This disclosure relates generally to machines for hauling material and, in particular, to drive trains in such machines distributing torque to the wheels of the machine based on a work cycle step being performed by the machine, a weight distribution of a load, the speed and direction of the machine, and the terrain over which the machine is driven.
Wheel loaders, rigid frame and articulated dump trucks and other machines known in the art are used for moving material from one place to another at a worksite. In loading and moving the work material, these work machines are subjected to varying load conditions and weight distributions caused by the movement and positioning of the components of the machine and the load of material being hauled. In a static or non-moving state, the weight distribution of a work machine, such as for example a wheeled front end loader, is affected by component geometry characteristics, including tire radius and tire pressure, payload mass and position, weights and centers of gravity of the frames, axles, front linkage and implements, as well as optional attachments and their corresponding masses and centers of gravity. The weight distribution is also affected by surface grade and slope that change the orientation of the work machine. In a dynamic state such as when performing work cycles, the weight distribution of the work machine may also be affected by movement of the machine with forward and reverse acceleration and deceleration, at a steering angle and steering rate, and of a front linkage to manipulate the work implement.
In a typical work cycle of a wheel loader, the operator executes several steps causing the wheel loader to approach a wall or pile of work material, to lower the front linkage and implement, such as a bucket, to ground level and to drive the bucket into the work material. As the wheel loader drives into the pile, the wheel loader's forward speed slows down to a stop as the bucket is lifted and tilted to fill the bucket with a load of work material. After sufficiently loading the bucket, the operator reverses the direction of the wheel loader and accelerates out of the pile, typically while turning in the direction that points the front end of the wheel loader toward the destination for unloading the work material, such as at another pile or in the bed of a dump truck. The operator stops the machine, reverses direction and steers and accelerates forward to the dumping location. Where the load of work material is unloaded into a dump truck or hopper, the operator lifts the bucket as the wheel loader is approaching the dump location and stops the wheel loader while tilting the bucket downward to dump the load. The operator will then reverse the direction of the wheel loader and back away from the dump location, turn and accelerate forward toward the work material and repeat the digging work cycle.
In general, work machines such as the described wheel loader are designed to balance the varying weight distributions across the wheels so that the work machine maintains stability during the work cycle. For example, a load of work material at the front of the wheel loader may be balanced by a counterweight in the rear. However, the locations of the centers of gravity of the bucket and linkage as well as the load of material change during the work cycle depending on the position of the linkage arms and the steering position and rate of the wheel loader. Aggressive digging or overloading of the bucket can cause the rear axle to lift partially or completely off of the ground. Quick accelerations, decelerations, steering maneuvers at high speeds or with heavy loads as well as operation on steep grades or slopes can significantly transfer weight to one side or one corner of the machine, thereby reducing the reactant force between the ground and the lightly loaded wheels. In some situations, the torque provided to the lightly loaded wheels may be sufficient to cause the wheels to slip and thereby waste power from the drive train that could be utilized to drive the work machine over the ground.
Mechanical systems have been developed for transferring torque from a sliding wheel to a non-sliding wheel in various vehicles. For example, limited slip differentials include gears that engage when one wheel loses traction and spins to transfer all the torque to the high traction wheel. Electro-mechanical slip limiting systems are known that stop the slipping wheel so that torque can be transferred to the high traction wheel. For example, in some automotive applications having open differentials and anti-lock braking systems, the brakes may be applied to limit or stop the slippage of the low traction wheel so that the open differential transfers the torque to the high traction wheel. The automotive industry has also introduced torque vectoring differentials having the ability to independently vary the torque being sent to each wheel. Automobiles, however, provide relatively consistent weight distributions since the weights of the passengers are in a known location and are relatively small relative to the vehicle weight. In contrast, work machines are subject to loads created by work material having a greater affect on the weight distribution across the wheels of the work machine and that move during the execution of a work cycle performed by the work machine.
One example of a torque distribution strategy is provided in U.K. Patent Appl. No. GB 2 358 163 A, published for Ranson et al. on Jul. 18, 2001, and entitled, “A Motor Vehicle with Controllable Drive Torque Distribution between Each of Its Driven Wheels Responding to Vehicle Load.” The Ranson et al. publication teaches a motor vehicle including load measuring means for each of its wheels and independent drive motors for each of its wheels. A control unit continually monitors the load on each of the wheels and distributes the drive torque accordingly, the wheels with the highest load being supplied with the highest drive torque. The load distribution is also measured before the vehicle starts moving so that the torque distribution can be optimally determined as soon as the vehicle starts off. Measuring loads independently at each wheel of the vehicle likely entails adding components and cost to the vehicle for performing the measurements in work machines designed for hauling loads of work material of varying size and location at a work site. The measurements are not used for recognizing a step of a work cycle being performed, and the torque distribution is not determined based on the step of the work cycle being performed by a work machine.
