CN103628517A - Excavator safety control system and method - Google Patents
Excavator safety control system and method Download PDFInfo
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- CN103628517A CN103628517A CN201310567692.3A CN201310567692A CN103628517A CN 103628517 A CN103628517 A CN 103628517A CN 201310567692 A CN201310567692 A CN 201310567692A CN 103628517 A CN103628517 A CN 103628517A
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Abstract
The invention discloses an excavator safety control system and method. The system comprises a main controller, a multifunctional monitor, a vehicle-mounted GPS unit, an engine control unit, a pilot safety switch, a sensor alarm switch, an independent cooling drive unit, a power adjusting proportional electromagnetic valve and a sound-light alarm buzzer. The main controller is in data exchange transmission with the multifunctional monitor, the vehicle-mounted GPS unit, the engine control unit and the independent cooling drive unit in a CAN bus communication mode. According to the excavator safety control system and method, the main controller and all control units, monitor equipment and sensors on the machine are in data communication through a CAN bus to achieve data sharing, the complexity of the system is effectively reduced, and the reliability and the flexibility of the system are improved. When the excavator safety control system and method are applied to large-scale hydraulic excavators, risks can be effectively lowered, and personnel safety and equipment safety can be guaranteed.
Description
Technical field
The present invention relates to a kind of excavator, relate in particular to a kind of excavator safety control system and method, belong to technical field of engineering machinery.
Background technology
Large hydraulic excavator volume is larger; in work progress, the sensitive field range of operating personnel institute is limited; and machine is often operated in the more severe danger zone of environment; security protection during machine operation is particularly important; large hydraulic excavator self-value, maintenance and cost of transportation are higher simultaneously; sometimes because manual operation is improper, cause machine down maintenance, often need to spend a large amount of manpower and materials costs.The tradition large hydraulic excavator person and device security are mainly grasped by operating personnel's Individual Consciousness, the person and device security often vary with each individual, restriction due to factors such as different driver's operation customs, the state of mind and driving qualifications, bring a lot of potential safety hazards, be necessary a kind of special control method of large hydraulic Excavator Design automatically to control for realizing the safety operation of large hydraulic excavator, to avoid the causing unnecessary person and property loss because manual operation is improper.
Summary of the invention
The object of the present invention is to provide a kind of excavator safety control system, deficiency for the security control of existing large hydraulic excavator, from the person and device security angle, in conjunction with large hydraulic excavator operating feature, use single-chip microcomputer control technology, CAN bus communication technology, GPS remote data transmission and monitoring technique, carry out sequencing, intelligent control, thereby effectively avoided some potential safety hazards of easily causing when operating machines.
Object of the present invention is achieved by the following technical programs:
An excavator safety control system, comprises master controller 1, Multifunctional monitor 2, vehicle GPS unit 3, control unit of engine 4, guide's safety switch 5, sensor and alarm switch 6, independent heat radiation driver element 7, power adjusting proportion magnetic valve 8, sound and light alarm buzzer 9; Described Multifunctional monitor 2 comprises vehicle-mounted camera 21, monitor 22, and described vehicle-mounted camera 21 is connected with monitor 22, and described monitor 22 carries out exchanges data transmission by CAN bus and master controller 1; Described guide's safety switch 5, sensor and alarm switch 6, power adjusting proportion magnetic valve 8, sound and light alarm buzzer 9 are connected with master controller 1; Described independent heat radiation driver element 7 comprises independent heat radiation motor control unit 71, independent heat radiation motor 72, independent heat radiation reversal valve 73, described independent heat radiation motor control unit 71 is connected with independent heat radiation motor 72, and described independent heat radiation reversal valve 73 is connected with master controller 1; Described master controller 1 carries out exchanges data transmission by CAN bus communication mode and vehicle GPS unit 3, control unit of engine 4, independent heat radiation driver element 7.
A kind of starting protection control method of excavator security system; detect whether engine speed too high, whether engine oil pressure too high, whether generator voltage too high simultaneously, whether dead-man's handle switch closed, above-mentioned any one eligible all permission starts the machine.
