CN115059128A - Lever pressure-regulating energy-saving device for recycling potential energy of movable arm of excavator and control method - Google Patents
Lever pressure-regulating energy-saving device for recycling potential energy of movable arm of excavator and control method Download PDFInfo
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- CN115059128A CN115059128A CN202210718026.4A CN202210718026A CN115059128A CN 115059128 A CN115059128 A CN 115059128A CN 202210718026 A CN202210718026 A CN 202210718026A CN 115059128 A CN115059128 A CN 115059128A
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- 238000000034 method Methods 0.000 title claims abstract description 49
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F3/00—Dredgers; Soil-shifting machines
- E02F3/04—Dredgers; Soil-shifting machines mechanically-driven
- E02F3/28—Dredgers; Soil-shifting machines mechanically-driven with digging tools mounted on a dipper- or bucket-arm, i.e. there is either one arm or a pair of arms, e.g. dippers, buckets
- E02F3/36—Component parts
- E02F3/42—Drives for dippers, buckets, dipper-arms or bucket-arms
- E02F3/43—Control of dipper or bucket position; Control of sequence of drive operations
- E02F3/435—Control of dipper or bucket position; Control of sequence of drive operations for dipper-arms, backhoes or the like
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F3/00—Dredgers; Soil-shifting machines
- E02F3/04—Dredgers; Soil-shifting machines mechanically-driven
- E02F3/28—Dredgers; Soil-shifting machines mechanically-driven with digging tools mounted on a dipper- or bucket-arm, i.e. there is either one arm or a pair of arms, e.g. dippers, buckets
- E02F3/36—Component parts
- E02F3/42—Drives for dippers, buckets, dipper-arms or bucket-arms
- E02F3/43—Control of dipper or bucket position; Control of sequence of drive operations
- E02F3/435—Control of dipper or bucket position; Control of sequence of drive operations for dipper-arms, backhoes or the like
- E02F3/437—Control of dipper or bucket position; Control of sequence of drive operations for dipper-arms, backhoes or the like providing automatic sequences of movements, e.g. linear excavation, keeping dipper angle constant
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Abstract
The invention discloses a lever pressure-regulating energy-saving device for recycling potential energy of a movable arm of an excavator and a control method, and belongs to the field of hydraulic transmission and control. Including excavator energy recuperation mechanical system, including retrieving the hydro-cylinder, the adjusting cylinder, the lever, slider and cylinder, wherein retrieve the hydro-cylinder and fix on the excavator revolving stage cylinder bottom, and the unanimous setting of piston rod direction, the tip of retrieving the hydro-cylinder is connected with the one end of lever through the loose axle, the tip and the slider swing joint of cylinder, the slider setting is at the lever and can move on the lever, adjusting cylinder and lever parallel arrangement, one end and lever fixed connection, the other end is connected with the slider, the piston rod that makes the adjusting cylinder follows the slider and removes and stretch out and draw back. The structure is simple, and the cost is low; the loss of hydraulic oil flowing through pipelines and elements is reduced to a certain extent, the system heating caused by the rise of oil temperature is relieved, and the efficiency of a hydraulic system is effectively improved.
Description
Technical Field
The invention relates to a lever pressure-regulating energy-saving device for recycling potential energy of a movable arm of an excavator and a control method, and belongs to the field of hydraulic transmission and control.
Background
As an important engineering machine, the hydraulic excavator has the advantages of strong mining capability, good environmental adaptability and the like, and has been widely applied to many fields such as industrial production, transportation, mining, infrastructure construction and the like.
With the increasing strictness of the national emission standards of engineering machinery, the disadvantage of low energy utilization efficiency of the hydraulic excavator draws wide attention. Only about 20% of the power output by a conventional hydraulic excavator engine is converted into useful work, with losses on the hydraulic system reaching 53%. Taking a movable arm of a hydraulic excavator as an example, because the working device has large mass, a large amount of potential energy needs to be released in the lowering process, and the energy is consumed at a throttling port of the hydraulic valve and converted into heat energy, so that the energy waste and the oil heating are caused, and the service life of a hydraulic element is shortened.
There is a similar problem of energy waste in the main motions of the boom, arm, bucket, and swing of the hydraulic excavator, and the specific weight occupied by the boom is at the maximum, about 51%. Therefore, the research on recycling of the boom-lowering potential energy of the excavator is an important step for improving the efficiency of the excavator, and has important significance for energy conservation, emission reduction and environmental protection.
For the recovery of the potential energy of the movable arm of the excavator, hydraulic and electrical recovery is generally adopted, but the existing methods greatly change the original system, a hydraulic element and an electric control system are additionally added, the process is complex, the operability is low, the cost is high, and the practical application of the method is limited to a certain extent.
The movable arm of the hydraulic excavator is frequently lifted and dropped in the operation process, and in a system without a potential energy recovery device, the potential energy of the movable arm can be converted into heat energy at a throttle valve port for dissipation, so that resources are wasted, the oil temperature is increased, a high-power radiator is required to be additionally added, and the installation cost of the excavator is increased. In order to improve the energy utilization efficiency of a hydraulic excavator and reduce the problems of energy consumption and environmental pollution, at present, most of potential energy recovery schemes for the descending of a movable arm mainly comprise a hydraulic energy recovery scheme and an electric energy recovery scheme, the two schemes have respective defects, the potential energy of the descending of the movable arm is stored in a hydraulic energy accumulator in a hydraulic energy mode by a hydraulic energy recovery system, and the pressure change of the energy accumulator is large, so that the pressure is difficult to match; the problems of complex equipment and high cost of the electric energy recovery system exist, the application of the recovery scheme in practice is limited due to the high cost of the electric energy storage element and the generator, and the utilization rate of energy recovery is reduced due to the repeated conversion of mechanical energy, pressure energy and electric energy. In addition, the original structure and system of the excavator are greatly changed, so that the performance of the excavator is greatly different from that of the original system, the operation of the excavator is difficult, and the working efficiency of the excavator is reduced.
Disclosure of Invention
The purpose of the invention is as follows: in order to overcome the defects in the prior art, the lever pressure regulating energy-saving device and the control method for recycling the potential energy of the movable arm of the excavator are provided, the potential energy of gravity in the descending process of the movable arm of the excavator can be converted into internal energy of gas through a lever and a gas cylinder and stored in the gas cylinder 13, the internal energy of the gas stored in the gas cylinder 13 is released when the movable arm of the excavator lifts, the movable arm is driven to ascend, the throttling loss of oil generated by a proportional reversing valve when the movable arm descends in an original hydraulic system is avoided, the efficiency of the hydraulic system is improved, the heating of the oil is reduced, the temperature rise of the oil is reduced, and the heat dissipation power of the system is reduced. Two closed-loop controls of the valve port pressure difference of the proportional throttle valve and the speed of the movable arm are added, and the lifting performance of the movable arm of the excavator is ensured to be consistent with that of the original system when the energy recovery system works.
The technical scheme is as follows: in order to achieve the aim, the lever pressure-regulating energy-saving device for recycling the potential energy of the movable arm of the excavator comprises an excavator hydraulic system and an excavator energy recycling mechanical system, the excavator hydraulic system is a hydraulic system of an excavator and comprises a variable pump and an auxiliary pump which are connected through a transmission shaft, wherein the variable pump is respectively connected with a movable arm locking valve, an overload oil supplementing valve one-way valve a and an overload oil supplementing valve one-way valve b through a proportional reversing valve;
the excavator energy recovery mechanical system comprises a recovery oil cylinder, an adjusting oil cylinder, a lever, a sliding block and an air cylinder, wherein the bottom of the recovery oil cylinder and the bottom of the air cylinder are fixed on an excavator rotary table, the directions of piston rods are arranged in a consistent manner, the end part of the recovery oil cylinder is connected with one end of the lever through a movable shaft, the end part of the air cylinder is movably connected with the sliding block, the sliding block is arranged on the lever and can move on the lever, the adjusting oil cylinder is arranged in parallel with the lever, one end of the adjusting oil cylinder is fixedly connected with the lever, and the other end of the adjusting oil cylinder is connected with the sliding block, so that the piston rod of the adjusting oil cylinder can move and stretch along with the sliding block;
a rod cavity pipeline of a movable arm oil cylinder for driving a movable arm of the excavator is connected with a rod cavity of a recovery oil cylinder through an upper cavity electromagnetic valve, a rodless cavity pipeline of the movable arm oil cylinder is connected with a rodless cavity of the recovery oil cylinder through a lower cavity electromagnetic valve and a proportional throttle valve which are sequentially arranged, and the rod cavity and the rodless cavity of the movable arm oil cylinder are also connected with an overload oil supplementing valve one-way valve b and an overload oil supplementing valve one-way valve b in a hydraulic system of excavator hydraulic through pipelines;
an oil inlet and an oil outlet of the adjusting oil cylinder are respectively connected with two working oil ports of the electromagnetic proportional directional valve through pipelines, and oil supply ports of the electromagnetic proportional directional valve, the movable arm descending control pilot valve and the movable arm ascending control pilot valve are connected with an outlet of an auxiliary pump of the original hydraulic system; oil outlets of the movable arm descending control pilot valve and the movable arm ascending control pilot valve are respectively connected to oil supply ports of the movable arm ascending signal cut-off valve and the movable arm descending signal cut-off valve, oil outlets of the movable arm descending signal cut-off valve and the movable arm ascending signal cut-off valve are respectively connected to the left end and the right end of a valve core of the proportional hydraulic control reversing valve and the control end of the hydraulic control reversing valve, two working oil ports of the hydraulic control reversing valve are respectively connected with a rod cavity and a rodless cavity of a movable arm oil cylinder, and oil return ports of all valves are connected with an oil tank.
