CN106400874A - Energy accumulator based excavator rotating mechanism energy recovery system and method - Google Patents
Energy accumulator based excavator rotating mechanism energy recovery system and method Download PDFInfo
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- 230000007246 mechanism Effects 0.000 title claims abstract description 104
- 238000011084 recovery Methods 0.000 title claims abstract description 30
- 238000000034 method Methods 0.000 title claims abstract description 27
- 238000013016 damping Methods 0.000 claims abstract description 5
- 239000002828 fuel tank Substances 0.000 claims abstract description 3
- 230000001133 acceleration Effects 0.000 claims description 26
- 238000009825 accumulation Methods 0.000 claims 11
- 230000001172 regenerating effect Effects 0.000 claims 1
- 239000000523 sample Substances 0.000 claims 1
- 238000004146 energy storage Methods 0.000 abstract description 23
- 238000006073 displacement reaction Methods 0.000 abstract description 6
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- 238000010521 absorption reaction Methods 0.000 description 1
- 238000009412 basement excavation Methods 0.000 description 1
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F9/00—Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
- E02F9/20—Drives; Control devices
- E02F9/22—Hydraulic or pneumatic drives
- E02F9/2217—Hydraulic or pneumatic drives with energy recovery arrangements, e.g. using accumulators, flywheels
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Abstract
本发明属于工程机械领域,公开了一种基于蓄能器的挖掘机回转机构能量回收系统及方法,包括通过管路依次连接的油箱、变量泵、第一换向阀、液压马达,第一换向阀与液压马达之间连接有第一油路和第二油路,液压马达的输出端上驱动连接有回转机构和阻尼机构,变量泵与第一换向阀之间的管路上还连接有蓄能管路,蓄能管路上连接有液压蓄能器,第一油路上连接有第二换向阀,第二油路上连接有第三换向阀,蓄能管路分别与第二换向阀和第三换向阀通过管路连通,对挖掘机回转机构的制动能量进行回收并且进行再利用,对挖掘机回转机构的节能研究具有重要意义。
The invention belongs to the field of engineering machinery, and discloses an energy recovery system and method for an excavator slewing mechanism based on an accumulator, which includes a fuel tank, a variable pump, a first reversing valve, a hydraulic motor, a first reversing valve, and a hydraulic motor connected sequentially through pipelines. The first oil circuit and the second oil circuit are connected between the directional valve and the hydraulic motor, the output end of the hydraulic motor is connected with a rotary mechanism and a damping mechanism, and the pipeline between the variable displacement pump and the first directional valve is also connected with a The energy storage pipeline is connected with a hydraulic accumulator, the first oil circuit is connected with a second reversing valve, the second oil circuit is connected with a third reversing valve, and the energy storage pipeline is connected with the second reversing valve and the second reversing valve respectively. The three-way reversing valve is connected through the pipeline to recover and reuse the braking energy of the slewing mechanism of the excavator, which is of great significance to the energy-saving research of the slewing mechanism of the excavator.
Description
技术领域technical field
本发明涉及工程机械领域,尤其涉及一种基于蓄能器的挖掘机回转机构能量回收系统及方法。The invention relates to the field of engineering machinery, in particular to an energy accumulator-based energy recovery system and method for a slewing mechanism of an excavator.
背景技术Background technique
液压挖掘机作为一种土石方施工机械,以其经济、高效等优点在国家基础建设中起着十分重要的作用,世界上各种土石方工程中约有65%-70%的土方量由挖掘机完成。As a kind of earthwork construction machinery, hydraulic excavator plays a very important role in national infrastructure construction due to its economical and efficient advantages. About 65%-70% of earthwork in various earthwork projects in the world is completed by excavators. .
由于挖掘机多在负载频繁剧烈波动且工况复杂的恶劣环境下作业,势必带来发动机燃油利用率低、尾气排放差、液压系统发热等问题,随着挖掘机的大量使用,这些问题愈益显现出来。据统计,挖掘机的能量利用率只有15%-25%左右,能量的损失最终多以热能的形式损失,工程机械的故障中,大约15%来自机械系统,40%来自液压系统。研究挖掘机节能不仅对环境保护和能源匮乏问题有积极的意义,同时有助于缓解液压系统的发热问题并提高挖掘机液压系统的可靠性和工作寿命,在一定程度上降低挖掘机的制造及维护成本。Excavators often operate in harsh environments with frequent and violent load fluctuations and complex working conditions, which will inevitably lead to problems such as low engine fuel utilization, poor exhaust emissions, and heating of the hydraulic system. With the extensive use of excavators, these problems are becoming more and more obvious. come out. According to statistics, the energy utilization rate of excavators is only about 15%-25%, and the energy loss is mostly lost in the form of heat energy. About 15% of construction machinery failures come from mechanical systems, and 40% come from hydraulic systems. Research on excavator energy saving is not only of positive significance to environmental protection and energy shortage, but also helps to alleviate the heating problem of the hydraulic system and improve the reliability and working life of the hydraulic system of the excavator. maintenance costs.
回转机构在液压挖掘机的一个工作循环中,运动时间约占50%-70%,能量消耗约占25%-40%,发热量约占35%-40%。因此对回转机构的节能研究意义重大。In a working cycle of the hydraulic excavator, the slewing mechanism accounts for about 50%-70% of the movement time, about 25%-40% of the energy consumption, and about 35%-40% of the heat generation. Therefore, the research on the energy saving of the slewing mechanism is of great significance.