A kind of commutation of independent heat radiation safety and antiport control method of excavator security system, regulate independent heat dissipation pump electromagnetic valve that independent heat dissipation pump discharge capacity is dropped to minimum, wait for engine start, detect engine speed, engine oil pressure, system voltage judgement machine in just not carrying out switch operation after starting state; After commutation running, by time delay, export control signal, make independent heat dissipation pump discharge capacity drop to the minimum motor of guaranteeing independently to dispel the heat and stop at lowest speed state.
A kind of work safety protection control method of excavator security system; monitoring ECT, hydraulic fluid temperature; working environment atmospheric pressure; when system hydraulic oil temperature, engine water temperature are too high; according to the temperature information collecting, regulate main pump proportion magnetic valve current reduction hydraulic system power; regulate engine speed to reduce engine power, flame-out by regulating master controller to regulate main pump proportion magnetic valve current reduction hydraulic system power to prevent that machine from transshipping when working environment atmospheric pressure is too low.
A kind of safety index analysis of excavator security system and long-range rescue skills, by master controller, gather control unit of engine, various temperature pick ups, pressure sensor, alarm switch abnormal information, the fault of the personal device security of impact and hidden danger are divided into harm personal safety fault, device security fault, user's improper use three classes, the DTC that each class is corresponding different, master controller sends DTC to vehicle GPS unit by CAN bus communication mode, by GSM network, monitored data information and DTC are sent to monitor supervision platform, monitor supervision platform receives described harm personal safety fault, the DTC of device security fault triggers long-range rescue, utilize GPS long range positioning information by vehicle particular location and fault message is sent to car owner and rescue personnel processes, monitor supervision platform is to user's improper use DTC cumulative record of accepting, and when number of times is accumulated to preset value, monitor supervision platform transmission error correction information to excavator and car owner reminded.
Compared with prior art, the invention has the beneficial effects as follows: 1, on master controller and machine, various control modules, monitoring equipment, sensor carry out data communication by CAN bus and realize data sharing, effectively reduce system complexity and reliability, improved system flexibility.2, be applied on large hydraulic excavator and can effectively reduce risk, the protection person and device security.
Accompanying drawing explanation
Fig. 1 is system hardware structure block diagram of the present invention;
Fig. 2 is starting protection module controls flow chart of the present invention;
Fig. 3 is starting protection module controls flow chart of the present invention;
Fig. 4 is independent heat radiation safety commutation control flow chart of the present invention;
Fig. 5 is machine work safety protection control module schematic diagram of the present invention;
Fig. 6 is safety index analysis of the present invention and long-range relief control module schematic diagram.
The specific embodiment
Below in conjunction with the drawings and specific embodiments, the invention will be further described.
As shown in Figure 1, excavator safety control system, comprises master controller 1, Multifunctional monitor 2, vehicle GPS unit 3, control unit of engine 4, guide's safety switch 5, sensor alarm switch 6, independent heat radiation driver element 7, power adjusting proportion magnetic valve 8, sound and light alarm buzzer 9; Described Multifunctional monitor 2 comprises vehicle-mounted camera 21, monitor 22, and described vehicle-mounted camera 21 is connected with monitor 22, and described monitor 22 carries out exchanges data transmission by CAN bus and master controller 1; Described guide's safety switch 5, sensor alarm switch 6, power adjusting proportion magnetic valve 8, sound and light alarm buzzer 9 are connected with master controller 1; Described independent heat radiation driver element 7 comprises independent heat radiation motor control unit 71, independent heat radiation motor 72, independent heat radiation reversal valve 73, described independent heat radiation motor control unit 71 is connected with independent heat radiation motor 72, and described independent heat radiation reversal valve 73 is connected with master controller 1; Described master controller 1 carries out exchanges data transmission by CAN bus communication mode and vehicle GPS unit 3, control unit of engine 4, independent heat radiation driver element 7.