Further, a fulcrum B fixed in the middle of the lever is fixed on a rotary table of the excavator, the right end of the lever and the top of a piston rod of the recovery oil cylinder are hinged to a point A, and the top of a piston rod of the air cylinder and the sliding block are hinged to a point C; the sliding block is sleeved at the left end of the lever and can slide on the lever, and the sliding block is hinged with a piston rod of the adjusting oil cylinder through a baffle; the right end of the lever is hinged to a point D through a baffle and a cylinder barrel of the adjusting oil cylinder, and the bottoms of the cylinder barrels of the recycling oil cylinder and the air cylinder are hinged to the excavator.
Further, a pressure sensor of a rodless cavity of the movable arm oil cylinder is arranged on a pipeline between a rod cavity of the movable arm oil cylinder and the electromagnetic valve of the upper cavity, and a pressure sensor of a rodless cavity of the recovery oil cylinder is arranged on a pipeline between the proportional throttle valve and the rodless cavity of the recovery oil cylinder.
Furthermore, a rodless cavity of the cylinder is connected with a gas cylinder through a pipeline, and a gas cylinder pressure sensor is arranged on a gas cylinder port.
A control method of a lever pressure-regulating energy-saving device for recycling potential energy of a movable arm of an excavator comprises the following steps:
when the movable arm descends, the gravitational potential energy is converted into internal energy of gas for storage:
operating a descending handle to enable a pilot control valve 28 to output control oil, in order to enable high-pressure oil in a rodless cavity of a movable arm to enter an energy recovery system without directly entering an original hydraulic system, electrifying an electromagnet of a movable arm descending signal cut-off valve, enabling an output control signal xBm1B to be 0, enabling a middle position of a proportional reversing valve to work, simultaneously enabling a left position of a hydraulic control reversing valve to work, enabling hydraulic oil in a rod cavity of a movable arm oil cylinder and hydraulic oil in the rodless cavity not to flow into the original hydraulic system, electrifying electromagnets of an upper cavity electromagnetic valve and a lower cavity electromagnetic valve, connecting the rod cavity of the movable arm oil cylinder and the rod cavity of a recovery oil cylinder, and connecting the rodless cavity of the movable arm with the rodless cavity of the recovery oil cylinder;
the movable arm oil cylinder descends under the action of pressure of a rodless cavity and gravity of the movable arm, high-pressure oil enters a lower cavity of the recovery oil cylinder through a lower cavity electromagnetic valve and a proportional throttle valve, low-pressure oil in an upper cavity of the recovery oil cylinder flows back to an upper cavity of the precession arm oil cylinder through an upper cavity electromagnetic valve to supplement oil in a rod cavity of the movable arm oil cylinder; a piston rod of the recovery oil cylinder pushes a lever, the other end of the recovery oil cylinder pushes a piston rod of the air cylinder under the action of the lever, the piston rod of the air cylinder retracts, compressed air stores pressure energy in an air cylinder, and gravitational potential energy of a movable arm is converted into internal gas energy to be stored;
when the movable arm ascends, the internal energy of the gas is released and reused:
before the gas energy is released, whether the energy stored in the gas cylinder can lift the movable arm once is judged; if the energy is insufficient, the energy recovery system is closed, and oil supply is continued to be carried out by using the original hydraulic system of the excavator to enable the movable arm to ascend; lifting the boom with the recovered energy if the gas energy is sufficient to lift the boom once;
because the boom rise time is short, the gas expansion process can be considered as an adiabatic process; the process of gas energy release in the cylinder follows the ideal gas state equation:
in the formula: n is a polytropic index, and the adiabatic process n is 1.4;
the gas cylinder does work outwards in the process of releasing energy
In the formula: v 1 Volume in the initial state of gas;
V 2 volume in the gas end state;
when the gas cylinder is released from high pressure to low pressure, the pressure is reduced and the volume is increased, the high pressure of the gas cylinder in the initial state is measured by a gas cylinder pressure sensor, and the value is P 13 Taking the volume of the gas with the highest working pressure as the volume of the gas cylinder and the value is V 13 The last state gas volume is the sum of the volume of the gas cylinder and the maximum volume of the lower cavity of the gas cylinder, and the value is V 15 +V 13 And then, a state equation and a work application equation are introduced, and the work application of the energy released by the gas cylinder to the piston rod of the cylinder is obtained as follows:
in the formula: p 13 Is the maximum pressure of the cylinder; v 13 Is the volume of the gas cylinder; v 15 Is the rodless maximum volume of the cylinder;
if the pressure of the lower cavity of the movable arm oil cylinder is constant in the movable arm lifting process, the liquid energy required in the movable arm lifting process is as follows:
W 2 ＝P 2 V 2 Ⅳ
in the formula: p 2 The rodless cavity pressure of the lower cavity of the movable arm oil cylinder is obtained;
V 2 the maximum rodless volume of the movable arm oil cylinder;
proportional throttle valve inlet and outlet pressure difference set value delta P i And the energy throttled by the proportional throttle valve is as follows:
W 5 ＝ΔP i ·V 2 Ⅴ
considering system energy loss, the total energy conversion efficiency is taken as eta, and in order to enable the energy stored in the gas cylinder to satisfy the condition that the movable arm ascends once, the following conditions are satisfied:
before the movable arm rises, whether the movable arm can be lifted to the highest position by analyzing the energy released by the gas according to the pressure values of the gas cylinder pressure sensor and the lower cavity pressure sensor 6 of the movable arm oil cylinder; if not, the movable arm ascending signal cut-off valve, the movable arm descending signal cut-off valve, the upper cavity electromagnetic valve and the lower cavity electromagnetic valve in the system are not electrified, and the energy recovery system does not operate and does not influence the work of the original hydraulic system;
if the movable arm can be lifted to the highest position by the energy released by the gas in the gas cylinder, the electromagnet of the movable arm lifting signal cut-off valve is electrified, the output control signal xBm1A is 0, the middle position of the proportional reversing valve works at the moment, the left position of the hydraulic control reversing valve works, and the rod cavity hydraulic oil and the rodless cavity hydraulic oil of the movable arm oil cylinder are not communicated with the original hydraulic system; meanwhile, electromagnets of the upper cavity electromagnetic valve and the lower cavity electromagnetic valve are electrified, low-pressure oil in a rod cavity of the movable arm is communicated with a rod cavity of the recovery oil cylinder, and low-pressure oil in a rodless cavity of the movable arm is communicated with a rodless cavity of the recovery oil cylinder through a proportional throttle valve;
the internal energy of the gas in the gas cylinder is released, the gas in the gas cylinder does work on a piston rod of the cylinder 13, the piston rod of the cylinder pushes a lever upwards, and the internal energy of the gas is converted into mechanical energy for the movement of the piston rod; the lever rotates around a fulcrum B, the other end pushes a piston rod of the recovery oil cylinder to retract downwards under the action of the lever, high-pressure oil generated by the rodless cavity enters the rodless cavity of the movable arm oil cylinder through the proportional throttle valve and the lower cavity electromagnetic valve, the piston rod of the movable arm oil cylinder is pushed to extend out, low-pressure oil in the rod cavity of the movable arm oil cylinder flows back into an upper cavity of the regulation recovery oil cylinder through the upper cavity electromagnetic valve, and oil in the rod cavity of the regulation recovery oil cylinder is supplemented; the movable arm rises, so that the internal energy of the gas in the gas cylinder is converted into the gravitational potential energy of the movable arm, and the energy is recycled.