发明内容Contents of the invention
本发明提供一种基于蓄能器的挖掘机回转机构能量回收系统及方法,对挖掘机回转机构的制动能量进行回收并且进行再利用,对挖掘机回转机构的节能研究具有重要意义。The invention provides an energy accumulator-based energy recovery system and method for a rotary mechanism of an excavator, which recovers and reuses the braking energy of the rotary mechanism of an excavator, which is of great significance to energy-saving research on the rotary mechanism of an excavator.
为达到上述目的,本发明的采用如下技术方案:To achieve the above object, the present invention adopts the following technical solutions:
技术方案一:Technical solution one:
一种基于蓄能器的挖掘机回转机构能量回收系统,包括通过管路依次连接的油箱、变量泵、第一换向阀、液压马达,所述第一换向阀与所述液压马达之间连接有第一油路和第二油路,所述液压马达的输出端上驱动连接有回转机构和阻尼机构,An energy recovery system for an excavator slewing mechanism based on an accumulator, including an oil tank, a variable pump, a first reversing valve, and a hydraulic motor connected in sequence through pipelines, and the gap between the first reversing valve and the hydraulic motor is The first oil circuit and the second oil circuit are connected, and the output end of the hydraulic motor is driven and connected with a slewing mechanism and a damping mechanism,
所述变量泵与所述第一换向阀之间的管路上还连接有蓄能管路,所述蓄能管路上连接有液压蓄能器,所述第一油路上连接有第二换向阀,所述第二油路上连接有第三换向阀,所述蓄能管路分别与所述第二换向阀和所述第三换向阀通过管路连通。An energy storage pipeline is also connected to the pipeline between the variable displacement pump and the first reversing valve, a hydraulic accumulator is connected to the energy storage pipeline, a second reversing valve is connected to the first oil circuit, A third reversing valve is connected to the second oil circuit, and the energy storage pipeline communicates with the second reversing valve and the third reversing valve through pipelines respectively.
本发明技术方案一的特点和进一步的改进为:The characteristics and further improvement of the technical solution of the present invention are:
(1)所述第二换向阀和所述第三换向阀上都具有进油口、出油口和回油口,所述第二换向阀和所述第三换向阀上的进油口分别与所述第一换向阀通过管路连接,所述第二换向阀上的出油口通过所述第一油路与所述液压马达上的一个端口连接,所述第三换向阀上的出油口通过所述第二油路与所述液压马达上的另一个端口连接;所述第二换向阀和所述第三换向阀上的回油口分别通过管路同时与所述蓄能管路连通。(1) The second reversing valve and the third reversing valve all have an oil inlet, an oil outlet and an oil return port, and the second reversing valve and the third reversing valve have The oil inlets are respectively connected to the first reversing valve through pipelines, the oil outlet on the second reversing valve is connected to a port on the hydraulic motor through the first oil passage, and the first reversing valve The oil outlet on the three-way valve is connected to another port on the hydraulic motor through the second oil passage; The pipeline communicates with the energy storage pipeline at the same time.
(2)所述蓄能管路上连接有蓄能阀门,所述蓄能阀门连接在所述液压蓄能器与所述变量泵的出口之间,所述第二换向阀上的回油口和所述第三换向阀上的回油口通过管路连接在所述蓄能管路上的所述蓄能阀门与所述液压蓄能器之间。(3)所述第二换向阀的回油口和所述第三换向阀的回油口与所述蓄能管路相连通的管路上分别设置有单向阀,两个所述单向阀的导通方向分别朝向所述蓄能管路。(2) The energy storage pipeline is connected with an energy storage valve, the energy storage valve is connected between the hydraulic accumulator and the outlet of the variable displacement pump, the oil return port on the second reversing valve and The oil return port on the third reversing valve is connected between the energy storage valve on the energy storage pipeline and the hydraulic accumulator through a pipeline. (3) The oil return port of the second reversing valve and the oil return port of the third reversing valve are respectively provided with one-way valves on the pipelines that communicate with the energy storage pipeline, and the two one-way valves The conduction directions of the valves respectively face the energy storage pipelines.
(4)所述回转机构的转轴上设置有转速传感器和转速加速度传感器。(4) A rotational speed sensor and a rotational speed acceleration sensor are arranged on the rotating shaft of the slewing mechanism.
技术方案二:Technical solution two:
一种基于蓄能器的挖掘机回转机构能量回收方法,所述方法应用于技术方案一所述的基于蓄能器的挖掘机回转机构能量回收系统,所述方法包括如下步骤:An accumulator-based energy recovery method for an excavator's slewing mechanism, the method is applied to the energy recovery system for an excavator's slewing mechanism based on an accumulator described in Technical Solution 1, and the method includes the following steps:
步骤1,当挖掘机回转机构开始制动时,所述挖掘机回转机构制动过程中产生制动能量,将所述制动能量通过第二换向阀和第三换向阀的回油口传送至液压蓄能器进行回收储存;当所述挖掘机回转机构制动完成时,液压蓄能器完成制动能量的回收;所述制动能量至少包含转动动能和摩擦热能;Step 1, when the slewing mechanism of the excavator starts to brake, the braking energy is generated during the braking process of the slewing mechanism of the excavator, and the braking energy is passed through the oil return ports of the second reversing valve and the third reversing valve Transfer to the hydraulic accumulator for recovery and storage; when the slewing mechanism of the excavator is braked, the hydraulic accumulator completes the recovery of braking energy; the braking energy includes at least rotational kinetic energy and frictional heat energy;
步骤2,当所述挖掘机回转机构反向启动时,所述液压蓄能器将回收的制动能量进行释放,从而使得所述挖掘机回转机构反向加速启动。Step 2, when the slewing mechanism of the excavator starts in reverse, the hydraulic accumulator releases the recovered braking energy, so that the slewing mechanism of the excavator starts to accelerate in reverse.