At starting protection, control function aspects; traditional starting protection is just from protecting the angle of machine; only by engine rotational speed signal, judge; prevent that engine secondary from starting, it is disconnected that this way interference of Chang Yinwei signal or sensor fault etc. in implementation procedure easily form erroneous judgement, and the present invention is from guaranteeing personal safety and two aspects of machine safety; take into full account multiple correlation factors; form distinctive startup basis for estimation, as shown in Figure 2,3, concrete Rule of judgment is as follows:
By judging before dead-man's handle on off state is determined machine startup whether meet safety work requirement, as do not meet safety work requirement (as closed in dead-man's handle switch), on Multifunctional monitor (hereinafter to be referred as ADU), with written form, point out user's operating mistake at once, after now as by force even if ato unit starts, master controller will cut out hydraulic pilot electromagnetic valve, operate machines and do not have any action, only have after dead-man's handle switch is put into home and again put back to again job state position, operate machines and just have action, can avoid like this machine startup mistiming to touch operating grip and cause machine involuntary maneuver, in case the unnecessary person and equipment harm.(note: when there is User Violations operation, MCU will record the operation frequency.) implementation method: after machine powers on, before engine start, master controller detects hydraulic pilot dead-man's handle state and control unit of engine (hereinafter to be referred as ECU) formation decision condition, thereby determines whether motor starts.
By detect and start rotating speed, engine oil pressure, generator voltage to start judgement simultaneously; because these three groups of data are diverse before and after engine start; if any any one undesirable ato unit that all do not allow, can effectively protect like this motor to avoid the machine accidental damage bringing for maloperation due to people
By master controller (hereinafter to be referred as MCU) and ECU, carry out CAN bus communication mode and detect and whether start in catastrophe failure alarm condition, or in preheat mode.If any any one eligible all permission, do not start the machine, can avoid like this machine tape jam or band to carry and start, thus the on-vehicle parts such as protection motor and battery.
As shown in Figure 4; large excavator adopts the independent cooling system of fluid motor-driven more; what in to independent radiating control, the most easily cause potential safety hazard is motor commutation; traditional motor commutation to be adopted low speed commutation or shuts down commutation method; in the former commutation process, more or less can cause the impact to hydraulic motor; the reverse hydraulic shock that the latter is many while not considering that shutting down moment works due to motor cut, causes severe impact to cause service life of equipment greatly to reduce to equipment.The present invention, in order effectively to avoid above-mentioned drawback, not only realizes safety commutation but also avoid moment equipment impact, and concrete methods of realizing is as follows:
Independent radiator fan commutation is selected to be arranged in the specific page of ADU, by menu setecting mode, realizes.The commutation of independent radiator fan must operate under engine shutdown state, and MCU just allows to enter the commutation selection page and operates by detecting engine speed, engine oil pressure, system voltage judgement machine after starting state not.
When meeting, above-mentioned condition selects after reversing mode, ADU sends to MCU to control independent heat radiation reversing solenoid valve commutation instruction by CAN bus and commutates, MCU is by regulating independent heat dissipation pump electromagnetic valve that independent heat dissipation pump discharge capacity is dropped to minimum simultaneously, wait for engine start, in the time of can guaranteeing to start the machine like this, fan speed be in lower-speed state.
After engine start, MCU is by regulating independent heat dissipation pump proportion magnetic valve electric current to improve gradually independent heat radiation pump delivery, until maximum, realize the cleaning to radiator.Whole process control is about 5 minutes; After reversion allows the suitable time, vehicle is flame-out; MCU continues to drive independent heat radiation reversal valve to work on about 10 seconds output time delayed signal; thereby MCU is by regulating independent heat radiation pump delivery rotation speed of the fan reduce and finally stop during this period; after shutting down, MCU automatic switchover reversal switch state reversal valve resets, and by this operating process, can avoid fan motor reverse rotation suddenly when running up to damage.By MCU, set and guarantee to be defaulted as fan motor forward state under each open state.
As shown in Figure 5, machine work safety protection control module realizes overload protection and warning prompting function in the machine course of work, and the potential hazard bringing in the time of can effectively avoiding machine to occur abnormal overload or abnormal operation, is implemented as follows:
MCU is by monitoring ECTS, hydraulic oil temperature sensor, when system hydraulic oil temperature, engine water temperature are too high, MCU will send a warning, by CAN bus communication mode, send to GPS unit, according to the temperature information collecting, regulate main pump proportion magnetic valve current reduction hydraulic system power simultaneously, regulate engine speed to reduce engine power, thereby avoid machine long-term work under the condition of high temperature, to cause vitals to damage.
MCU gathers ECU data by CAN bus communication mode, obtain barometric pressure sensor data message, according to the automatic regulator solution pressing system of current atmospheric pressure value, guarantee the power match between motor and hydraulic pump, avoid machine because of after ambient atmosphere environment change causes engine power to reduce, load too high causes motor accident extinguishing.