Furthermore, the flow rate of the proportional throttle valve is controlled by two quantities of the valve port pressure difference and the valve opening, so the control system can ensure that the valve port pressure difference of the proportional throttle valve is constant, the flow rate of the proportional throttle valve is only controlled by the valve opening, the flow rate of the proportional throttle valve is only related to the lifting control signal,
the valve port pressure difference of the proportional throttle valve is automatically controlled: for ensuring rodless chamber pressure P of boom cylinder 2 And recovering the pressure P of the rodless cavity of the oil cylinder 8 Actual pressure difference Δ P of e And the inlet and outlet set pressure difference delta P of the proportional throttle valve i Remain equal;
pressure control is based on the given pressure difference delta P of the inlet and the outlet of the proportional throttle valve i For input quantity, pressure P of rodless cavity of boom cylinder 2 And the pressure P of rodless cavity of the recovery oil cylinder 8 Pressure difference Δ P of e As the amount of feedback, the feedback amount,
rodless cavity pressure P of movable arm oil cylinder 2 The pressure P of the rodless cavity of the recovery oil cylinder is measured by a pressure sensor at the lower cavity of the movable arm oil cylinder 8 The actual pressure difference of the two cavities is obtained by measuring by a rodless cavity pressure sensor 7 of the recovery oil cylinder: delta P e ＝P 8 -P 2 ；
When the movable arm is in a lifting working condition:
when the actual difference value Δ P e Less than a predetermined pressure difference DeltaP at inlet and outlet i Setting the difference value delta P between the inlet-outlet pressure difference and the actual pressure difference ie ＝△P i -△P e To be positive, the processor applies a control algorithm (e.g., PID) to derive a positive control voltage signal u p The output is sent to a proportional amplifier 2, and the proportional amplifier 2 outputs a positive control current signal i to an electromagnet of the electromagnetic proportional reversing valve p The pilot pump 27 outputs the supply pressure P 27 The valve core of the electromagnetic proportional directional valve moves leftwards, the rodless cavity of the adjusting oil cylinder is filled with oil and returned by the rod cavity, the piston rod of the adjusting oil cylinder extends, and the distance X between the two points BC is obtained BC Increasing the force F of the point A at the right end of the lever to the piston rod of the recovery oil cylinder under the action of the lever A Increasing and recovering pressure P generated by rodless cavity of oil cylinder 8 Increasing until the actual difference value delta P between the rodless cavity pressure of the movable arm oil cylinder and the rodless cavity pressure of the recovery oil cylinder e Equal to the set pressure difference delta P of the inlet and the outlet of the proportional throttle valve i When the pressure is enough to lift the movable arm to rise, the system is in balance at the position;
when the actual difference Δ P e Greater than a predetermined pressure difference delta P at inlet and outlet i Setting the difference value delta P between the inlet-outlet pressure difference and the actual pressure difference ie ＝△P i -△P e To be negative, the processor applies a control algorithm (e.g., PID) to derive a negative control voltage signal u p The output is sent to a proportional amplifier in a self-contained driver of the excavator, and the proportional amplifier outputs a negative control current signal i to an electromagnet of an electromagnetic proportional directional valve p The pilot pump 27 outputs a supply pressure P 27 The valve core of the electromagnetic proportional reversing valve moves rightwards, the rod cavity of the adjusting oil cylinder is filled with oil and returned by the rodless cavity, the piston rod of the adjusting oil cylinder retracts, and the distance X between the two points BC is obtained BC The force F of the point A at the right end of the lever to the piston rod of the recovery oil cylinder is reduced under the action of the lever A Reduce and recover the pressure P generated by the rodless cavity of the oil cylinder 8 Reducing until the actual difference value delta P between the rodless cavity pressure of the movable arm oil cylinder and the rodless cavity pressure of the recovery oil cylinder e Equal to the pressure difference delta P between the inlet and the outlet of the proportional throttle valve i When the pressure is enough to lift the movable arm to rise, the system is balanced at the position(ii) a Thereby achieving the rodless cavity pressure P of the movable arm oil cylinder 2 And the pressure P of the rodless cavity of the recovery oil cylinder 8 Matching purposes;
when the movable arm is in a descending working condition:
the working condition of recovering hydraulic energy when the movable arm descends still needs to ensure the rodless cavity pressure P of the movable arm oil cylinder 2 Pressure P of rodless cavity of recovery oil cylinder 8 The pressure difference is equal to a set value, and the control method is the same as the working condition of the boom ascending.
Further, the speed of the movable arm of the excavator is automatically controlled to control the speed v of the movable arm in real time 1 And (3) synchronizing with the working speed of the original system:
the lifting speed of the movable arm of the original system excavator is realized by controlling a pilot control handle, changing the size of a pilot control pressure signal xBmA and further controlling the opening amount of a proportional reversing valve, and before an energy recovery system works, a pilot pressure signal P needs to be measured firstly X And boom velocity v i Functional relationship of (a):
v i ＝f(P X )
in the formula: p X Is a pilot pressure control signal; v. of i The speed control is the speed v of the movable arm when the original system works i To input, the actual speed v 1 Is the feedback quantity.
Further, the speed of the movable arm of the excavator under the working condition of the movable arm rising is automatically controlled:
the processor is based on the input pilot signal P X Calculating the ascending speed v of the movable arm when the original system works i ＝f(P X ) If the actual boom speed v 1 Is less than the speed v of the original system during working i The processor calculates the difference v e ＝v i -v 1 To be positive, the processor applies a control algorithm (e.g., PID) to increase the control voltage signal u q The proportional amplifier 1 outputs a control current signal i to the proportional throttle valve electromagnet q The opening of the valve core of the proportional throttle valve is increased, and the pressure difference delta P between the inlet and the outlet of the proportional throttle valve is ensured e And rated working pressure difference delta P i Under the equal condition, enters a rodless cavity of a boom cylinderFlow rate q of 2 Increase, then the actual boom speed v 1 Increase until the speed v of the movable arm is increased when the movable arm works with the original system i Equal, the system is in balance in this state;
when actual speed v of the boom 1 Greater than the speed v of the original system during operation i The processor calculates the difference v e ＝v i -v 1 To be negative, the processor applies a control algorithm (e.g., PID) to reduce the control voltage signal u q The proportional amplifier 1 outputs a control current signal i to the proportional throttle valve electromagnet q The opening amount of a valve core of the proportional throttle valve is reduced, and the pressure difference delta P between the inlet and the outlet of the proportional throttle valve is ensured e And rated working pressure difference delta P i Under the condition of equal flow q entering a rodless cavity of a boom cylinder 2 Decrease, then the actual speed v of the boom 1 Decrease until the velocity v of the movable arm is reduced when the original system works i Equal, the system is in balance in this state; thereby achieving the ascending speed v of the piston rod of the movable arm oil cylinder 1 And velocity v of the original system i The purpose of consistency;
the speed of the movable arm of the excavator under the working condition of the movable arm descending is automatically controlled:
the working condition of recovering hydraulic energy when the movable arm descends still needs to ensure the actual speed v of the movable arm 1 And velocity v of the original system i And the control method is the same as the boom raising condition.
Has the advantages that:
when the movable arm of the excavator descends, the movable arm oil cylinder and the recovery oil cylinder are connected through a loop, the movable arm descends, oil enters a rodless cavity of the recovery oil cylinder from the rodless cavity of the movable arm oil cylinder to push a piston rod of the recovery oil cylinder to extend out, the piston rod enables the lever to rotate, the other end of the lever exerts force on the piston rod of the air cylinder to enable the piston rod of the air cylinder to retract, gas in the air cylinder and the gas cylinder is compressed, and potential energy of the descending of the movable arm is converted into internal energy of gas molecules to be stored. Along with the increase of the gas compression pressure, the adjusting oil cylinder enables the force arm of the air cylinder to the lever to be reduced, and pressure matching is achieved.
When a movable arm of the excavator ascends, the internal energy of the gas is released, the stored internal energy of gas molecules is converted into mechanical energy, a piston rod of the cylinder is pushed to extend out, the recovery oil cylinder retracts under the action of a lever, high-pressure oil is discharged from a lower cavity of the recovery oil cylinder and enters the movable arm oil cylinder to push the movable arm to ascend, so that the internal energy of the gas is converted into movable arm potential energy, and the effects of energy conservation and emission reduction are achieved. In the process, the pressure is reduced along with the increase of the volume of the gas, the oil cylinder is adjusted to increase the force arm of the cylinder to the lever, and the pressure matching is realized.
Compared with the existing excavator movable arm potential energy recycling device, the excavator movable arm potential energy recycling and reusing scheme based on the sliding pair and the gas energy storage does not need to change an original hydraulic system of the excavator, is convenient to modify and high in reliability, avoids a complex energy conversion link, and ensures the utilization rate of energy recycling. The structure is simple, and the cost is low; the loss of hydraulic oil flowing through pipelines and elements is reduced to a certain extent, the system heating caused by the rise of oil temperature is relieved, and the efficiency of a hydraulic system is effectively improved; the invention also comprises two closed-loop control systems of the proportional throttle valve differential pressure and the movable arm speed, thereby ensuring that the operation performance of the excavator is consistent with that of the original system in the processes of energy recovery and reutilization.
Drawings
FIG. 1 is a schematic structural view of an energy recovery device according to the present invention;
FIG. 2 is a block diagram of the automatic control operation of the present invention.