Therefore, a need exists for an improved method for recognition of work cycle steps being performed by a machine, for determining weight distribution and operating conditions for a work machine that is subjected to loads having varying weights and positions while moving work material during a work cycle, and for managing the distribution of torque from a powertrain of the work machine between the wheels of the work machine in response to the recognized work cycle step and determined weight distribution to improve the efficiency of the operation of the work machine, and to maintain stability and safety during use of the work machine.
In one aspect of the present disclosure, a machine is disclosed. The machine may include a powertrain drivingly connected to at least one left front wheel, at least one right front wheel, at least one left rear wheel, and at least one right rear wheel through a torque transfer unit, the torque transfer unit configured to transfer torque to the front wheels as a function of a desired front torque, and to transfer a different torque to the rear wheels as a function of a desired rear torque. The machine may further include at least one first sensor configured to detect a value of an operating parameter of the machine that is indicative of a work cycle step being performed by the machine, wherein the machine performs a work cycle comprising a plurality of work cycle steps, and to generate a parameter signal corresponding to the value of the operating parameter. The machine may also include a control unit configured to determine the work cycle step being performed by the machine as a function of the parameter signal and to determine the desired front torque and the desired rear torque as a function of the work cycle step being performed by the machine.
In another aspect of the present disclosure, a method for distributing a powertrain drive torque from a powertrain of a machine to left and right front and rear wheels of the machine based on a work cycle step being performed by the machine, wherein the machine performs a work cycle comprising a plurality of work cycle steps. The method includes detecting a value of an operating parameter of the machine that is indicative of the work cycle step being performed by the machine, determining the work cycle step being performed by the machine based on the value of the operating parameter, and distributing the powertrain drive torque from the powertrain of the machine between the front wheels and the rear wheels of the machine based on the work cycle step being performed by the machine.
In a further aspect of the present disclosure, a machine for transporting a load of material is disclosed. The machine may include a left front wheel, a right front wheel, a left rear wheel, a right rear wheel, a powertrain operatively connected to the left front wheel, the right front wheel, the left rear wheel and the right rear wheel, the powertrain operable for generating a powertrain drive torque and outputting the powertrain drive torque to the left and right front and rear wheels, and at least one first sensor for detecting a value of an operating parameter of the machine that is indicative of a work cycle step being performed by the machine, wherein the machine performs a work cycle comprising a plurality of work cycle steps, and for outputting a sensor signal corresponding to the value of the operating parameter. The machine may further include a control unit operatively connected to the powertrain and the at least one first sensor, with the control unit configured to receive the sensor signal from the at least one first sensor, to determine the work cycle step being performed by the machine based on the value of the operating parameter in the sensor signal, and to transmit a torque distribution signal to the powertrain to cause the powertrain to distribute the powertrain drive torque to the front and rear wheels as a function of the work cycle step being performed by the machine.
Additional aspects are defined by the claims of this patent.
Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of the invention is defined by the words of the claims set forth at the end of this patent. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims defining the scope of protection.
It should also be understood that, unless a term is expressly defined in this patent using the sentence “As used herein, the term ‘______’ is hereby defined to mean . . . ” or a similar sentence, there is no intent to limit the meaning of that term, either expressly or by implication, beyond its plain or ordinary meaning, and such term should not be interpreted to be limited in scope based on any statement made in any section of this patent (other than the language of the claims). To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term be limited, by implication or otherwise, to that single meaning. Finally, unless a claim element is defined by reciting the word “means” and a function without the recital of any structure, it is not intended that the scope of any claim element be interpreted based on the application of 35 U.S.C. §112, sixth paragraph.
The rotation of the bucket 26 may be controlled by a linkage of the end frame 14. The linkage may include a tilt lever 32 pivotally connected to a tilt lever support 34 mounted on the lift arms 28 such that the tilt lever support 34 moves with the lift arms 28. At one end of the tilt lever 32, a tilt link 36 has one end pivotally connected to the end of the tilt lever 32, and the opposite end pivotally connected to the bucket 26 proximate the top. A tilt actuator or cylinder 38 couples the opposite end of the tilt lever 32 to the end frame 14 with pivotal connections at either end. For a given position of the lift arms 28, the bucket 26 is rotated toward the racked position by extending the tilt cylinder 38, and rotated in the opposite direction toward the dump position by retracting the tilt cylinder 38.
The wheel loader 10 may further include an electronic control unit 44 receiving commands from implement, steering and braking controls (not shown) in the cab 24 of the wheel loader 10. As the operator manipulates the controls, the electronic control unit (ECU) 44 in response controls the powertrain 18 to drive the wheel loader 10 over a surface, and operably controls actuators that can change the elevation and orientation of the bucket 26 to perform the necessary excavation of the work material. The ECU 44 may also be operatively connected to a plurality of sensors 48 that provide feedback to the electronic control unit 44 regarding the operation of the components of the wheel loader 10 and the operating conditions in and around the machine 10.
The wheel loader 10 may be all-wheel drive, with the powertrain 18 driving the rear wheels 20 and the front wheels 22 to provide stability as the machine 10 is operated to move work material.