MCU judges that by the collection pressure sensor signal of walking whether machine is in walking states, controls vehicle carried buzzer during in walking states and sends audible and visible alarm information, to point out personnel around to avoid the personal injury that meets accident when machine.
As shown in Figure 6, digging machine safety index and long-range rescue function are by the data analysis of MCU, intelligent control technology combines with GPS remote data transmission technology, MCU is by setting in advance and by vehicle-mounted various kinds of sensors, alarm switch, the hidden danger that the mode of control module Real-time Collection statistics just affects digging machine person device security is divided into A, B, C tri-classes, according to DTC corresponding to each class of failure condition, illustrate: category-A represents directly to endanger because of equipment fault the problem of personal safety, as DTC A00 represents that machine is in danger zone, motor cannot start, after A01 represents machine startup, operating grip is out of control, digging machine is please organized rescue as early as possible in danger zone, category-B fault is generally the fault that causes device security, as DTC B11 represents ECT, is greater than 98 ℃, need to overhaul as early as possible, B20 represents that hydraulic oil temperature is higher than 100 degrees Celsius, agnogenioly need arrive as early as possible in-situ processing, C class fault is generally because user's improper use causes, and has certain potential safety hazard but can not affect again in a short time the situation of the person and device security, and when this class fault is generally accumulated to certain number of times, Surveillance center can notify car owner to correct improper operation.For example: when C01 representative of consumer starts the machine at every turn, dead-man's handle is placed on to improper position, cause complete machine attonity after engine start, and for example C11 fault representative of consumer digging machine scope of activities has surpassed the default fence region of GPS, MCU carries out record by each improper operation, identical improper operation reports while occurring 3 times in one day, MCU passes to GPS terminal by CAN bus communication mode by fault data, utilize GSM network that MCU is monitored to the irregular monitor supervision platform that sends to of data message, monitor supervision platform is put arrangement in storage to data, regularly send to car owner, situation for the serious breach of security index of frequent appearance, monitor supervision platform attendant understands in time and car owner links up, to more effectively take precautions against potential safety hazard.
Once category-A and category-B fault occur to trigger long-range rescue in above-mentioned DTC, wherein category-A rank is the highest generally presets, when there is such fault, general operation personnel can enter the flash appeal page by watch-dog (ADU), select corresponding menu, the code of can seeking help sends to monitor supervision platform, once can make the rapid response of highest level after monitor supervision platform receives help information, vehicle particular location and fault message can be notified to car owner, served rescue personnel and hurry to as early as possible the scene of the accident to process as early as possible with prestissimo simultaneously.Once declaring Surveillance center, category-B fault can knit relevant relief matters according to different fault relief code characters.
The most obvious advantage of this function is accurate positioned vehicle position, can notify in time again each side personnel to respond in time.
The realization of above 4 modules is all by various control modules, monitoring equipment, sensor on MCU and machine, to carry out data communication to realize data sharing; whole communication system adopts CAN bus control technology; being applied in large excavator of this control method can effectively reduce risk, the protection person and device security.
In addition to the implementation, the present invention can also have other embodiments, and all employings are equal to the technical scheme of replacement or equivalent transformation formation, all drop in the protection domain of requirement of the present invention.
Claims (5)
1. an excavator safety control system, it is characterized in that, comprise master controller (1), Multifunctional monitor (2), vehicle GPS unit (3), control unit of engine (4), guide's safety switch (5), sensor and alarm switch (6), independent heat radiation driver element (7), power adjusting proportion magnetic valve (8), sound and light alarm buzzer (9); Described Multifunctional monitor (2) comprises vehicle-mounted camera (21), monitor (22), described vehicle-mounted camera (21) is connected with monitor (22), and described monitor (22) carries out exchanges data transmission by CAN bus and master controller (1); Described guide's safety switch (5), sensor and alarm switch (6), power adjusting proportion magnetic valve (8), sound and light alarm buzzer (9) are connected with master controller (1); Described independent heat radiation driver element (7) comprises independent heat radiation motor control unit (71), independent heat radiation motor (72), independent heat radiation reversal valve (73), described independent heat radiation motor control unit (71) is connected with independent heat radiation motor (72), and described independent heat radiation reversal valve (73) is connected with master controller (1); Described master controller (1) carries out exchanges data transmission by CAN bus communication mode and vehicle GPS unit (3), control unit of engine (4), independent heat radiation driver element (7).