In the figure, 1, a movable arm; 2. a boom cylinder; 3. an upper cavity electromagnetic valve; 4. a lower cavity electromagnetic valve; 5. a proportional throttle valve; 6. a pressure sensor of a rodless cavity of the movable arm oil cylinder; 7. a rodless cavity pressure sensor of the recovery oil cylinder; 8. recovering the oil cylinder; 9. adjusting the oil cylinder; 10 electromagnetic proportional directional valve; 11. a lever; 12. a slider; 13. a gas cylinder; 14. a gas cylinder pressure sensor; 15. a cylinder;
21. a variable displacement pump; 22. a proportional directional valve; 23. a hydraulic control directional control valve; 24. a boom lock valve; 25. 26, an overload oil replenishing valve one-way valve; 27. an auxiliary pump; 28. a boom-down control pilot valve; 29. a boom-up control pilot valve; 30. a boom-up signal pressure sensor; 31. a boom down signal pressure sensor; 32. a movable arm ascending signal cut-off valve; 33. movable arm descending signal cut-off valve
The point A is hinged with the recycling oil cylinder 8 and the lever 11; point B, lever 11 fulcrum; point C, the hinge point of the cylinder 15 and the slider 12; point D, the bottom of the adjusting oil cylinder 9 and the hinge point of the lever 11; and point E, the top of the adjusting oil cylinder 9 and the hinged point of the sliding block 12.
Detailed Description
The present invention will be further described with reference to the accompanying drawings.
As shown in the attached figure 1, the lever pressure-regulating energy-saving device for recycling the potential energy of the movable arm of the excavator comprises a movable arm 1; a boom cylinder 2; an upper cavity electromagnetic valve 3; a lower cavity electromagnetic valve 4; a proportional throttle valve 5; a boom cylinder rodless cavity pressure sensor 6; a rodless cavity pressure sensor 7 of the recovery oil cylinder; a recovery oil cylinder 8; an adjusting oil cylinder 9; an electromagnetic proportional directional valve 10; a lever 11; a slider 12; a gas cylinder 13; a cylinder pressure sensor 14; a cylinder 15; and the original excavator hydraulic system: a variable displacement pump 21; a proportional hydraulic control directional valve 22; a pilot operated directional control valve 23; a boom lock valve 24; an overload oil supplementing valve one-way valve a25 and an overload oil supplementing valve one-way valve b 26; a pilot pump 27; a boom-down control pilot valve 28; a boom-up control pilot valve 29; a boom-up signal pressure sensor 30; boom-down signal pressure sensor 31; a boom-up signal cut-off valve 32; a boom-down signal cut-off valve 33.
The excavator energy recovery system consists of a hydraulic system and a mechanical system.
The mechanical system part comprises a recovery oil cylinder 8, an adjusting oil cylinder 9, a lever 11, a slide block 12 and the like. The lever 11 is fixed at the pivot B, the right end of the lever 11 and the top of a piston rod of the recovery oil cylinder 8 are hinged at a point A, and the top of a piston rod of the air cylinder 15 and the sliding block 12 are hinged at a point C; the sliding block 12 is sleeved at the left end of the lever 11 and can slide on the lever 11, and the sliding block 12 is hinged with a piston rod of the adjusting oil cylinder 9 at a point E through a baffle; the right end of the lever 11 is hinged with the cylinder barrel of the adjusting oil cylinder 9 at a point D through a baffle plate. The cylinder barrels of the recovery oil cylinder 8 and the air cylinder 13 are hinged on the excavator.
The hydraulic system consists of the original excavator hydraulic system and a newly added hydraulic system. Since the invention only recovers potential energy of a movable arm of the hydraulic excavator, other hydraulic circuits of the excavator are not represented in fig. 1, and a hydraulic system part, the movable arm 1 and a movable arm oil cylinder 2 of the original excavator in fig. 1 are original elements of the excavator.
The connection relation of the hydraulic system is as follows: a piston rod of the movable arm oil cylinder 2 is hinged to the movable arm 1, a rod cavity of the recovery oil cylinder 8 is connected with a rod cavity of the movable arm oil cylinder 2 through an upper cavity electromagnetic valve 3, and the upper cavity electromagnetic valve 3 controls the on-off of an oil path; a rodless cavity of the recovery oil cylinder 8 is connected with the proportional throttle valve 5, the other oil port of the proportional throttle valve 5 is connected with a lower cavity electromagnetic valve, the other oil port of the lower cavity electromagnetic valve is connected with the rodless cavity of the movable arm oil cylinder 2, a pressure sensor 7 is installed in the lower cavity of the recovery oil cylinder 8, and a lower cavity pressure sensor 6 of the movable arm oil cylinder 2 is installed in the lower cavity of the movable arm oil cylinder 2; a rodless cavity of the cylinder 13 is connected with a gas cylinder 15 through a pipeline, and a gas cylinder pressure sensor 14 is arranged in a lower cavity of the cylinder; the oil inlet and outlet of the adjusting oil cylinder 9 are connected with two working oil ports of the electromagnetic proportional directional valve 10, and oil supply ports of the electromagnetic proportional directional valve 10, the boom descending control pilot valve 28 and the boom ascending control pilot valve 29 are connected with an outlet of an auxiliary pump of the original hydraulic system; oil outlets of the boom-down control pilot valve 28 and the boom-up control pilot valve 29 are respectively connected to oil supply ports of the boom-up signal cut-off valve 32 and the boom-down signal cut-off valve 33, and oil outlets of the boom-down signal cut-off valve 33 and the boom-up signal cut-off valve 32 are respectively connected to the left end and the right end of the valve body of the proportional hydraulic control directional valve 22 and the control end of the hydraulic control directional valve 23. Two working oil ports of the hydraulic control reversing valve 23 are respectively connected with the upper cavity and the lower cavity of the movable arm oil cylinder 2. The oil return ports of all the valves are connected with an oil tank.
1. When the energy recovery and reuse system does not work, the working principle of the original hydraulic system
When the energy recovery system does not work, the electromagnets of the movable arm ascending signal cut-off valve 32, the movable arm descending signal cut-off valve 33, the upper cavity electromagnetic valve 3 and the lower cavity electromagnetic valve 4 in the system are not electrified, and the energy recovery system does not operate and does not influence the work of the original hydraulic system.
1.1 boom raising procedure
A driver pulls the control lifting handle to enable the pilot control valve 29 to output control oil, the control signal xBm1A passing through the boom lifting signal cut-off valve 32 is transmitted to the right end of a valve core of the proportional directional valve 22 to enable the proportional directional valve 22 to be reversed to the right position, high-pressure oil output by the variable pump 21 enters the boom locking valve 24 through the one-way valve and the proportional directional valve 22, at the moment, the left position of the hydraulic control directional valve 23 is connected, the high-pressure oil output by the variable pump 21 jacks the valve core of the boom locking valve 24, and the oil flows out from the boom locking valve 24; entering a rodless cavity of the movable arm oil cylinder 2, and extending a piston rod of the movable arm oil cylinder 2 out of a movable arm to rise; the oil in the rod chamber of the boom cylinder 2 flows back to the tank through the proportional directional valve 22.
1.2 boom lowering procedure
A driver pulls the operating descending handle to enable the pilot control valve 28 to output control oil, the control oil is connected to the left end of a valve core of the proportional reversing valve 22 through a control signal xBm1B of the boom descending signal cut-off valve 33 to enable the proportional reversing valve 22 to be reversed to a left position, high-pressure oil output by the variable pump 21 enters a rod cavity of the boom cylinder 2 through the one-way valve and the proportional reversing valve 22, and a piston rod of the boom cylinder 2 retracts into a boom to descend; the control signal xBm1B also enters the control end of the pilot-controlled directional control valve 23 at the same time, so that the pilot-controlled directional control valve 23 operates at the right position, the control end of the boom locking valve 24 is communicated with the oil tank through the pilot-controlled directional control valve 23, so that the boom locking valve 24 is conducted in the reverse direction, and the oil in the rodless cavity of the boom cylinder 2 flows back to the oil tank through the boom locking valve 24 and the proportional directional control valve 22.
2. When the energy recovery and reuse system works, the working principle of lifting of the movable arm
2.1, working condition one: internal energy storage process for converting gravitational potential energy into gas when movable arm descends
In order to enable the high-pressure oil in the rodless cavity of the boom to enter the energy recovery system and not directly enter the original hydraulic system, the electromagnet of the boom descending signal cut-off valve 33 is electrified, the output control signal xBm1B is 0, at the moment, the middle position of the proportional reversing valve 22 works, meanwhile, the left position of the hydraulic control reversing valve 23 works, and the hydraulic oil in the rod cavity and the hydraulic oil in the rodless cavity of the boom cylinder 2 do not flow into the original hydraulic system. Meanwhile, electromagnets of the upper cavity electromagnetic valve 3 and the lower cavity electromagnetic valve 4 are electrified, a rod cavity of the movable arm oil cylinder 2 is communicated with a rod cavity of the recovery oil cylinder 8, and a rodless cavity of the movable arm is connected with a rodless cavity of the recovery oil cylinder 8.