本发明产生的有益效果为:(1)在传统挖掘机回转机构中加入液压蓄能器,建立了基于蓄能器能量回收系统;(2)该发明有效的回收了液压挖掘机回转制动过程中以热能形式损耗的转动动能,从而不仅节约能源和降低液压系统的油温,同时也提高设备的可靠性和使用寿命。其次,该节能方案不仅可以推广到其他型号液压挖掘机,这也为相关类型的工程机械提供了参考。The beneficial effects produced by the present invention are: (1) a hydraulic accumulator is added to the slewing mechanism of the traditional excavator, and an energy recovery system based on the accumulator is established; (2) the invention effectively recovers the slewing braking process of the hydraulic excavator The rotational kinetic energy lost in the form of heat energy can not only save energy and reduce the oil temperature of the hydraulic system, but also improve the reliability and service life of the equipment. Secondly, this energy-saving solution can not only be extended to other types of hydraulic excavators, but also provides a reference for related types of construction machinery.
附图说明Description of drawings
为了更清楚地说明本发明实施例或现有技术中的技术方案,下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings that need to be used in the description of the embodiments or the prior art. Obviously, the accompanying drawings in the following description are only These are some embodiments of the present invention. Those skilled in the art can also obtain other drawings based on these drawings without creative work.
图1为本发明实施例提供的传统挖掘机回转机构液压系统仿真模型示意图;Fig. 1 is the schematic diagram of the traditional excavator slewing mechanism hydraulic system simulation model provided by the embodiment of the present invention;
图2为本发明实施例提供的基于蓄能器的挖掘机回转机构能量回收系统的仿真模型示意图;2 is a schematic diagram of a simulation model of an energy recovery system for an excavator slewing mechanism based on an accumulator provided by an embodiment of the present invention;
图3为本发明实施例提供的基于蓄能器的挖掘机回转机构能量回收方法流程示意图;Fig. 3 is a schematic flowchart of an energy recovery method for an excavator slewing mechanism based on an accumulator provided by an embodiment of the present invention;
图4为本发明实施例提供的制动阶段转速对比曲线示意图;Fig. 4 is a schematic diagram of a rotational speed comparison curve in the braking phase provided by an embodiment of the present invention;
图5为本发明实施例提供的加速阶段转速对比曲线示意图;Fig. 5 is a schematic diagram of the rotational speed comparison curve in the acceleration phase provided by the embodiment of the present invention;
图6为本发明实施例提供的液压蓄能器气体体积和压力变化示意图;Fig. 6 is a schematic diagram of gas volume and pressure changes of a hydraulic accumulator provided by an embodiment of the present invention;
图7为本发明实施例提供的三位四通换向阀与两位三通换向阀控制信号示意图;Fig. 7 is a schematic diagram of the control signals of the three-position four-way reversing valve and the two-position three-way reversing valve provided by the embodiment of the present invention;
图8为本发明实施例提供的蓄能器释放能量控制信号示意图;Fig. 8 is a schematic diagram of the energy release control signal of the accumulator provided by the embodiment of the present invention;
图9为本发明实施例提供的液压蓄能器供能时回转机构反转的转速对比曲线示意图;Fig. 9 is a schematic diagram of the rotational speed comparison curve of the slewing mechanism reversed when the hydraulic accumulator is powered by the embodiment of the present invention;
图10为本发明实施例提供的液压蓄能器释放能量时流量和充气体积的变化示意图。Fig. 10 is a schematic diagram of the change of the flow rate and the charging volume when the hydraulic accumulator releases energy according to the embodiment of the present invention.
具体实施方式detailed description
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only some, not all, embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by persons of ordinary skill in the art without making creative efforts belong to the protection scope of the present invention.
本发明实施例提供一种基于蓄能器的挖掘机回转机构能量回收系统,示例性的,如图1所示,为传统挖掘机回转机构液压系统仿真模型示意图,包括:变量泵1、电动机2,三位四通换向阀3,单向阀4,溢流阀5,马达6以及回转机构7和阻尼机构8。An embodiment of the present invention provides an energy recovery system for an excavator turning mechanism based on an accumulator. Exemplarily, as shown in FIG. 1 , it is a schematic diagram of a hydraulic system simulation model of a traditional excavator turning mechanism, including: , Three-position four-way reversing valve 3, one-way valve 4, overflow valve 5, motor 6, rotary mechanism 7 and damping mechanism 8.