The torque transfer unit 56 and the rear and front differentials 60, 66 may be torque vectoring differentials that may distribute torque among the wheels 20L, 20R, 22L, 22R in order to optimize the traction and enhance the loading performance of the wheel loader 10 for the operations being performed by the machine 10. The torque transfer unit 56 and differentials 60, 66 may be any appropriate torque vectoring mechanism with the ability to vary the amount of power sent to each wheel in response to receiving a control signal from a control unit. Applicable torque vectoring mechanisms, such as those in taught U.S. Pat. No. 7,334,670 issued to Namuduri et al. on Feb. 26, 2008 and entitled “Torque Vectoring Differential for Controlling Vehicle Stability” and U.S. Pat. No. 7,294,083 issued Bowen on Nov. 13, 2007 and entitled “Torque Vectoring Axle Assembly,” which are expressly incorporated by reference herein, will be apparent to those skilled in the art and are contemplated by the inventor as having use in machines in accordance with the present disclosure. The transmission 52, the torque transfer unit 56 and the differentials 60, 66 may be operably connected to and controlled by the ECU 44. The ECU 44 may receive signals from the transmission 52 and the sensors 48 to recognize work cycle steps or other operations being performed by the machine 10 and the conditions for performing the operations, to determine a corresponding torque distribution for the wheels 20L, 20R, 22L, 22R, and to transmit control signals to the torque transfer unit 56 and the differentials 60, 66 to execute the calculated torque distribution.
Various operation conditions may be relevant to determining the torque distribution to be applied to the wheels 20L, 20R, 22L, 22R of the wheel loader 10 or any other machine that may haul material and be subject to varying weight distributions among its wheels. In a static state, weight distribution of a work machine such as the wheel loader 10 is affected by components geometries including wheel radius and pressure, mass and position of a load of work material, weights and centers of gravity of the body portion 12, non-engine end frame 14, axles 62, 68, linkage components 28-38 and the implement 26, as well as optional attachment masses and centers of gravity. Weight distribution is also affected by surface grade and slope. The fundamental design and operation of these machines is an exercise in weight balancing, with the weight of a load of material borne by the implement 26 being balanced by the counterweight of the components of the machine 10 pivoted about the axles 62, 68.
The static condition of the wheel loader 10 is illustrated in
When the operator drives the wheel loader 10 forward and in reverse, the powertrain 18 creates torque on the axles 62L, 62R, 68L, 68R that results is powertrain forces PRL, PRR, PFL, PFR on the wheels 20L, 20R, 22L, 22R, respectively, to rotate the wheels 20L, 20R, 22L, 22R and move the wheel loader 10. The movement is possible because the surface applies ground reactant forces GRL, GRR, GFL, GFR to the wheels 20L, 20R, 22L, 22R, respectively, parallel to the surface and in the opposite direction as the powertrain forces PRL, PRR, PFL, PFR. The maximum ground reactant forces GRL, GRR, GFL, GFR that may be produced is determined by the coefficient of friction between the ground and the wheels 20L, 20R, 22L, 22R and the magnitude of the normal forces NRL, NRR, NFL, NFR. Consequently, depending on the amount of torque applied to the axles 62L, 62R, 68L, 68R, the surface over which the wheel loader 10 travels, and the amount of weight supported by each of the wheels 20L, 20R, 22L, 22R, one or more of the powertrain forces Pi may exceed the corresponding ground reactant force Gi and the wheel(s) 20L, 20R, 22L, 22R may lose traction and skid and cause instability in the operation of the wheel loader. Drive train torque vectoring as disclosed herein will operate to improve the torque distribution efficiency by reducing or eliminating such traction loss and attendant instability.
The drive train torque vectoring method may implement an analysis of the forces in a free body diagram such as that shown in
ΣFX=0 (1)
ΣFY=0 (2)
ΣMO=0 (3)
Using the coordinate axes of
G
RL
+G
RR
+G
FL
+G
FR
−P
RL
−P
RR
−P
FL
−P
RR=0 (4)
Equation (4) is true where the powertrain force Fi at each wheel 20, 22 does not exceed the maximum ground reactant force Gi at the wheel 20, 22 as determined by multiplying the normal force F at the wheel 20, 22 by the coefficient of friction between the wheel 20, 22 and the ground and, consequently, no wheel slippage is occurring.
Equilibrium equation (2) requires that the sum of the vertical forces FY is also equal to zero. This is generally accurate where the surface fully supports the weight of the machine 10 and the payload 26A as expressed by the following:
N
RL
+N
RR
+N
FL
+N
FR
−W
BP
−W
EF
−W
L
−W
B
−W
RA
−W
FA
−W
P=0 (5)
The final equilibrium equation (3) indicates that sum of the moments about the Z-axis at a point on the machine 10 is equal to zero. Though any point may be used, an origin O may be selected at the point at which the front wheels 22 touch the ground to simplify the equation by eliminating the forces WFA, GRL, GRR, GFL, GFR, PRL, PRR, PFL and PRR having lines of action through the origin O and consequently causing no moments about the origin O. Equilibrium equation (3) becomes:
(WBP×XBP)+(WRA×XWB)−(NRL×XWB)−(NRR−XWB)+(WEF×XEF)−(WL×XL)−(WB−XB)−(WP×XP)=0 (6)
Which simplifies to:
(WBP×XBP)+((WRA−NRL−NRR)×XWB)+(WEF×XEF)−(WL×XL)−(WB×XB)−(WP×XP)=0 (7)
Where Xi is the horizontal distance from the origin O to the corresponding center of gravity or line of action of the normal force. XWB in the example is equal to the wheel base and horizontal distance of each of the rear axle weight WRA and the rear left and right normal forces NRL, NRR. As with equation (4), equations (6) and (7) are true where the wheels 20, 22 do not slip due to the powertrain forces F exceeding the ground reactant forces G.