The movable arm oil cylinder 2 descends under the action of the pressure of the rodless cavity and the gravity of the movable arm, high-pressure oil enters a lower cavity of the recovery oil cylinder 8 through a lower cavity electromagnetic valve 4 and a proportional throttle valve 5, low-pressure oil in the upper cavity of the recovery oil cylinder 8 flows back to the upper cavity of the precession arm oil cylinder 2 through an upper cavity electromagnetic valve 3, and oil in a rod cavity of the movable arm oil cylinder 2 is supplemented. The piston rod of the recovery oil cylinder 8 pushes the lever 11, the other end pushes the piston rod of the air cylinder 15 under the action of the lever 11, the piston rod of the air cylinder 15 retracts, pressure energy is stored in the air cylinder 13 by compressed air, and the gravitational potential energy of the movable arm is converted into gas internal energy to be stored.
2.2 working condition two: when the movable arm rises, the internal energy of the gas is released and reused
Before the gas energy is released, it is determined whether the boom 2 can be raised once by the energy stored in the gas cylinder 13. If the energy recovery system is not enough, the energy recovery system is closed, and oil supply is continued by the original hydraulic system of the excavator to lift the movable arm 2. If the gas energy is sufficient to lift the boom 2 once, the recovered energy is used to lift the boom.
Since the boom-up time is short, the gas expansion process may be regarded as an adiabatic process. The process of gas energy release in the cylinder follows the ideal gas state equation:
in the formula: n is a polytropic index, and the adiabatic process n is 1.4.
The gas cylinder does work outwards in the process of releasing energy
In the formula: v 1 Volume in the initial state of gas;
V 2 is the volume of the gas end state.
Comprehensive working condition analysis shows that when the gas cylinder 13 is released from a high-pressure state to a low-pressure state, the pressure is reduced, the volume is increased, the high-pressure of the gas cylinder 13 in the initial state is measured by a gas cylinder pressure sensor 14, and the value is P 13 To get the bestThe volume of the gas with high working pressure is the volume of the gas cylinder, and the value is V 13 The last state gas volume is the sum of the volume of the gas cylinder and the maximum volume of the lower cavity of the gas cylinder, and the value is V 15 +V 13 If the state equation and the work equation are brought, the work of the gas cylinder releasing energy on the piston rod of the cylinder 15 can be obtained as follows:
in the formula: p 13 The maximum pressure of the gas cylinder 13;
V 13 the volume of the gas cylinder 13;
V 15 is the rodless maximum volume of the cylinder 15.
If the pressure of the lower cavity of the movable arm oil cylinder 2 is constant in the movable arm lifting process, the liquid energy required in the movable arm lifting process is as follows:
W 2 ＝P 2 V 2 (4)
in the formula: p is 2 The rodless cavity pressure of the lower cavity of the movable arm oil cylinder 2;
V 2 is the rodless maximum volume of the boom cylinder 2.
Pressure difference set value delta P of inlet and outlet of proportional throttle valve 5 i And the energy throttled by the proportional throttle valve is as follows:
W 5 ＝ΔP i ·V 2 (5)
considering the energy loss of the system, the total energy conversion efficiency is taken as eta, and in order to enable the energy stored in the gas cylinder to satisfy the condition that the movable arm ascends once, the requirement is met
Before the movable arm rises, whether the movable arm can be lifted to the highest position by analyzing the energy released by the gas according to the pressure values of the gas cylinder pressure sensor 14 and the movable arm oil cylinder lower cavity pressure sensor 6 is analyzed. If not, electromagnets of the movable arm ascending signal cut-off valve 32, the movable arm descending signal cut-off valve 33, the upper cavity electromagnetic valve 3 and the lower cavity electromagnetic valve 4 in the system are not electrified, the energy recovery system does not operate, and the work of the original hydraulic system is not influenced.
If the movable arm 1 can be lifted to the highest position by the energy released by the gas in the gas cylinder 15, the electromagnet of the movable arm ascending signal cut-off valve 32 is electrified, the output control signal xBm1A is 0, the middle position of the proportional reversing valve 22 works at the moment, the left position of the hydraulic control reversing valve 23 works, and the rod cavity hydraulic oil and the rodless cavity hydraulic oil of the movable arm oil cylinder 2 are not communicated with the original hydraulic system. Meanwhile, electromagnets of the upper cavity electromagnetic valve 3 and the lower cavity electromagnetic valve 4 are electrified, low-pressure oil in a rod cavity of the movable arm 1 is communicated with a rod cavity of the recovery oil cylinder 8, and low-pressure oil in a rodless cavity of the movable arm 1 is communicated with a rodless cavity of the recovery oil cylinder 8 through the proportional throttle valve 5.
The internal energy of the gas in the gas cylinder 15 is released, the gas in the gas cylinder 15 applies work to the piston rod of the cylinder 13, the piston rod of the cylinder 15 pushes the lever 11 upwards, and the internal energy of the gas is converted into mechanical energy for the movement of the piston rod. The lever 11 rotates around the fulcrum B, the other end pushes the piston rod of the oil cylinder 8 to retract downwards under the action of the lever 11, high-pressure oil generated by the rodless cavity enters the rodless cavity of the movable arm oil cylinder 2 through the proportional throttle valve 5 and the lower cavity electromagnetic valve 4, the piston rod of the movable arm oil cylinder 2 is pushed to extend out, low-pressure oil in the rod cavity of the movable arm oil cylinder 2 flows back into the upper cavity of the adjusting oil cylinder 8 through the upper cavity electromagnetic valve 3, and oil in the rod cavity of the adjusting oil cylinder 8 is supplemented. The movable arm 1 rises, so that the internal energy of the gas in the gas cylinder is converted into the gravitational potential energy of the movable arm, and the energy is recycled.
3. Automatic control working principle of energy recovery and reuse system
In order to make the system have the same maneuverability as the original system, that is, the lifting speed of the movable arm of the two systems is the same as the lifting control signal law, the flow of the proportional throttle valve 5 is only controlled by the lifting pilot signal, and an automatic flow control system is designed, as shown in fig. 2. Because the flow of the proportional throttle valve 5 is controlled by two quantities, namely valve port pressure difference and valve opening, the control system can ensure that the valve port pressure difference of the proportional throttle valve 5 is constant (the pressure difference is the minimum pressure difference required by the throttle valve flow regulation, the throttling loss of the throttle valve is minimum, the system efficiency is highest), the flow is only controlled by the valve opening, the flow of the proportional throttle valve 5 is only related to the lifting control signal, and the control system designed for the purpose is composed of two closed loop control loops. The right half of fig. 2 is a closed loop control circuit of the valve port pressure difference of the proportional throttle valve 5, and the left half of fig. 2 is a speed control circuit of the movable arm 2.
3.1 proportion throttle valve 5 valve port pressure difference automatic control working principle
The purpose of this control is to ensure the rodless chamber pressure P of the boom cylinder 2 2 And the pressure P of rodless cavity of the recovery oil cylinder 8 8 Actual pressure difference Δ P of e And the inlet and outlet set pressure difference delta P of the proportional throttle valve 5 i Remain equal.
The control block diagram is shown on the right side of fig. 2. The pressure control is the given pressure difference delta P at the inlet and the outlet of the proportional throttle valve 5 i For input quantity, the pressure P of rodless cavity of boom cylinder 2 2 Pressure P of rodless cavity of recovery oil cylinder 8 8 Pressure difference Δ P of e For feedback quantity, the control system comprises a processor, a proportional amplifier 2, an electromagnetic proportional directional valve 10, an adjusting oil cylinder 9, an air bottle 13, an air cylinder 15, a lever 11, a recovery oil cylinder 8 and the like.
Pressure P of rodless cavity of boom cylinder 2 2 The pressure P of a rodless cavity of the recovery oil cylinder 8 is measured by a lower cavity pressure sensor 6 of the movable arm oil cylinder 8 The actual pressure difference of the two cavities is obtained by the measurement of a rodless cavity pressure sensor 7 of the recovery oil cylinder
△P e ＝P 8 -P 2 。
(1) Working condition of boom rising
When the actual difference Δ P e Less than a predetermined pressure difference DeltaP at inlet and outlet i Setting the difference value delta P between the inlet-outlet pressure difference and the actual pressure difference ie ＝△P i -△P e To be positive, the processor applies a control algorithm (e.g., PID) to derive a positive control voltage signal u p The output is sent to a proportional amplifier 2, the proportional amplifier 2 outputs a positive control current signal i to an electromagnet of an electromagnetic proportional directional valve 10 p The pilot pump 27 outputs a supply pressure P 27 The valve core of the electromagnetic proportional directional valve 10 moves leftwards, the rodless cavity of the adjusting oil cylinder 9 is filled with oil and returns with oil in the rod cavity, the piston rod of the adjusting oil cylinder 9 extends, and then the distance X between the two points BC is obtained BC The size of the mixture is increased, and the mixture is,under the action of the lever, the force F of the point A at the right end of the lever to the piston rod of the recovery oil cylinder 8 A Increase and recover the pressure P generated by the rodless cavity of the oil cylinder 8 8 Increasing until the actual difference value delta P between the rodless cavity pressure of the movable arm oil cylinder 2 and the rodless cavity pressure of the recovery oil cylinder 8 e Equal to the set pressure difference delta P of the inlet and the outlet of the proportional throttle valve i At this point, the pressure is sufficient to lift the boom up, and the system is in equilibrium at this point.
