is determined and stored. By applying the condition for the derivative dP/dt to be greater than the predetermined threshold for a predetermined period of time, a more accurate assessment of when valve 26, 28, 30, 32 is opening may be determined.
The calibration for a given valve 26, 28, 30, 32 may be performed multiple times, and the maximum deviation is calculated each time. When the maximum deviation is below the predetermined threshold, the calibration of the given valve 26, 28, 30, 32 is considered valid and corresponding calibration offset current command 74 is stored. As a result, pressure transients and pressure sensor noise, such as pressure spikes, may be prevented from causing an invalid calibration. Thus, pressure-based calibration may be more consistent and suitably accurate for field calibrations where conditions are not always strictly controlled.
It will be apparent to those skilled in the art that various modifications and variations can be made to the method for calibrating IMVs. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed method for calibrating IMVs. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.