Where the machine 10 is balanced from side-to-side by design and only evenly distributed payloads 26A are expected, it may be assumed that the weight of the machine 10 and payload 26A will be divided equally between the left wheels 20L, 22L and the right wheels 20R, 22R so that NRL=NRR and NFL=NFR and two variables are eliminated from equations (4)-(7). Where imbalance is expected due to uneven weight distribution or operation of the machine 10 on side slopes where one side of the machine 10 is lower than the other, the normal forces Ni on the wheels 20, 22 on each side of the machine 10 may not be equal. However, applying the moment equilibrium equation (3) to the moments about the X-axis with the origin O located, for example, at approximately the center of the front right wheel 22R yields a fourth equilibrium equation:
(WBP×ZBP)+(WRA×ZRA)+(WEF×ZEF)+(WFA×ZFA)+(WL×ZL)+(WB×ZB)+(WP×ZP)−((NRL−NFL)×ZWW)=0 (8)
where Zi is the horizontal distance from the origin O in the Z direction to the corresponding center of gravity CGi or line of action of the normal force Ni. ZWW in the equation is equal to the wheel width between the wheel tread centers and is the horizontal distance of left front and rear normal forces NFL, NRL.
In the present example, masses of the machine 10 were grouped together for simplicity in visualization, explanation and management of the mathematical equations. However, in practice, greater precision may be attained with less grouping of elements and more precisely locating each mass affecting the determination of the distribution of torque to be applied to the wheels 20, 22. For example, each of the components contributing to the body portion weight WBP, such as the rear frame rails, engine, transmission, operator module, cooling system and other components, could be treated as an individual mass having a center of gravity located in three dimensions within the machine 10 and included in equations (4)-(8). Those skilled in the art will understand that a trade off will exist between increasing the precision of the modeling of the components of the machine 10 and the processing and data storage requirements necessary to perform calculations using the additional data. The use of various combinations of precision and processing requirements in drive train torque vectoring is contemplated by the inventor as having use in work machines in accordance with the present disclosure.
Knowing the distribution of weight at the four wheels 20, 22 of the work machine 10 during operation as calculated using equations (4)-(8) makes it possible to modulate powertrain torque to the wheels 20, 22 in proportion to the ground reactant forces Gi and available traction. However, additional factors beyond the locations of the centers of gravity CGi will affect the weight distribution and, correspondingly the torque distribution, as the machine 10 operates during steps of a work cycle. For example, acceleration and deceleration in forward and reverse, and turning of the machine, may create dynamic forces and moments according to Newton's Second Law of Motion that have effects on the equilibrium equations (1)-(3) and, correspondingly, the weight distribution of the machine. Such factors are discussed further below and may be quantified and utilized in calculating the torque distribution in accordance with the present disclosure.
The direction and speed of the machine 10 may dictate variations in the torque distribution between the rear differential 60 and the front differential 66 as transmitted by the torque transfer unit 56. In general, and in particular when the wheel loader 10 has a full payload 26A of material in the bucket 26, the inertia of the various masses causes moments about the origin O as the wheel loader 10 accelerates and decelerates in each direction, thereby causing fluctuations in the distribution of the normal forces Ni. For example, the rear wheels 20 may support a lesser portion of the combined weight of the wheel loader 10 and the payload 26A when the wheel loader 10 moves in reverse than when moving forward, making it desirable to reduce the torque to the rear differential 60 to prevent the rear wheels 20 from slipping. Consequently, the ECU 44 may store an indication of the engaged gear of the transmission 52, which may be known to the ECU 44 if it is controlling the transmission 52, or may be provide to the ECU 44 by the transmission 52 via a feedback signal indicating the engaged gear. Alternatively, a rotary speed sensor operatively connected to one of the wheels 20L, 20R, 22L, 22R or one of the axles 62L, 62R, 68L, 68R may provide a signal indicating a magnitude, direction and rate of change of the rotation of the corresponding component of the machine 10 to the ECU 44.