如图2所示,本发明实施例提供的基于蓄能器的挖掘机回转机构能量回收系统包括通过管路依次连接的油箱D、变量泵1、第一换向阀3、液压马达6,所述第一换向阀3与所述液压马达6之间连接有第一油路和第二油路,所述液压马达6的输出端上驱动连接有回转机构7和阻尼机构8,所述变量泵1与所述第一换向阀3之间的管路上还连接有蓄能管路,所述蓄能管路上连接有液压蓄能器B,所述第一油路上连接有第二换向阀E2,所述第二油路上连接有第三换向阀E3,所述蓄能管路分别与所述第二换向阀E2和所述第三换向阀E3通过管路连通。As shown in Figure 2, the accumulator-based excavator slewing mechanism energy recovery system provided by the embodiment of the present invention includes an oil tank D, a variable pump 1, a first reversing valve 3, and a hydraulic motor 6 connected in sequence through pipelines. The first reversing valve 3 and the hydraulic motor 6 are connected with a first oil circuit and a second oil circuit, and the output end of the hydraulic motor 6 is connected with a rotary mechanism 7 and a damping mechanism 8. The variable An energy storage pipeline is also connected to the pipeline between the pump 1 and the first reversing valve 3, a hydraulic accumulator B is connected to the energy storage pipeline, and a second reversing valve E2 is connected to the first oil circuit , the third reversing valve E3 is connected to the second oil circuit, and the energy storage pipeline communicates with the second reversing valve E2 and the third reversing valve E3 respectively through pipelines.
进一步的,所述第二换向阀E2和所述第三换向阀E3上都具有进油口、出油口和回油口,所述第二换向阀E2和所述第三换向阀E3上的进油口分别与所述第一换向阀3通过管路连接,所述第二换向阀E2上的出油口通过所述第一油路与所述液压马达6上的一个端口连接,所述第三换向阀E3上的出油口通过所述第二油路与所述液压马达6上的另一个端口连接;所述第二换向阀E2和所述第三换向阀E3上的回油口分别通过管路同时与所述蓄能管路连通。Further, both the second reversing valve E2 and the third reversing valve E3 have an oil inlet, an oil outlet and an oil return port, and the second reversing valve E2 and the third reversing valve The oil inlet on the valve E3 is respectively connected to the first reversing valve 3 through pipelines, and the oil outlet on the second reversing valve E2 is connected to the hydraulic motor 6 through the first oil passage. One port is connected, and the oil outlet on the third reversing valve E3 is connected with the other port on the hydraulic motor 6 through the second oil circuit; the second reversing valve E2 and the third reversing valve E2 The oil return port on the reversing valve E3 communicates with the energy storage pipeline through pipelines respectively.
进一步的,所述蓄能管路上连接有蓄能阀门A,所述蓄能阀门A连接在所述液压蓄能器B与所述变量泵1的出口之间,所述第二换向阀E2上的回油口和所述第三换向阀E3上的回油口通过管路连接在所述蓄能管路上的所述蓄能阀门A与所述液压蓄能器B之间。Further, an energy storage valve A is connected to the energy storage pipeline, and the energy storage valve A is connected between the hydraulic accumulator B and the outlet of the variable displacement pump 1, and the second reversing valve E2 and the oil return port on the third reversing valve E3 are connected between the accumulator valve A and the hydraulic accumulator B on the accumulator pipeline through pipelines.
更进一步的,所述第二换向阀E2的回油口和所述第三换向阀E3的回油口与所述蓄能管路相连通的管路上分别设置有单向阀F,两个所述单向阀F的导通方向分别朝向所述蓄能管路。Furthermore, the oil return port of the second reversing valve E2 and the oil return port of the third reversing valve E3 are respectively provided with check valves F on the pipelines connected with the energy storage pipeline, two The conduction directions of the one-way valves F are respectively towards the energy storage pipelines.
可选的,所述液压蓄能器B的端口与油箱D的进油口之间还连接有一个溢流阀C,所述溢流阀C可以当液压蓄能器B中回收的剩余油量过多时,将剩余油量送到油箱D内。Optionally, an overflow valve C is also connected between the port of the hydraulic accumulator B and the oil inlet of the oil tank D, and the overflow valve C can be used as the residual oil recovered in the hydraulic accumulator B When it is too much, send the remaining oil to the fuel tank D.
进一步的,所述能量回收系统还包括设置在所述挖掘机回转机构转轴上的转速传感器和转速加速度传感器,所述转速传感器用于采集所述挖掘机回转机构转轴的转速,所述转速加速度传感器用于采集所述挖掘机回转机构转轴的加速度。Further, the energy recovery system further includes a rotational speed sensor and a rotational speed acceleration sensor arranged on the rotating shaft of the slewing mechanism of the excavator, the rotational speed sensor is used to collect the rotational speed of the rotating shaft of the slewing mechanism of the excavator, and the rotational speed acceleration sensor It is used to collect the acceleration of the rotating shaft of the slewing mechanism of the excavator.
本发明实施例提供的基于蓄能器的挖掘机回转机构能量回收系统,所述第一换向阀为三位四通换向阀,所述第二换向阀和所述第三换向阀为两位三通换向阀,所述蓄能阀门为两位两通换向阀:In the energy recovery system for the slewing mechanism of an excavator based on an accumulator provided in an embodiment of the present invention, the first reversing valve is a three-position four-way reversing valve, the second reversing valve and the third reversing valve It is a two-position three-way reversing valve, and the energy storage valve is a two-position two-way reversing valve:
当所述挖掘机回转机构开始制动,且所述三位四通换向阀中位接通、所述两个两位三通换向阀左位接通,所述液压马达的出油口分别通过两个单向阀与所述液压蓄能器接通,所述液压蓄能器开始回收所述挖掘机回转机构的制动能量;When the slewing mechanism of the excavator starts to brake, and the middle position of the three-position four-way reversing valve is connected, and the left position of the two two-position three-way reversing valves is connected, the oil outlet of the hydraulic motor Connect with the hydraulic accumulator through two one-way valves respectively, and the hydraulic accumulator starts to recover the braking energy of the excavator slewing mechanism;
当所述挖掘机回转机构制动完成,且所述三位四通换向阀左位接通时,所述挖掘机回转机构开始反向启动;When the braking of the slewing mechanism of the excavator is completed, and the left position of the three-position four-way reversing valve is turned on, the slewing mechanism of the excavator starts to start in reverse;
当所述挖掘机回转机构反向匀速运动,且所述两位两通换向阀右位接通时,所述液压蓄能器开始释放制动能量,从而使得所述挖掘机回转机构反向加速启动。When the slewing mechanism of the excavator moves in the reverse direction at a constant speed, and the right position of the two-position two-way reversing valve is turned on, the hydraulic accumulator starts to release braking energy, so that the slewing mechanism of the excavator reverses Accelerate start.
