JP4179726B2 - Construction machinery data processing equipment - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a data processing apparatus for a construction machine that collects and processes data related to an engine load state in the construction machine.
[0002]
[Prior art]
In construction machines such as hydraulic excavators and bulldozers, in order to systematically check and maintain the engine, it is extremely important to accurately predict the engine overhaul time, in other words, the engine life. However, even with the same type of construction machine equipped with the same type of engine, the operating environment and operating conditions vary greatly from one vehicle to another, so the engine life is accurately predicted for each vehicle. It is extremely difficult.
[0003]
Conventionally, attempts have been made to collect engine data related to the load state of the engine over a long period of time and to predict the engine life from changes over time. However, such a method is effective when the engine is continuously operated at a constant load, but may be applied when the engine load fluctuates over time. It is extremely difficult.
[0004]
As a solution to this, there is a prior invention proposed by the present applicant (a life prediction apparatus for a machine having an engine and a heat source; Japanese Patent Application Laid-Open No. 11-212622). In the prior invention, a load map is set by dividing an operation parameter indicating a load applied to the engine into a plurality of levels, and the value of the operation parameter belonging to that level is detected for each level of the load map. The actual amount of damage applied to the engine is calculated based on the accumulated time, and the engine life corresponding to the calculated amount of damage is calculated based on the damage amount and life set in advance. It is comprised so that it may obtain | require from the correspondence with the length of. Here, engine speed, output torque (or fuel injection amount) and the like are selected as the operating parameters.
[0005]
[Problems to be solved by the invention]
However, in the invention of the prior application, the detection data from the engine speed sensor mounted for basic performance control can be used for the detection of the engine speed, but the rack is newly added for the detection of the output torque. There is a problem that it is necessary to add a dedicated sensor such as a position sensor or a pump swash plate sensor, which increases the cost.
[0006]
On the other hand, there is a method for estimating the output torque without adding such a dedicated sensor. That is, the nominal line of the engine output characteristic diagram as shown in FIG. 9A is stored in the controller in advance, and the output torque T ′ is estimated from the actual rotational speed Na detected by the engine rotational speed sensor. Is the method. However, when this estimation method is used, it is difficult to ensure the detection accuracy, and there is a problem that a reverse can occur between the detected load and the actual load as shown in FIG. 9B. . That is, in FIG. 9B, when the two engine data indicated by the chain line A and the chain line B, which vary in regulation, are compared with the ideal line indicated by the solid line, the engine speeds Na (A), Na Although the actual torques T (A) and T (B) with respect to (B) are in the relationship of T (A)> T (B), the estimated torques T ′ (A) and T ′ (B) are T ′. (A) <T ′ (B) is established, and a reverse rotation occurs between the magnitude of the actual torque and the magnitude of the estimated torque.
[0007]
The present invention has been made in view of such problems, and it is possible to store a load state without incurring a cost increase due to the addition of a sensor and without depending on variations in engine output torque. It is an object of the present invention to provide a construction machine data processing apparatus capable of performing data processing such as calculation of engine life prediction based on the above.
[0008]
[Means for solving the problems and actions / effects]
In order to achieve the above object, a data processing apparatus for a construction machine according to the present invention comprises:
A data processing apparatus for a construction machine that collects and processes data relating to the engine load state in the construction machine,
(A) detecting means for detecting an actual rotation speed of the no-load Rotational speed and the engine of the engine,
(B) The first parameter value consisting of the value of the engine's no-load speed is on the horizontal axis, and the second parameter value consisting of the difference between the engine's no-load speed and the actual speed is on the vertical axis, create a load map, from said no-load speed and detected by the detecting means and the actual rotational speed, the a first parameter value, a plurality of the created load map a combination of the second parameter value Load map setting means for setting the load map by allocating to the area, and (c) the first parameter value and the second time until a predetermined time elapses for each area of the load map set by the load map setting means. The present invention is characterized by comprising calculation / storage means for calculating and integrating the detection time of the parameter value and storing the calculation result for each area of the load map.