The steering direction and steering rate of the machine 10 also affects the normal force Ni distribution over the wheels 20L, 20R, 22L, 22R. The centrifugal forces exerted by the masses of the wheel loader 10 and the payload 26A when the wheel loader 10 turns tend to shift the weight distribution to the outside wheels 20, 22 as the machine 10 turns. The centrifugal forces may cause moments about the X-axis in equation (8) tending to lift the inside wheels 20, 22 off the ground, reducing the normal forces Ni supporting the inside wheels 20, 22 and correspondingly increasing the normal forces Ni supporting the outside wheels 20, 22. Consequently, the machine 10 may include an appropriate steering direction sensor. Where the machine 10 includes a steering wheel in the cab 24, a rotary position sensor may transmit the angular position of the steering wheel or steering column to the ECU 44. Other machines 10 may be steered by joystick controls that do not merely rotate to cause the machine 10 to turn. Where the machine 10, such as that shown in
As mentioned previously, the positions of the centers of gravity CGL, CGB, CGP may change the weight distribution between the rear wheels 20 and the front wheels 22 of the machine 10. As the bucket 26 is lifted by the lift arms 28 and reoriented by the tilt lever 32 and tilt link 36, the horizontal and vertical positions of the linkage components 28-38, the bucket 26 and the payload 26A vary relative to the origin O. Correspondingly, the moment arms and moments caused by the weights and inertias of the linkage components 28-38, the bucket 26 and the payload 26A change, and change the distribution of the normal forces Ni between the rear wheels 20 and the front wheels 22. For example, as the bucket 26 is raised, the moment arms in the Y direction increase, and the moments created by the centers of gravity CGL, CGB, CGP when the wheel loader 10 accelerates and decelerates increase. Where linkages and hydraulic cylinders are used to manipulate an implement such as the bucket 26, forks or the like, the weight of the load carried by the implement may be determined by pressure sensors operatively connected to the lift cylinder(s) 30 and/or the tilt cylinder(s) 38 and transmitting pressure amounts in the cylinders 30, 38 to the ECU 44. Rotary position sensors on the links 28, 32, 36 and/or the cylinders 30, 38, which are already present in many machines, may transmit signals to the ECU 44 for calculating the link positions and, correspondingly, the position of the bucket 26 and payload 26A. Other types of sensors for determining the weight of the load and the position of the implement may also be implemented.
Depending on the work material and the manner in which the material is loaded onto the wheel loader 10, the weight may not be distributed evenly across the axles 62, 68. In such cases, the left wheels 20L, 22L or right wheels 20R, 22R may bear more of the load, and it may be desirable for stability to provide more torque to the higher loaded wheels 20, 22. The unbalanced load may be detected by pressure sensors on the lift cylinder(s) 30 and/or the tilt cylinder(s) 38, or on the wheels themselves to signal an abnormal wheel pressure shift to the left side or the right side. In machines such as articulated dump trucks as discussed further below, a system may be implemented wherein a camera takes a photograph of the load and the ECU 44 may analyze the image to determine whether the load is unbalanced. Other mechanisms for detecting unbalanced loads will be apparent to those skilled in the art.
It is common at work sites to have uneven surfaces having varying grades of slopes over which the wheel loader 10 may drive to get to and transport a load of work material. The wheel loader 10 may have to drive uphill or downhill, or along the side of a hill. In many instances, driving on a graded or sloped surface can affect the tendency of the wheels 20, 22 to slip and affect the weight distribution across the wheels 20, 22. The grade or slope of the hill creates weight components acting on the wheels parallel to the ground that must be balanced by the ground reactant forces G in equilibrium equation (1) to maintain equilibrium. Also, changes in the moments created about the origin O cause the lower or downhill wheels 20, 22 to bear more of the weight of the wheel loader 10 and the payload 26A than the upper or uphill wheels 20, 22. In such situations, it may be desirable to change the torque distribution to provide more torque to the downhill wheels 20, 22 to move the machine 10 and less torque to the uphill wheels 20, 22 to prevent slippage. Uphill or downhill grades, and left or right slopes may be detected in the machine by providing grade sensors or inclinometers capable of determining the pitch (rotation up or down about an axis parallel to the axles 62, 68) and/or the roll (rotation about an axis running from front to rear) of the machine 10. The inclinometer(s) would provide signals to the ECU 44 having values representing the pitch and roll of the machine for use in determining the weight distribution across the wheels 20L, 20R, 22L, 22R and a corresponding torque distribution to be implemented by the torque transfer unit 56 and differentials 60, 66.
Those skilled in the art will understand that the various sensors discussed herein are exemplary of the types of sensors or other mechanisms that may be implemented in machines 10 in accordance with the present disclosure. Other sensors and mechanisms for determining the direction, speed and steering or turning radius of the machine 10, the magnitude and location of a load of material, and the orientation of the surface over which the machine 10 travels and/or the machine 10 itself will be apparent to those skilled in the art, and are contemplated by the inventor as having use in machines in accordance with the present disclosure. In the succeeding discussion, such mechanisms referred to generically as a sensor of a particular operating condition for the machine 10 should be considered to include any appropriate sensor or mechanism for detecting the operating condition and providing information regarding the operating condition to the ECU 44.