本发明实施例还提供一种基于蓄能器的挖掘机回转机构能量回收方法,所述方法应用于上述实施例所述的基于蓄能器的挖掘机回转机构能量回收系统,所述方法包括如下步骤:An embodiment of the present invention also provides an energy recovery method for an excavator slewing mechanism based on an accumulator. The method is applied to the energy recovery system for an excavator slewing mechanism based on an accumulator described in the above embodiment. The method includes the following step:
步骤1,当挖掘机回转机构开始制动时,所述挖掘机回转机构制动过程中产生制动能量,将所述制动能量通过第二换向阀和第三换向阀的回油口传送至液压蓄能器进行回收储存;当所述挖掘机回转机构制动完成时,液压蓄能器完成制动能量的回收;所述制动能量至少包含转动动能和摩擦热能;Step 1, when the slewing mechanism of the excavator starts to brake, the braking energy is generated during the braking process of the slewing mechanism of the excavator, and the braking energy is passed through the oil return ports of the second reversing valve and the third reversing valve Transfer to the hydraulic accumulator for recovery and storage; when the slewing mechanism of the excavator is braked, the hydraulic accumulator completes the recovery of braking energy; the braking energy includes at least rotational kinetic energy and frictional heat energy;
步骤2,当所述挖掘机回转机构反向启动时,所述液压蓄能器将回收的制动能量进行释放,从而使得所述挖掘机回转机构反向加速启动。Step 2, when the slewing mechanism of the excavator starts in reverse, the hydraulic accumulator releases the recovered braking energy, so that the slewing mechanism of the excavator starts to accelerate in reverse.
具体的,所述方法包括如下步骤:Specifically, the method includes the following steps:
步骤1,当挖掘机回转机构开始制动,将所述三位四通换向阀的输入控制信号与定值信号0分别输入至第一比较器,所述第一比较器输出信号1;Step 1, when the slewing mechanism of the excavator starts to brake, the input control signal and the fixed value signal 0 of the three-position four-way reversing valve are respectively input to the first comparator, and the first comparator outputs signal 1;
步骤2,将所述比较器输出信号1输入比例放大器,从而得到所述比例放大器输出信号k;Step 2, inputting the output signal 1 of the comparator into a proportional amplifier, thereby obtaining the output signal k of the proportional amplifier;
步骤3,将所述比例放大器输出信号k分别作为两个两位三通换向阀的输入控制信号,从而每个两位三通换向阀的左位接通,液压蓄能器开始回收能量;Step 3, using the output signal k of the proportional amplifier as the input control signals of the two two-position three-way reversing valves, so that the left position of each two-position three-way reversing valve is connected, and the hydraulic accumulator starts to recover energy ;
步骤4,当所述挖掘机回转机构制动完成,所述三位四通换向阀输入控制信号调节所述三位四通换向阀左位接通,所述挖掘机回转机构开始反向启动;Step 4, when the braking of the slewing mechanism of the excavator is completed, the input control signal of the three-position four-way reversing valve adjusts the left position of the three-position four-way reversing valve to turn on, and the slewing mechanism of the excavator starts to reverse start up;
步骤5,确定所述液压蓄能器释放制动能量的开始时刻和结束时刻,并在所述开始时刻和所述结束时刻之间两位两通换向阀左位接通,所述液压蓄能器开始释放制动能量。Step 5, determine the start time and end time for the hydraulic accumulator to release braking energy, and turn on the left position of the two-position two-way reversing valve between the start time and the end time, the hydraulic accumulator The accumulator starts releasing braking energy.
具体的,步骤5中,所述确定所述液压蓄能器释放制动能量的开始时刻和结束时刻具体为:Specifically, in step 5, the determination of the start time and end time of releasing the braking energy of the hydraulic accumulator is specifically:
(5a)获取角速度传感器采集到的挖掘机回转机构反向启动后转轴的实时角速度,将所述挖掘机回转机构转轴的实时角速度与设定的角速度阈值进行比较,并记录所述实时角速度小于所述角速度阈值的第一时间段;(5a) Obtain the real-time angular velocity of the rotary shaft of the excavator rotary mechanism collected by the angular velocity sensor after the reverse start, compare the real-time angular velocity of the rotary shaft of the excavator with the set angular velocity threshold, and record that the real-time angular velocity is less than the set angular velocity The first time period of the angular velocity threshold;
(5b)获取角加速度传感器采集到的挖掘机回转机构反向启动后转轴的实时角加速度绝对值,将所述实时角加速度绝对值与设定的角加速度阈值进行比较,并记录所述实时角加速度小于所述角加速度阈值的第二时间段;(5b) Obtain the real-time angular acceleration absolute value of the rotating shaft after the reverse start of the slewing mechanism of the excavator collected by the angular acceleration sensor, compare the real-time angular acceleration absolute value with the set angular acceleration threshold, and record the real-time angular acceleration a second time period during which the acceleration is less than the angular acceleration threshold;
(5c)确定所述第一时间段和所述第二时间段的公共时间段,所述公共时间段的起始时刻即为所述液压蓄能器释放制动能量的开始时刻,所述公共时间段的结束时刻即为所述液压蓄能器释放制动能量的结束时刻。(5c) Determine the common time period of the first time period and the second time period, the starting moment of the common time period is the starting moment when the hydraulic accumulator releases braking energy, and the common time period The end moment of the time period is the end moment when the hydraulic accumulator releases braking energy.