2. the starting protection control method of an excavator safety control system as claimed in claim 1; it is characterized in that; detect whether engine speed too high, whether engine oil pressure too high, whether generator voltage too high simultaneously, whether dead-man's handle switch closed, above-mentioned any one eligible all permission starts the machine.
3. the independent heat radiation safety of an excavator safety control system as claimed in claim 1 commutates and antiport control method, it is characterized in that, regulate independent heat dissipation pump electromagnetic valve that independent heat dissipation pump discharge capacity is dropped to minimum, wait for engine start, detect engine speed, engine oil pressure, system voltage judgement machine in just not carrying out switch operation after starting state; After commutation running, by time delay, export control signal, make independent heat dissipation pump discharge capacity drop to the minimum motor of guaranteeing independently to dispel the heat and stop at lowest speed state.
4. the work safety of an excavator safety control system as claimed in claim 1 is protected control method; it is characterized in that; monitoring ECT, hydraulic fluid temperature; working environment atmospheric pressure; when system hydraulic oil temperature, engine water temperature are too high; according to the temperature information collecting, regulate main pump proportion magnetic valve current reduction hydraulic system power; regulate engine speed to reduce engine power, flame-out by regulating master controller to regulate main pump proportion magnetic valve current reduction hydraulic system power to prevent that machine from transshipping when working environment atmospheric pressure is too low.
5. the safety index analysis of an excavator safety control system as claimed in claim 1 and long-range rescue skills, it is characterized in that, by master controller, gather control unit of engine, various temperature pick ups, pressure sensor, alarm switch abnormal information, the fault of the personal device security of impact and hidden danger are divided into harm personal safety fault, device security fault, user's improper use three classes, the DTC that each class is corresponding different, master controller sends DTC to vehicle GPS unit by CAN bus communication mode, by GSM network, monitored data information and DTC are sent to monitor supervision platform, monitor supervision platform receives described harm personal safety fault, the DTC of device security fault triggers long-range rescue, utilize GPS long range positioning information by vehicle particular location and fault message is sent to car owner and rescue personnel processes, monitor supervision platform is to user's improper use DTC cumulative record of accepting, and when number of times is accumulated to preset value, monitor supervision platform transmission error correction information to excavator and car owner reminded.
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| CN109268156A (en) * | 2018-09-27 | 2019-01-25 | 潍柴动力股份有限公司 | A kind of anti-stall control method of engine and control device |
| CN109901545A (en) * | 2017-12-08 | 2019-06-18 | 柳工常州机械有限公司 | A kind of bull-dozer safety control system and method |
| CN110106937A (en) * | 2019-05-14 | 2019-08-09 | 三一重机有限公司 | Low oil consumption control method and device |
| CN111465737A (en) * | 2017-12-14 | 2020-07-28 | 住友重机械工业株式会社 | Excavator |
| CN111962602A (en) * | 2020-08-26 | 2020-11-20 | 徐州徐工挖掘机械有限公司 | Active anti-overbreak control system and method installed on excavator |
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| CN104149719A (en) * | 2014-08-27 | 2014-11-19 | 苏州工业园区驿力机车科技有限公司 | Automobile heat radiation local area network |
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| CN111465737A (en) * | 2017-12-14 | 2020-07-28 | 住友重机械工业株式会社 | Excavator |
| CN109268156A (en) * | 2018-09-27 | 2019-01-25 | 潍柴动力股份有限公司 | A kind of anti-stall control method of engine and control device |
| CN109235531A (en) * | 2018-11-08 | 2019-01-18 | 北京拓疆者智能科技有限公司 | Rear dress unmanned systems and excavator for excavator |
| CN109235530A (en) * | 2018-11-08 | 2019-01-18 | 北京拓疆者智能科技有限公司 | Hydraulic system and excavator for excavator |
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| CN113685275A (en) * | 2021-08-30 | 2021-11-23 | 潍柴雷沃重工股份有限公司 | Starting method and system of engine and agricultural machine comprising engine |
| CN113774983A (en) * | 2021-09-01 | 2021-12-10 | 延安大学 | Control early warning device of hybrid working machine |
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