Referring now to
The sensors 80-94 may be of the types mechanisms described above or any other appropriate mechanisms for monitoring the corresponding operating conditions. Moreover, one or more of the sensors 80-94 may be omitted where the information is available from other sources, such as the vehicle direction being obtained from the transmission 52 or the ECU 44. Additionally, two or more of the sensors 80-94 may be combined or the information provided by a single mechanism, such as pressure sensors on or in the wheels 20, 22, on the axles 62, 68, and the like, providing information indicative of load weight amount and position, or a two or three axis inclinometer performing the functions of the machine grade sensor 92 and machine slope sensor 94 by providing indications of the pitch, roll and/or yaw of the machine 10.
Another type of material hauling machine is illustrated in
As with the wheel loader 10, the articulated dump truck 100 may be all-wheel drive, with the powertrain 108 driving the front wheels 110 and the rear wheels 112, 114 to provide stability as the dump truck 100 is operated to move work material.
The torque to the rear wheels 112, 114 may be transmitted by a main rear torque transfer shaft 136 to an intermediate gear box 138 that may divide the torque between a first rear torque transfer shaft 140 and a second rear torque transfer shaft 142. The first rear torque transfer shaft 140 connects to a first rear differential 144 that distributes torque to the left and right first rear wheels 112L, 112R via left and right first rear axles 146L, 146R, respectively. The second rear torque transfer shaft 142 connects to a second rear differential 148 that distributes torque to the left and right second rear wheels 114L, 114R via left and right second rear axles 150L, 150R, respectively.
The torque transfer unit 128, the front differential 132 and the rear differentials 144, 148 may be torque vectoring differentials as discussed above that may distribute torque among the wheels 110L, 110R, 112L, 112R, 114L, 114R in order to optimize the traction and enhance the loading performance of the articulated dump truck 100 for the operations being performed by the truck 100. The transmission 124, the torque transfer unit 128 and the differentials 132, 144, 148 may be operable connected to and controlled by an ECU 152. The ECU 152 may receive signals from the transmission 124 and sensors 154 to determine the path and speed of the dump truck 100, characteristics of a load of material being hauled by the dump truck 100, and the conditions for hauling the load over a surface, to determine a corresponding torque distribution for the wheels 110L, 110R, 112L, 112R, 114L, 114R, and to transmit control signals to the torque transfer unit 128 and the differentials 132, 144, 148 to execute the calculated torque distribution.
The dump truck 100 and other material hauling machines having drive train torque vectoring in accordance with the present disclosure may be subjected a similar analysis of the forces in a free body diagram as discussed above in relation to
As discussed above, machines such as the wheel loader 10 and the articulated dump truck 100 in accordance with the present disclosure provide a distribution of the power provided by the powertrains 18, 108 to the wheels 20, 22, 110, 112, 114 based on the distribution of the weight of the machines 10, 100 and loads of material being hauled, and the conditions under which the material is being hauled. The ECUs 44, 152 receive signals from the sensors 80-94, 164-176 providing information regarding the load of material, the operations of the machines 10, 100 and the operating conditions at the worksite, use the information to determine, among other factors, the weight distribution of the machines 10, 100 and loads of material, calculate the power distribution to the wheels 20, 22, 110, 112, 114 for driving the machines to haul the material, and output control signals to the torque transfer units 56, 128 and differentials 60, 66, 132, 144, 148 to operate to distribute power to the wheels 20, 22, 110, 112, 114.
The values of the operating parameters detected at the block 184 may be transmitted by the sensors 48 to the ECU 44 so that the ECU 44 may recognize the work cycle step being performed by the wheel loader at a block 186, and determine the corresponding powertrain torque distribution at a block 188. The ECU 44 may use the values provided by some or all of the sensors 48 in determining the work cycle step being performed by the wheel loader 10. For example, the values provided by the machine direction sensor 80, machine speed sensor 82, load weight sensor 86 and load position sensor 88 may be sufficient for recognizing a work cycle step. If the machine direction sensor 80 indicates that the wheel loader 10 is moving forward, the load weight sensor 86 indicates that the bucket 26 is empty, and the load position sensor 88 indicates that the bucket 26 is located near ground level, the ECU 44 may determine that the wheel loader 10 is performing a forward pre-digging step of the work cycle that may generally require a 50/50 distribution of powertrain torque between the rear wheels 20 and the front wheels 22. Similarly, if the machine direction sensor 80 indicates that the wheel loader 10 is moving in reverse, the machined speed sensor 82 indicates that the wheel loader 10 is decelerating, the load weight sensor 86 indicates that the bucket 26 is full, and the load position sensor 88 indicates that the bucket 26 is raised, the ECU 44 may determine that the wheel loader 10 is performing a loaded reverse-to-forward transition step of the work cycle that may require a 60/40 distribution of powertrain torque between the rear wheels 20 and the front wheels 22 to reflect an increase in the normal forces Ni on the rear wheels 20 during the transition.