需要说明的是,本发明实施例在传统挖掘机的回转系统中增加了液压蓄能器回路,挖掘机初次启动过程中,挖掘机回转机构按照传统模式正常工作,挖掘机回转机构制动时液压蓄能器才工作。It should be noted that the embodiment of the present invention adds a hydraulic accumulator circuit to the slewing system of the traditional excavator. During the initial start-up process of the excavator, the slewing mechanism of the excavator works normally according to the traditional mode. When the slewing mechanism of the excavator brakes, the hydraulic pressure The accumulator works.
需要说明的是,在挖掘机会还机构制动过程中,液压蓄能器在两个两位三通换向阀作用下接入回路,回收制动能量。It should be noted that during the braking process of the excavator return mechanism, the hydraulic accumulator is connected to the circuit under the action of two two-position three-way reversing valves to recover braking energy.
需要说明的是,由于回转机构在加速启动时有较大的速度波动,鉴于液压蓄能器回收的能量有限,选择回转机构匀速运动时释放液压蓄能器回收的制动能量。It should be noted that since the slewing mechanism has large speed fluctuations when accelerating and starting, in view of the limited energy recovered by the hydraulic accumulator, the braking energy recovered by the hydraulic accumulator is released when the slewing mechanism moves at a constant speed.
需要说明的是,在两个两位三通换向阀都处于右位时,挖掘机回转机构工作在传统模式。It should be noted that when the two two-position three-way reversing valves are both in the right position, the slewing mechanism of the excavator works in the traditional mode.
本发明实施例提供的基于蓄能器的挖掘机回转机构能量回收系统的完整工作过程如下:The complete working process of the excavator slewing mechanism energy recovery system based on the accumulator provided by the embodiment of the present invention is as follows:
(1)变量泵的控制信号调节变量泵启动,三位四通换向阀右位接通,此时回转机构开始正转启动。(1) The control signal of the variable pump adjusts the start of the variable pump, the right position of the three-position four-way reversing valve is connected, and the slewing mechanism starts to rotate forward at this time.
(2)回转机构启动完成,旋转到工作位置,挖掘机开始挖掘作业。(2) The slewing mechanism is started, rotated to the working position, and the excavator starts digging.
(3)挖掘机挖掘作业完成,旋转到卸料位置,回转机构开始制动。(3) After the excavation operation is completed, the excavator rotates to the unloading position, and the slewing mechanism starts to brake.
(4)三位四通换向阀的控制信号调节三位四通换向阀处于中位(此时,变量泵控制信号和三位四通换向阀控制信号的输入均为0,变量泵的排量也为0),两个左边两位三通换向阀处于左位,从而使马达的出油口通过两个单向阀与液压蓄能器接通,液压蓄能器开始储存能量。(4) The control signal of the three-position four-way reversing valve adjusts the three-position four-way reversing valve to be in the neutral position (at this time, the input of the control signal of the variable pump and the control signal of the three-position four-way reversing valve are both 0, and the variable pump The displacement is also 0), the two left two-position three-way reversing valves are in the left position, so that the oil outlet of the motor is connected to the hydraulic accumulator through the two one-way valves, and the hydraulic accumulator starts to store energy .
(5)在蓄能器工作压力的作用下,实现制动。制动完成后,三位四通换向阀控制信号调节三位四通换向阀处于左位,回转机构开始反向启动。(5) Under the action of the working pressure of the accumulator, braking is realized. After the braking is completed, the control signal of the three-position four-way reversing valve adjusts the three-position four-way reversing valve to be in the left position, and the slewing mechanism begins to reverse start.
(6)在回转机构反向匀速运动后,两位两通换向阀的控制信号调节两位两通换向阀处于右位,蓄能器开始释放能量,实现回转机构反向的加速。(6) After the slewing mechanism reverses and moves at a constant speed, the control signal of the two-position two-way reversing valve adjusts the two-position two-way reversing valve to the right position, and the accumulator starts to release energy to realize the reverse acceleration of the slewing mechanism.
示例性的,如图4所示,为传统挖掘机回转机构制动阶段与本发明技术方案的挖掘机回转机构制动阶段的转速对比曲线示意图。Exemplarily, as shown in FIG. 4 , it is a schematic diagram of the rotational speed comparison curve between the braking stage of the slewing mechanism of the traditional excavator and the braking stage of the slewing mechanism of the excavator according to the technical solution of the present invention.
从图4中可以看出,本发明实施例提供的挖掘机回转装在在制动阶段速度波动较小,且能较快制动,降低了系统在制动时的液压冲击。It can be seen from Fig. 4 that the excavator slewing device provided by the embodiment of the present invention has less speed fluctuation during the braking phase, and can brake faster, reducing the hydraulic shock of the system during braking.