When the actual difference Δ P e Greater than a predetermined pressure difference delta P at inlet and outlet i Setting the difference value delta P between the inlet-outlet pressure difference and the actual pressure difference ie ＝△P i -△P e To be negative, the processor applies a control algorithm (e.g., PID) to derive a negative control voltage signal u p The output is sent to a proportional amplifier 2, the proportional amplifier 2 outputs a negative control current signal i to an electromagnet of a proportional reversing valve 10 p The pilot pump 27 outputs the supply pressure P 27 The valve core of the electromagnetic proportional directional valve 10 moves rightwards, the rod cavity of the adjusting oil cylinder 9 is filled with oil and returned by the rodless cavity, the piston rod of the adjusting oil cylinder 9 retracts, and the distance X between the two points BC is BC The force F of the point A at the right end of the lever to the piston rod of the recovery oil cylinder 8 is reduced under the action of the lever A Reduce and recover the pressure P generated by the rodless cavity of the oil cylinder 8 8 Reducing until the actual difference value delta P between the rodless cavity pressure of the movable arm oil cylinder 2 and the rodless cavity pressure of the recovery oil cylinder 8 e Equal to the pressure difference delta P between the inlet and the outlet of the proportional throttle valve i At this point, the pressure is sufficient to lift the boom up, and the system is in equilibrium at this point. Thereby achieving the rodless cavity pressure P of the movable arm oil cylinder 2 2 And the pressure P of the rodless cavity of the recovery cylinder 8 8 The purpose of matching.
(2) Working condition of boom descent
The working condition of recovering hydraulic energy when the movable arm descends still needs to ensure the rodless cavity pressure P of the movable arm oil cylinder 2 2 Pressure P of rodless cavity of recovery oil cylinder 8 8 The pressure difference is equal to a set value, and the control method is the same as the working condition of the boom ascending.
3.2 working principle of automatic control of speed of movable arm
The purpose of this control is to control the speed v of the boom 1 in real time 1 And the speed of the original system during operationThe same is true.
The lifting speed of the movable arm of the original system excavator is realized by controlling a pilot control handle, changing the magnitude of a pilot control pressure signal xBmA and further controlling the opening amount of a proportional directional valve 22.
Before the energy recovery system works, a pilot pressure signal P needs to be measured X And boom velocity v i Functional relationship of (a):
v i ＝f(P X ) (7)
in the formula: p X Is a pilot pressure control signal;
v i the speed of the movable arm when the original system works is obtained.
The control block diagram is shown on the left side of fig. 2. The speed control is the speed v of the movable arm when the original system works i For input, the actual speed v 1 For feedback quantity, the control system comprises a processor, a proportional amplifier 1, a proportional throttle valve 5 and a movable arm oil cylinder 2; v. of i The speed of the movable arm 1 under the original system work; v. of 1 Actual speed of the boom 1; v. of e Deviation of the speed of the movable arm 1 under the operation of the original system and the actual speed; u. of q The voltage signal which is output by the processor and used for controlling the proportional throttle valve 5; i.e. i q The current signal which is output by the operational amplifier and controls the proportional throttle valve 5; q. q.s 2 The flow rate of the oil entering the lower cavity of the movable arm oil cylinder 2; delta P i The inlet-outlet pressure difference set value of the proportional throttle valve 5; p 2 The rodless cavity pressure of the movable arm oil cylinder 2; p 8 The pressure of a rodless cavity of the oil recovery cylinder 8 is recovered; delta P e The actual difference value of the rodless cavity pressure of the movable arm oil cylinder 2 and the rodless cavity pressure of the recovery oil cylinder 8; delta P ie The difference value of the actual pressure of the rodless cavity of the movable arm oil cylinder 2 and the rodless cavity of the recovery oil cylinder 8 and the working pressure difference of the proportional throttle valve 5; u. of p The voltage signal which is output by the processor and used for controlling the electromagnetic proportional directional valve 10; i.e. i p The current signal which is output by the operational amplifier and used for controlling the electromagnetic proportional directional valve 10; q. q.s 9 The flow entering the lower cavity of the adjusting oil cylinder 9; x BC Distance between the two points BC; p 13 The pressure of the gas cylinder 13; f 15 The acting force of the piston rod of the air cylinder 15 on the hinge point C; f A And the acting force of the hinged point A at the right end of the lever 11 on the piston rod of the recovery oil cylinder 8.
(1) Working condition of boom rising
The processor is based on the input pilot signal P X Calculating the ascending speed v of the movable arm when the original system works i ＝f(P X ) If the actual boom speed v 1 Is less than the speed v of the original system during working i The processor calculates the difference v e ＝v i -v 1 To be positive, the processor applies a control algorithm (e.g., PID) to increase the control voltage signal u q The proportional amplifier 1 outputs a control current signal i to the electromagnet of the proportional throttle valve 5 q The valve core opening of the proportional throttle valve 5 is increased, and the pressure difference delta P between the inlet and the outlet of the proportional throttle valve 5 is ensured e And a high constant working pressure difference DeltaP i Equal flow q into the rodless chamber of boom cylinder 2 2 Increasing, then the actual speed v of the boom 1 Increase until the speed v of the movable arm is increased when working with the original system i Equal, the system is in equilibrium in this state.
When actual boom speed v 1 Greater than the speed v of the original system during operation i The processor calculates the difference v e ＝v i -v 1 To be negative, the processor applies a control algorithm (e.g., PID) to reduce the control voltage signal u q The proportional amplifier 1 outputs a control current signal i to the electromagnet of the proportional throttle valve 5 q The opening amount of the valve core of the proportional throttle valve 5 is reduced, and the pressure difference delta P between the inlet and the outlet of the proportional throttle valve 5 is ensured e And a high constant working pressure difference DeltaP i Equal flow q into the rodless chamber of boom cylinder 2 2 Decrease, then the actual speed v of the boom 1 Decrease until the velocity v of the movable arm is reduced when the original system works i Equal, the system is in equilibrium in this state. Thereby achieving the ascending speed v of the piston rod of the movable arm oil cylinder 2 1 And velocity v of the original system i The purpose of the correspondence is.
(2) Working condition of boom descent
The working condition of recovering hydraulic energy when the movable arm descends still needs to ensure the actual speed v of the movable arm 1 And velocity v of the original system i In accordance with the above, the control method and the above-mentioned actionsThe arm lifting conditions are the same.
In conclusion, the energy recovery and recycling system can convert gravitational potential energy into internal energy of gas through the lever and the gas cylinder in the descending process of the movable arm of the excavator, store the internal energy of the gas in the gas cylinder 13 and release the internal energy of the gas stored in the gas cylinder 13 to drive the movable arm to ascend when the movable arm of the excavator ascends, so that throttling loss of oil generated by a proportional reversing valve when the movable arm descends in an original hydraulic system is avoided, the efficiency of the hydraulic system is improved, the heating of the oil is reduced, the temperature rise of the oil is reduced, and the heat dissipation power of the system is reduced. Two closed-loop controls of the valve port pressure difference of the proportional throttle valve and the speed of the movable arm are added, and the lifting performance of the movable arm of the excavator is ensured to be consistent with that of the original system when the energy recovery system works.