The ECU 44 may be configured in an appropriate manner to recognize the work cycle step being performed by the wheel loader 10 at the block 186. For example, a work cycle step look-up table may be stored in memory 72 having a list of the work cycle steps that may be performed by the wheel loader 10, the combinations of values of the sensors 48 corresponding to the work cycle steps, and a corresponding powertrain torque distribution between the rear wheels 20 and the front wheels 22 during the performance of the work cycle step. Alternatively, logic for recognizing the work cycle step and determining a corresponding powertrain torque distribution may be programmed into the program of the ECU 44 controlling the torque transfer unit 56 and differentials 60, 66. Other configurations of the ECU 44 for recognizing the work cycle step and determining the corresponding torque distribution based on values input from the sensors 48 will be apparent to those skilled in the art and are contemplated by the inventor as having use in work machines in accordance with the present disclosure.
After the work cycle step is recognized and torque distribution is determined by the ECU 44 at the blocks 186, 188, respectively, control may pass to a block 190 where the ECU 44 transmits signals to the torque transfer unit 56 and the differentials 60, 66 to distribute the torque between the wheels 20, 22 as dictated by the work cycle step. In some implementations, torque distribution based solely on the work cycle step being performed may be sufficient to efficiently perform the steps of the work cycle without slippage of the wheels 20, 22 and instability of the wheel loader 10. In addition to the vehicle direction and speed, and load weight and position, the steering direction may be used in determining the work cycle steps such that, for example, loaded backing with a left turn and loaded backing with a right turn are distinct work cycle steps with different side-to-side torque distributions from the differentials 60, 66. In such cases, the ECU 44 may be configured to return control to the block 184 to continue monitoring the values of the operating parameters until a change in the work cycle step being performed by the wheel loader 10 is detected and a new torque distribution is determined and executed.
In other implementations, the work cycle step torque distribution determined at the block 188 may serve as a baseline torque distribution that may be adjusted based on the actual operation conditions indicated by the values provided by the sensors 48. For example, the work cycle step torque distributions may assume motion of the machine along a straight path on level ground with a balanced load such that the powertrain torque is evenly distributed by the differentials 60, 66 between the left and right wheels. The torque distributions in some work cycle steps may disregard the position of the bucket 26 and the corresponding effects on the equilibrium equations (1)-(3). In these implementations, after the work cycle step torque distribution is executed at the block 190, control may pass to a block 192 to evaluate the operating parameter values provided by the sensors 48 to determine whether adjustments to the baseline torque distribution is required. Values from the machine speed sensor 82, load weight sensor 86, load position sensor 88 and machine grade sensor 92 may affect the front-to-rear torque distribution of the torque transfer unit 56, and values from the machine turn direction sensor 84, load weight sensor 86, load position sensor 88 and machine slope sensor 94 may affect the side-to-side torque distributions of the differentials 60, 66. If the operating parameter values indicate that an adjustment to the torque distribution is required, control is transferred from the block 192 back to the block 188 for the ECU 44 to determine an adjusted torque distribution based on operating conditions within the previously recognized work cycle step.
If the operating parameter values are within limits for operating the wheel loader 10 at the baseline torque distribution for the work cycle step at the block 192, control passes to a block 194 where the ECU 44 continues to monitor the operating parameter values from the sensors 48 and determine whether the wheel loader 10 is performing a subsequent step of the work cycle. If the work cycle step has not changed, control may pass back to the block 192 to determine whether adjustments to the torque distribution are needed. If the ECU 44 detects a change in the work cycle step being performed, control passes back to the block 186 to determine which work cycle step is being performed to that the appropriate torque distribution may be applied to the wheels 20, 22. The ECU 44 continues to execute the algorithm 180 until the operator shuts down the engine 50 of the wheel loader 10.
The ECU 44 may be programmed with a default or baseline torque distribution for operation of the wheel loader 10 under the forward pre-digging work cycle step shown in
The load weight sensor 170 and the load offset sensor 172 may transmit signals to the ECU 152 indicating that the bed 118 of the truck 100 is empty, and the truck grade sensor 174 and the truck slope sensor 176 may transmit signals to the ECU 152 indicating that the pitch and roll angles for the truck 100 are essentially zero. Under these conditions, the ECU 152 may transmit control signals to the torque transfer unit 128 and differentials 132, 144, 148 when the dump truck 100 is moving to implement the default torque distribution for the truck 100 for an empty forward drive step. In this example, a greater amount of torque may be transferred by the torque transfer unit 128 to the rear differentials 144, 148 than to the front differential 132 at, for example, a 60/40 or 70/30 ratio as indicated by the arrows at the articulating joint 106.