从图5中可以看出,挖掘机回转机构反向启动期间,在液压蓄能器释放制动能量的作用下,回转机构得到再次加速。It can be seen from Figure 5 that during the reverse start of the slewing mechanism of the excavator, the slewing mechanism is accelerated again under the action of the braking energy released by the hydraulic accumulator.
从图6可以看出液压蓄能器的压力和体积随着制动能量的回收和释放产生相应的变化,实现能量的再利用。It can be seen from Figure 6 that the pressure and volume of the hydraulic accumulator change accordingly with the recovery and release of braking energy, realizing energy reuse.
综上所述,本发明实施例提供的基于蓄能器的挖掘机回转机构能量回收系统在回转机构制动时能回收制动能量,在回转机构再次启动时,能释放能量。In summary, the accumulator-based energy recovery system for the slewing mechanism of excavators provided by the embodiments of the present invention can recover braking energy when the slewing mechanism is braking, and can release energy when the slewing mechanism starts up again.
需要补充的是,关于蓄能器释放能量时机的选择,需要分析回转机构在运动过程中的运动规律以及能量供应情况。What needs to be added is that regarding the selection of the timing for the accumulator to release energy, it is necessary to analyze the motion law and energy supply of the slewing mechanism during the motion process.
回转机构在启动时,马达进油口的压力迅速达到泵出口溢流阀的调定压力,溢流阀将多余流量溢流。随后马达和回转机构加速启动,随着马达速度的提升,吸收流量增加,溢流阀的溢流量减少,系统的压力依然维持在溢流阀的调定压力,直到释放能量时刻。When the slewing mechanism is started, the pressure at the oil inlet of the motor quickly reaches the set pressure of the relief valve at the pump outlet, and the relief valve overflows the excess flow. Then the motor and the slewing mechanism are accelerated and started. With the increase of the motor speed, the absorption flow increases and the overflow of the relief valve decreases. The pressure of the system remains at the set pressure of the relief valve until the moment of energy release.
当马达吸收的流量等于泵的输出流量时,溢流阀不再溢流,系统压力开始下降,但此时系统压力产生的驱动力矩依然大于负载阻力矩,所以,虽然回转机构转动加速度减小,但还在加速。随着转速的进一步增加,马达的流量供不应求,当系统压力产生的驱动力矩等于回转阻力矩时,回转机构转速达到最大值,以后将匀速转动,稍有速度波动。When the flow absorbed by the motor is equal to the output flow of the pump, the relief valve will no longer overflow, and the system pressure will begin to drop, but at this time the driving torque generated by the system pressure is still greater than the load resistance torque, so although the rotational acceleration of the slewing mechanism decreases, But still accelerating. With the further increase of the rotational speed, the flow of the motor is in short supply. When the driving torque generated by the system pressure is equal to the rotational resistance torque, the rotational speed of the slewing mechanism reaches the maximum value, and then it will rotate at a constant speed with slight speed fluctuations.
在溢流阀开启时,变量泵的流量供过于求,开启后速度波动较大,由于液压蓄能器回收的能量有限,可以选择在回转机构速度稳定之后再释放能量。同时,当回转机构的转速趋于稳定后,转速虽有波动,但转动加速度很小,所以选择加速度较小时释放液压蓄能器收集的制动能量。When the overflow valve is opened, the flow rate of the variable displacement pump exceeds the demand, and the speed fluctuates greatly after opening. Since the energy recovered by the hydraulic accumulator is limited, the energy can be released after the speed of the slewing mechanism is stable. At the same time, when the speed of the slewing mechanism tends to be stable, although the speed fluctuates, the rotational acceleration is very small, so the braking energy collected by the hydraulic accumulator is released when the acceleration is small.
本发明实施例所提供的能量回收和释放的控制原理具体步骤如下:The specific steps of the control principle of energy recovery and release provided by the embodiments of the present invention are as follows:
步骤一:将三位四通换向阀控制信号与定值0作比较,当三位四通换向阀控制信号为0时,比较后输出1。Step 1: Compare the control signal of the three-position four-way reversing valve with the fixed value 0. When the control signal of the three-position four-way reversing valve is 0, output 1 after the comparison.
步骤二:把输出信号按比例k放大,作为左右两边两位三通换向阀的控制信号。Step 2: Amplify the output signal according to the ratio k, and use it as the control signal of the two-position three-way reversing valve on the left and right sides.
步骤三:左边两位三通换向阀的控制信号调节左边两位三通换向阀处于左位,右边两位三通换向阀的控制信号调节右边两位三通换向阀也处于左位,此时蓄能器开始储存能量。Step 3: Adjust the control signal of the two-position three-way reversing valve on the left to the left position, and adjust the control signal of the two-position three-way reversing valve on the right to the left position. At this point, the accumulator starts to store energy.
步骤四:制动完成后,三位四通换向阀控制信号调节三位四通换向阀处于左位,回转机构开始反向启动。Step 4: After the brake is completed, the three-position four-way reversing valve control signal is adjusted to the left position of the three-position four-way reversing valve, and the slewing mechanism starts to start in reverse.
步骤五:回转机构反向启动后,由于当角速度达到12r/min时加速度有最大值降到0,在0处波动且幅度越来越小。将通过角速度传感器采集到回转机构的角速度与设定的角速度阈值(示例性的,可以设置为12r/min)作比较,当该值大于k时输出信号值为1,否则输出信号值为0。Step 5: After the slewing mechanism is started in reverse, since the acceleration has a maximum value and drops to 0 when the angular velocity reaches 12r/min, it fluctuates at 0 and the amplitude becomes smaller and smaller. The angular velocity of the rotary mechanism collected by the angular velocity sensor is compared with the set angular velocity threshold (for example, it can be set to 12r/min). When the value is greater than k, the output signal value is 1, otherwise the output signal value is 0.