Claims (8)
1. The utility model provides an excavator swing arm potential energy is retrieved and is recycled lever pressure regulating economizer which characterized in that: comprises an excavator hydraulic system and an excavator energy recovery mechanical system, wherein the excavator hydraulic system is the hydraulic system of the excavator, the excavator hydraulic system comprises a variable pump (21) and an auxiliary pump (27) which are connected through a transmission shaft, the variable pump (21) is respectively connected with a movable arm locking valve (24) through a proportional reversing valve (22), the auxiliary pump is characterized by comprising an overload oil supplementing valve one-way valve a (25) and an overload oil supplementing valve one-way valve b (26), wherein a movable arm locking valve (24) is arranged on a pipeline between a proportional reversing valve (22) and the overload oil supplementing valve one-way valve a (25), the movable arm locking valve (24) is connected with an oil tank through a hydraulic control reversing valve (23), the auxiliary pump is respectively connected with a movable arm descending control pilot valve (28) and a movable arm ascending control pilot valve (29) through pipelines, the movable arm descending control pilot valve (28) is connected with a movable arm ascending signal pressure sensor, and the movable arm ascending control pilot valve (29) is connected with a movable arm descending signal pressure sensor;
the excavator energy recovery mechanical system comprises a recovery oil cylinder (8), an adjusting oil cylinder (9), a lever (11), a sliding block (12) and an air cylinder (15), wherein the bottoms of the recovery oil cylinder (8) and the air cylinder (15) are fixed on an excavator rotary table, the directions of piston rods are arranged consistently, the end part of the recovery oil cylinder (8) is connected with one end of the lever (11) through a movable shaft, the end part of the air cylinder (15) is movably connected with the sliding block (12), the sliding block (12) is arranged on the lever (11) and can move on the lever (11), the adjusting oil cylinder (9) is arranged in parallel with the lever (11), one end of the adjusting oil cylinder is fixedly connected with the lever (11), and the other end of the adjusting oil cylinder is connected with the sliding block (12), so that the piston rod of the adjusting oil cylinder (9) moves along with the sliding block (12) to stretch;
a pipeline with a rod cavity of a movable arm oil cylinder (2) for driving a movable arm (1) of the excavator is connected with a rod cavity of a recovery oil cylinder (8) through an upper cavity electromagnetic valve (3), a pipeline without the rod cavity of the movable arm oil cylinder (2) is connected with a rod cavity of the recovery oil cylinder (8) through a lower cavity electromagnetic valve (4) and a proportional throttle valve (5) which are sequentially arranged, and the pipeline with the rod cavity and the rod cavity of the movable arm oil cylinder (2) are also connected with an overload oil supplementing valve one-way valve b (26) and an overload oil supplementing valve one-way valve b (25) in a hydraulic system of the excavator through pipelines;
an oil inlet and an oil outlet of the adjusting oil cylinder (9) are respectively connected with two working oil ports of the electromagnetic proportional directional valve (10) through pipelines, and oil supply ports of the electromagnetic proportional directional valve (10), the movable arm descending control pilot valve (28) and the movable arm ascending control pilot valve (29) are connected with an outlet of an auxiliary pump (27) of the original hydraulic system; oil outlets of a movable arm descending control pilot valve (28) and a movable arm ascending control pilot valve (29) are respectively connected to oil supply ports of a movable arm ascending signal cut-off valve (32) and a movable arm descending signal cut-off valve (33), oil outlets of the movable arm descending signal cut-off valve (33) and the movable arm ascending signal cut-off valve (32) are respectively connected to the left end and the right end of a valve element of a proportional hydraulic control reversing valve (22) and a control end of the hydraulic control reversing valve (23), two working oil ports of the hydraulic control reversing valve (23) are respectively connected with a rod cavity and a rodless cavity of a movable arm oil cylinder (2), and oil return ports of all valves are connected with oil tanks.
2. The excavator movable arm potential energy recycling lever pressure regulating energy-saving device as claimed in claim 1, characterized in that: a fulcrum B fixed in the middle of the lever (11) is fixed on a turntable of the excavator, the right end of the lever (11) and the top of a piston rod of the recovery oil cylinder (8) are hinged to a point A, and the top of a piston rod of the air cylinder (15) and the sliding block (12) are hinged to a point C; the sliding block (12) is sleeved at the left end of the lever (11) and can slide on the lever (11), and the sliding block (12) is hinged to a point of a piston rod of the adjusting oil cylinder (9) through a baffle; the right end of the lever (11) is hinged with a cylinder barrel of the adjusting oil cylinder (9) at a point D through a baffle, and the bottoms of the cylinder barrels of the recycling oil cylinder (8) and the air cylinder (13) are hinged on the excavator.
3. The excavator boom potential energy recycling lever pressure regulating energy-saving device as claimed in claim 1, characterized in that: a pipeline between a rod cavity of the movable arm oil cylinder (2) and the upper cavity electromagnetic valve (3) is provided with a movable arm oil cylinder rodless cavity pressure sensor (6), and a pipeline between the proportional throttle valve (5) and a rodless cavity of the recovery oil cylinder (8) is provided with a recovery oil cylinder rodless cavity pressure sensor (7).
4. The excavator movable arm potential energy recycling lever pressure regulating energy-saving device as claimed in claim 1, characterized in that: the rodless cavity of the air cylinder (15) is connected with an air cylinder (13) through a pipeline, and an air cylinder pressure sensor (14) is arranged on the opening of the air cylinder (13).
5. A control method for the lever pressure-regulating energy-saving device for recycling the potential energy of the movable arm of the excavator is characterized by comprising the following steps of:
when the movable arm descends, the gravitational potential energy is converted into internal energy of gas for storage:
operating a descending handle to enable a pilot control valve 28 to output control oil, in order to enable high-pressure oil in a rodless cavity of a movable arm to enter an energy recovery system without directly entering an original hydraulic system, electrifying an electromagnet of a movable arm descending signal cut-off valve (33), enabling an output control signal xBm1B to be 0, enabling a middle position of a proportional reversing valve (22) to work, simultaneously enabling a left position of a hydraulic control reversing valve (23) to work, enabling hydraulic oil in a rod cavity and hydraulic oil in a rodless cavity of a movable arm oil cylinder (2) not to flow into the original hydraulic system, electrifying electromagnets of an upper cavity electromagnetic valve (3) and a lower cavity electromagnetic valve (4), connecting the rod cavity of the movable arm oil cylinder (2) with the rod cavity of a recovery oil cylinder (8), and connecting the rodless cavity of the movable arm with the rodless cavity of the recovery oil cylinder (8);
the movable arm oil cylinder (2) descends under the action of pressure of a rodless cavity and gravity of the movable arm, high-pressure oil enters a lower cavity of the recovery oil cylinder (8) through a lower cavity electromagnetic valve (4) and a proportional throttle valve (5), low-pressure oil in an upper cavity of the recovery oil cylinder (8) flows back to an upper cavity of the precession arm oil cylinder (2) through an upper cavity electromagnetic valve (3) to supplement oil in a rod cavity of the movable arm oil cylinder (2); a piston rod of the recovery oil cylinder (8) pushes a lever (11), the other end of the piston rod pushes a piston rod of an air cylinder (15) under the action of the lever (11), the piston rod of the air cylinder (15) retracts, compressed air stores pressure energy in an air cylinder (13), and gravitational potential energy of a movable arm is converted into internal gas energy to be stored;
when the movable arm ascends, the internal energy of the gas is released and reused:
before the gas energy is released, whether the energy stored in the gas cylinder (13) can enable the movable arm (1) to ascend once is judged; if the energy is insufficient, the energy recovery system is closed, and oil supply is continued by using the original hydraulic system of the excavator to enable the movable arm (1) to ascend; if the gas energy is enough to lift the movable arm (1) once, lifting the movable arm by using the recovered energy;
the gas expansion process can be regarded as an adiabatic process due to the short boom rise time; the process of gas energy release in the cylinder follows the ideal gas state equation:
PV n ＝P 0 V 0 n Ⅰ
in the formula: n is a polytropic index, and the adiabatic process n is 1.4;
the gas cylinder does work outwards in the process of releasing energy
In the formula: v 1 Volume in the initial state of gas;
V 2 volume in the gas end state;
when the gas cylinder (13) is released from a high-pressure state to a low-pressure state, the pressure is reduced, the volume is increased, the high-pressure of the gas cylinder (13) in the initial state is measured by a gas cylinder pressure sensor (14), and the value is P 13 Taking the volume of the gas with the highest working pressure as the volume of the gas cylinder and the value is V 13 The last state gas volume is the sum of the volume of the gas cylinder and the maximum volume of the lower cavity of the gas cylinder, and the value is V 15 +V 13 And then, a state equation and a work application equation are introduced, and the work application of the energy released by the gas cylinder to the piston rod of the cylinder (15) can be obtained as follows:
in the formula: p 13 Is the maximum pressure of the gas cylinder (13); v 13 Is the volume of the gas cylinder (13); v 15 Is the rodless maximum volume of the cylinder (15);
the pressure of the lower cavity of the movable arm oil cylinder (2) is constant in the movable arm lifting process, and the hydraulic energy required in the movable arm lifting process is as follows:
W 2 ＝P 2 V 2 Ⅳ
in the formula: p 2 The rodless cavity pressure of the lower cavity of the movable arm oil cylinder (2);
V 2 the maximum rodless volume of the movable arm oil cylinder (2);
the pressure difference set value delta P of the inlet and the outlet of the proportional throttle valve (5) i And the energy throttled by the proportional throttle valve is as follows:
W 5 ＝ΔP i ·V 2 Ⅴ
considering system energy loss, the total energy conversion efficiency is taken as eta, and in order to enable the energy stored in the gas cylinder to satisfy the condition that the movable arm ascends once, the following conditions are satisfied:
before the movable arm rises, analyzing whether the energy released by the gas can lift the movable arm to the highest position or not according to the pressure values of a gas cylinder pressure sensor (14) and a movable arm oil cylinder lower cavity pressure sensor 6; if not, electromagnets of a movable arm ascending signal cut-off valve (32), a movable arm descending signal cut-off valve (33), an upper cavity electromagnetic valve (3) and a lower cavity electromagnetic valve (4) in the system are not electrified, the energy recovery system does not operate, and the work of the original hydraulic system is not influenced;
if the movable arm (1) can be lifted to the highest position by the energy released by the gas in the gas cylinder (15), the electromagnet of the movable arm ascending signal cut-off valve (32) is electrified, the output control signal xBm1A is 0, the middle position of the proportional reversing valve (22) works at the moment, the left position of the hydraulic control reversing valve (23) works, and the rod cavity hydraulic oil and the rodless cavity hydraulic oil of the movable arm oil cylinder (2) are not communicated with the original hydraulic system; meanwhile, electromagnets of the upper cavity electromagnetic valve (3) and the lower cavity electromagnetic valve (4) are electrified, low-pressure oil in a rod cavity of the movable arm (1) is communicated with a rod cavity of the recovery oil cylinder (8), and low-pressure oil in a rodless cavity of the movable arm (1) is communicated with a rodless cavity of the recovery oil cylinder (8) through a proportional throttle valve (5);
the internal energy of the gas in the gas cylinder (15) is released, the gas in the gas cylinder (15) does work on the piston rod of the cylinder (13), the piston rod of the cylinder (15) pushes the lever (11) upwards, and the internal energy of the gas is converted into mechanical energy for the movement of the piston rod; the lever (11) rotates around a fulcrum B, the other end pushes a piston rod of the recovery oil cylinder (8) to retract downwards under the action of the lever (11), high-pressure oil generated by a rodless cavity enters a rodless cavity of the movable arm oil cylinder (2) through the proportional throttle valve (5) and the lower cavity electromagnetic valve (4) to push the piston rod of the movable arm oil cylinder (2) to extend out, low-pressure oil in a rod cavity of the movable arm oil cylinder (2) flows back into an upper cavity of the regulation recovery oil cylinder (8) through the upper cavity electromagnetic valve (3), and oil in the rod cavity of the regulation recovery oil cylinder (8) is supplemented; the movable arm (1) rises, so that the internal energy of the gas in the gas cylinder is converted into the gravitational potential energy of the movable arm, and the energy is recycled.