After accumulating the payload 26A in the bucket 26, the operator backs the wheel loader 10 out of the pile 200 in a loaded backing step and begins to reposition the wheel loader 10 to dump the payload 26A in the bed 118 of the dump truck 100. As shown in
The machine turn direction sensor 84 may transmit signals indicating that the wheels 22L, 22R are turned to the right. For simplicity in the schematic illustrations of the wheel loader 10, the front wheels 22L, 22R turn independently as with a rack-and-pinion mechanism, as opposed to the end frame 14 articulating as shown in
As the wheel loader 10 accelerates toward the dump truck 100 in an acceleration and lift step in
In
With the bucket 26 empty, the operator backs the wheel loader 10 away from the dump truck 100 in an empty backing step and begins to reposition the wheel loader 10 to pick up another load of material from the pile 200. As shown in
To simplify the calculations of the normal forces N, the equilibrium equations (1)-(3) may be applied by rotating the XYZ coordinate system about the Z-axis by an Euler angle equal to the grade angle θG so the X-axis is aligned parallel to the graded surface 204 and the Y-axis is normal to the graded surface 204 as shown. Using this adjusted coordinate system, the weight W at each center of gravity CGi may be broken up into an X component that acts parallel to the graded surface 204 and a Y component that acts normal to the graded surface 204. For example, the weight WTP of the tractor portion 102 may have a weight component WTpp parallel to the graded surface 204 and a weight component WTPN normal to the graded surface 204. The parallel weight component WTPP would be used in equilibrium equation (1), the normal weight component WTPN would be used in equilibrium equation (2), and both weight components WTPP, WTPN may be used in equilibrium equation (3) depending on the location chosen for the origin O. Similar components would be determined for each of the other weights and act at the corresponding centers of gravity CGi.
As the dump truck 100 drives up the graded surface 204, the various sensors 154 of the dump truck 100 provide signals to the ECU 152 for determining the operating conditions of the dump truck 100. The truck direction sensor 164 and truck speed sensor 166 may transmit signals to the ECU 152 indicating that the truck 100 is moving forward at a certain speed and may be accelerating or decelerating. The truck turn direction sensor 168 may transmit a signal indicating that the dump truck 100 is moving in a straight path. The load weight sensor 170 and load offset sensor 172 may transmit signals indicating the magnitude and position of the payload 26A within the bed 118. The signals in the sensors 164-172 may be interpreted by the ECU 152 in a similar manner as previously described above for the corresponding sensor 48 of the wheel loader 10 in determining the weight distribution and torque distribution.
The magnitude of the X and Y weight components is determined based on the grade angle θG in a manner commonly known to those skilled in the art. The truck grade sensor 174 may be, for example, an inclinometer capable of detecting rotation about a line parallel to the Z-axis to measure the grade angle θG over which the dump truck 100 is traveling. The truck grade sensor 174 transmits a signal indicative of the grade angle θG to the ECU 152, and the ECU 152 calculates the values of the weight components for the various masses to be used in equilibrium equations (1)-(3). The parallel weight components used in equilibrium equation (1) act in the same direction as the powertrain forces Pi and in the opposite direction as the ground reactant forces G. Consequently, the ground reactant forces G required to maintain equilibrium may be greater and the likelihood of wheel slippage increases.
The weight components normal to the graded surface 204 are used in equilibrium equation (2) and necessarily have magnitudes less than the corresponding weights Wi. As result, the sum of the normal forces Ni decreases as the grade angle θG increases. Correspondingly, the maximum possible ground reactant forces Gi decrease so that the likelihood of wheel slippage increases and the ECU 152 will cause the torque transfer unit 128 to transfer torque from the powertrain 108 to the front wheels 110 and the rear wheels 112, 114 as necessary to avoid having the wheels slip. Equilibrium equation (3) also changes as the grade angle θG changes. The moment arms about an origin O located at the point of contact between the front wheels 110 and the graded surface 204 increase for the centers of gravity CGTF, CGRA1, CGRA2, CGB, CGP, and decrease for the center of gravity CGTP. A moment arm exists for the center of gravity CGFA that acts through the origin O and creates no moment about the origin O when the dump truck 100 is on a level surface. The signal from the truck grade sensor 174 allows the ECU 152 to determine the grade angle θG and calculate the moment arms for the centers of gravity CGi for use in solving the equilibrium equations (1)-(3). In general, though, the uphill grade increases the clockwise moments about the origin O and increases the normal forces Ni exerted on the rear wheels 112, 114 by the graded surface 204 so that the ECU 152 will cause the torque transfer unit 128 to increase the torque transmitted to the rear wheels 112, 114 and reduce the torque to the front wheels 110.
In
As discussed throughout the examples provided herein, the improved efficiency in allocating the powertrain torque among the wheels of the work machines based on a work cycle step being performed reduces slippage and instability during the operation of the work machines. Using the work cycle step being performed by the work machine to determine the torque distribution at least initially may streamline and simplify the process for determining the torque distribution where the steps may be readily identified and known torque distributions may be applied. By directing more of the powertrain torque to the wheels bearing greater portions of the weight of the work machine and the payload of work material, and correspondingly less torque to the remaining wheels, the overall powertrain torque required to perform the operations of the work machine may be reduced. In some implementations, use of the drive train torque vectoring strategy may allow for downsizing the engine of the work machine, as the smaller engine may be capable of generating sufficient powertrain torque to perform the operations of the work machine when the torque is efficient distributed among the wheels.
While the preceding text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of protection is defined by the words of the claims set forth at the end of this patent. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims defining the scope of protection.