步骤五:记录输出信号为1的时间段。Step 5: Record the time period when the output signal is 1.
步骤六:将通过角加速度传感器采集到回转机构的角加速度取绝对值。Step 6: Take the absolute value of the angular acceleration of the slewing mechanism collected by the angular acceleration sensor.
步骤七:将角加速度的绝对值与预设的角加速度阈值(示例性的,可以设置为0.01)作比较,记录叫加速度的绝对值小于设定的角加速度阈值的时间段。Step 7: Compare the absolute value of the angular acceleration with a preset angular acceleration threshold (for example, it can be set to 0.01), and record the time period when the absolute value of the acceleration is less than the preset angular acceleration threshold.
步骤八:得到步骤五所述的速度值较稳定的时间段且步骤七所述的角加速度较小的时间段,即得到了前文所述蓄能器释放能量时间段。Step 8: Obtain the time period during which the speed value in step 5 is relatively stable and the time period during which the angular acceleration described in step 7 is small, that is, the time period during which the accumulator releases energy as described above is obtained.
步骤九:将时钟信号与定值K(1s)作比较,当时钟信号的值大于K(1s)值时输入时钟信号。Step 9: Compare the clock signal with the fixed value K(1s), and input the clock signal when the value of the clock signal is greater than the value of K(1s).
步骤十:同时满足步骤八和步骤九所述时,两位两通换向阀控制信号调节两位两通换向阀处于左位,蓄能器开始释放能量。Step 10: When both steps 8 and 9 are satisfied, the control signal of the two-position two-way reversing valve adjusts the two-position two-way reversing valve to the left position, and the accumulator starts to release energy.
示例性的,如图7是三位四通换向阀与两位三通换向阀控制信号,从图7中可以看出,利用三位四通换向阀与两位三通换向阀的控制信号来控制蓄能器回路环节简单易操作。Exemplary, as shown in Figure 7 is the control signal of the three-position four-way reversing valve and the two-position three-way reversing valve, as can be seen from Figure 7, using the three-position four-way reversing valve and the two-position three-way reversing valve The control signal to control the accumulator circuit is simple and easy to operate.
如图8是蓄能器释放能量的控制信号,通过控制信号液压蓄能器完成适量的释放。Figure 8 is the control signal of the accumulator to release energy, through the control signal hydraulic accumulator to complete the appropriate amount of release.
如图9是液压蓄能器释放能量后,回转机构反转的转速曲线,由图9可以明显看到释放能量后回转机构反向运动得到了加速。As shown in Figure 9, after the hydraulic accumulator releases energy, the rotation speed curve of the slewing mechanism reverses. From Figure 9, it can be clearly seen that the reverse movement of the slewing mechanism is accelerated after the energy is released.
如图10是液压蓄能器释放能量时流量和充气体积的变化,由图10可知,液压蓄能器稳定释放能量时刻与图8中的控制信号基本符合,充分证明了该控制方法的正确可行。As shown in Figure 10, the change of flow rate and inflated volume when the hydraulic accumulator releases energy, it can be seen from Figure 10 that the time when the hydraulic accumulator releases energy stably is basically consistent with the control signal in Figure 8, which fully proves that the control method is correct and feasible .
本发明产生的有益效果为:(1)在传统挖掘机回转机构中加入液压蓄能器,建立了基于蓄能器能量回收系统;(2)在蓄能器能量回收系统的基础上,在回收系统加入了逻辑信号控制系统,通过角速度、角加速度的反馈信号和逻辑运算验证了能量回收与释放的控制过程。该系统实现了在制动时回收能量,再次启动时释放能量的目的;(3)该发明有效的回收了液压挖掘机回转制动过程中以热能形式损耗的转动动能,从而不仅节约能源和降低液压系统的油温,同时也提高设备的可靠性和使用寿命。其次,该节能方案不仅可以推广到其他型号液压挖掘机,这也为相关类型的工程机械提供了参考。The beneficial effects produced by the present invention are: (1) a hydraulic accumulator is added to the slewing mechanism of the traditional excavator, and an energy recovery system based on the accumulator is established; (2) on the basis of the energy recovery system of the accumulator, in the recovery A logic signal control system is added to the system, and the control process of energy recovery and release is verified through the feedback signals of angular velocity and angular acceleration and logical operations. The system achieves the purpose of recovering energy when braking and releasing energy when starting again; (3) the invention effectively recovers the rotational kinetic energy lost in the form of heat energy during the slewing braking process of the hydraulic excavator, thereby not only saving energy and reducing The oil temperature of the hydraulic system also improves the reliability and service life of the equipment. Secondly, this energy-saving solution can not only be extended to other types of hydraulic excavators, but also provides a reference for related types of construction machinery.
以上所述,仅为本发明的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,可轻易想到变化或替换,都应涵盖在本发明的保护范围之内。因此,本发明的保护范围应以所述权利要求的保护范围为准。The above is only a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Anyone skilled in the art can easily think of changes or substitutions within the technical scope disclosed in the present invention. Should be covered within the protection scope of the present invention. Therefore, the protection scope of the present invention should be determined by the protection scope of the claims.
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