6. The control method according to claim 5, characterized in that: the flow rate of the proportional throttle valve (5) is controlled by two quantities of valve port pressure difference and valve opening amount, so the control system can ensure that the valve port pressure difference of the proportional throttle valve (5) is constant, the flow rate is only controlled by the valve opening amount, the flow rate of the proportional throttle valve (5) is only related to the lifting control signal,
the proportional throttle valve (5) is automatically controlled by valve port pressure difference: for ensuring the rodless chamber pressure P of the boom cylinder (2) 2 And the pressure P of rodless cavity of the recovery oil cylinder (8) 8 Actual pressure difference Δ P of e And the inlet and outlet set pressure difference delta P of the proportional throttle valve (5) i Remain equal;
the pressure control is based on the given pressure difference delta P of the inlet and the outlet of the proportional throttle valve (5) i For input quantity, the pressure P of rodless cavity of boom cylinder (2) 2 Pressure P of rodless cavity of recovery oil cylinder (8) 8 Pressure difference Δ P of e As the amount of feedback, the feedback amount,
movable arm oil cylinder (2) rodlessChamber pressure P 2 The pressure P of a rodless cavity of the recovery oil cylinder (8) is measured by a lower cavity pressure sensor (6) of the movable arm oil cylinder 8 The actual pressure difference of the two cavities is obtained by measuring by a rodless cavity pressure sensor 7 of the recovery oil cylinder: delta P e ＝P 8 -P 2 ；
When the movable arm is in a lifting working condition:
when the actual difference Δ P e Less than a predetermined pressure difference DeltaP at inlet and outlet i Setting the difference value delta P between the inlet-outlet pressure difference and the actual pressure difference ie ＝△P i -△P e To be positive, the processor applies a control algorithm (e.g., PID) to derive a positive control voltage signal u p The output is sent to a proportional amplifier 2, and the proportional amplifier 2 outputs a positive control current signal i to an electromagnet of an electromagnetic proportional directional valve (10) p The pilot pump 27 outputs the supply pressure P 27 The valve core of the electromagnetic proportional directional valve (10) moves leftwards, the rodless cavity of the adjusting oil cylinder (9) is filled with oil and returned by the rod cavity, the piston rod of the adjusting oil cylinder (9) extends, and the distance X between the two points BC is obtained BC The force F of the point A at the right end of the lever to the piston rod of the recovery oil cylinder (8) is increased under the action of the lever A Increase and recover the pressure P generated by the rodless cavity of the oil cylinder (8) 8 Increasing until the actual difference value delta P between the rodless cavity pressure of the movable arm oil cylinder (2) and the rodless cavity pressure of the recovery oil cylinder (8) e Equal to the set pressure difference delta P of the inlet and the outlet of the proportional throttle valve i When the pressure is enough to lift the movable arm to rise, the system is in balance at the position;
when the actual difference value Δ P e Greater than a predetermined pressure difference delta P at inlet and outlet i Setting the difference value delta P between the inlet-outlet pressure difference and the actual pressure difference ie ＝△P i -△P e To be negative, the processor applies a control algorithm (e.g., PID) to derive a negative control voltage signal u p The output is sent to a proportional amplifier in a self-contained driver of the excavator, and the proportional amplifier outputs a negative control current signal i to an electromagnet of an electromagnetic proportional directional valve (19) p The pilot pump 27 outputs the supply pressure P 27 The valve core of the electromagnetic proportional directional valve (10) moves rightwards, the rod cavity of the adjusting oil cylinder (9) is filled with oil and returned without the rod cavity, the piston rod of the adjusting oil cylinder (9) retracts, and then the distance X between the two points BC is obtained BC Reduce the effect of leverLower, the force F of the right end A point of the lever to the piston rod of the recovery oil cylinder (8) A Reduce and recover the pressure P generated by the rodless cavity of the oil cylinder (8) 8 Reducing until the actual difference value delta P between the rodless cavity pressure of the movable arm oil cylinder (2) and the rodless cavity pressure of the recovery oil cylinder (8) e Equal to the pressure difference delta P between the inlet and the outlet of the proportional throttle valve i When the pressure is enough to lift the movable arm to rise, the system is in balance at the position; thereby achieving the rodless cavity pressure P of the movable arm oil cylinder (2) 2 And the pressure P of a rodless cavity of the recovery oil cylinder (8) 8 Matching purposes;
when the movable arm is in a descending condition:
the working condition of recovering hydraulic energy when the movable arm descends still needs to ensure the rodless cavity pressure P of the movable arm oil cylinder (2) 2 Pressure P of rodless cavity of recovery oil cylinder (8) 8 The pressure difference is equal to a set value, and the control method is the same as the working condition of the boom ascending.
7. Control method according to claim 5, characterized in that the excavator boom speed is automatically controlled to control the speed v of the boom (1) in real time 1 And (3) synchronizing with the working speed of the original system:
the lifting speed of the movable arm of the original system excavator is realized by controlling a pilot control handle, changing the size of a pilot control pressure signal xBmA and further controlling the opening amount of a proportional reversing valve (22), and before an energy recovery system works, a pilot pressure signal P needs to be measured firstly X And boom velocity v i Functional relationship of (a):
v i ＝f(P X ) (7)
in the formula: p X Is a pilot pressure control signal; v. of i The speed control is the speed v of the movable arm when the original system works i For input, the actual speed v 1 Is the feedback quantity.
8. The control method according to claim 7, characterized in that:
the speed of the movable arm of the excavator under the working condition of the movable arm rising is automatically controlled:
processor based on the inputIncoming pilot signal P X Calculating the ascending speed v of the movable arm when the original system works i ＝f(P X ) If the actual boom speed v 1 Is less than the speed v of the original system during working i The processor calculates the difference v e ＝v i -v 1 To be positive, the processor applies a control algorithm (e.g., PID) to increase the control voltage signal u q The proportional amplifier 1 outputs a control current signal i to the electromagnet of the proportional throttle valve (5) q The valve core opening of the proportional throttle valve (5) is increased, and the pressure difference delta P between the inlet and the outlet of the proportional throttle valve (5) is ensured e And rated working pressure difference delta P i Under the condition of equal flow q entering a rodless cavity of the boom cylinder (2) 2 Increasing, then the actual speed v of the boom 1 Increase until the speed v of the movable arm is increased when the movable arm works with the original system i Equal, the system is in balance in this state;
when actual speed v of the boom 1 Greater than the speed v of the original system during operation i The processor calculates the difference v e ＝v i -v 1 To be negative, the processor applies a control algorithm (e.g., PID) to reduce the control voltage signal u q The proportional amplifier 1 outputs a control current signal i to the electromagnet of the proportional throttle valve (5) q The opening amount of the valve core of the proportional throttle valve (5) is reduced, and the pressure difference delta P between the inlet and the outlet of the proportional throttle valve (5) is ensured e And rated working pressure difference delta P i Under the condition of equal flow q entering a rodless cavity of the boom cylinder (2) 2 Decrease, then the actual speed v of the boom 1 Decrease until the velocity v of the movable arm is reduced when the original system works i Equal, the system is in balance in this state; thereby achieving the rising speed v of the piston rod of the movable arm oil cylinder (2) 1 And velocity v of the original system i The purpose of consistency;
the speed of the movable arm of the excavator under the working condition of the movable arm descending is automatically controlled:
the working condition of recovering hydraulic energy when the movable arm descends still needs to ensure the actual speed v of the movable arm 1 And velocity v of the original system i And the control method is the same as the boom raising condition.
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