[0009]
In the present invention, first, the first parameter value consisting of the value of the engine's no-load speed is set on the horizontal axis, and the second parameter value consisting of the difference between the engine's no-load speed and the actual speed is set to the vertical axis. in the shaft, the load map is created, the no-load speed and the actual number of rotations detected by the detecting means, the combination of the second parameter value and the first parameter value, depending on a plurality of levels A load map indicating the load state of the engine is set by being assigned to each of the divided areas. In each area of the load map, the time during which the first parameter value and the second parameter value are detected until a predetermined time elapses is integrated, and the calculation result is calculated for each area of the load map. It is memorized every time. According to the present invention, the first parameter value and the second parameter value can be obtained by using, for example, an engine speed sensor and a governor position sensor that have been used for basic performance control. Data relating to the engine load state can be obtained without increasing the cost due to the addition of the sensor. Instead of detecting the absolute value of the engine load (output horsepower) as in the past, the relationship between the no-load speed and the difference between the no-load speed and the actual speed is stored as a load map. Since the load map is recognized as a pattern, the load state of the engine can be stored without being affected by the detection accuracy, and a reverse phenomenon between a plurality of data can be prevented.
[0010]
According to the concept of the present invention, for example, as shown in FIG. 1 (a), in the engine speed (Na) -torque (T) diagram, the point P _{1 where} the throttle is large and the load is large, and the point where the throttle is large and the load is small. The point P ₂ , the point Q _{1 with} a small throttle and a large load, and the point Q _{2 with a} small throttle and a small load are the unloaded rotation speed (N ₀ ) and the unloaded rotation speed shown in FIG. In the load map with the actual rotational speed difference (N ₀ −Na), the engine output torque varies because it is phased to P ₁ ′, P ₂ ′, Q ₁ ′, and Q ₂ ′, respectively. Even if the map pattern is not changed only by changing the absolute values of N ₀ -Na and N ₀ , the problem described with reference to FIG. 9B of the conventional example does not occur.
[0011]
In the present invention, for each region of the load map, the integrated time calculated by the calculating / storing means is weighted, and the fixed time elapses based on the weighted integrated time. A damage amount calculating means for calculating the actual damage amount applied to the engine until the time, a correspondence setting means for presetting a correspondence relationship between the magnitude of the damage amount and the engine life, and this correspondence setting means It is preferable to provide life prediction means for obtaining an engine life corresponding to the actual damage amount calculated by the damage amount calculation means based on the set correspondence. In such a case, the accumulated time calculated by the calculation / storage means is weighted, and the actual damage amount applied to the engine until a certain time elapses is calculated. Based on the correspondence between the size and the engine life, the engine life is determined by the life prediction means. Thus, the predicted value of the engine life can be quantified based on the data relating to the engine load state described above.
[0012]
In the present invention, it is preferable that data stored in the calculation / storage means can be read from the outside. In this way, data relating to the engine load state can be taken into an external personal computer or IC memory for processing, and displayed on a display device so that the data contents can be seen visually.
[0013]
Further, in the present invention, the first transmission / reception means for transmitting / receiving data stored in the calculation / storage means and the first transmission / reception means provided at a position separated from the first transmission / reception means. The second transmission / reception means for transmitting and receiving data, the data processing means for processing the data received by the second transmission / reception means, and the display means for displaying the data processed by the data processing means. It can also be configured. With such a configuration, it is possible to collectively process and store data related to the engine load state in a plurality of construction machines at a remote place separated from the construction machines. Therefore, even when a plurality of different types of construction machines are scattered over a wide area, the data can be obtained even if an operator who performs maintenance on the construction machines does not go to the construction machines. The data can be collected and stored in one base station, and load data of a plurality of construction machines can be obtained while the worker or the manager is in the base station. Further, based on the obtained load data, a predicted value of the engine life can be obtained to predict overhaul and replacement time of devices and parts. In this way, it is possible to provide each construction machine with necessary services at an appropriate time, and it is possible to prevent the occurrence of a situation in which work cannot be performed due to a machine failure.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Next, a specific embodiment of a data processing apparatus for a construction machine according to the present invention will be described with reference to the drawings.
[0015]
FIG. 2 is a system configuration diagram of a data processing apparatus for a construction machine according to a first embodiment of the present invention applied to a hydraulic excavator.
[0016]
In the hydraulic excavator of the present embodiment, an engine 1 and a variable displacement hydraulic pump 2 driven by the engine 1 are provided, and the hydraulic excavator 2 is driven by the flow of discharge pressure oil. A hydraulic cylinder 3 is provided, and a flow rate control valve 4 is provided in a hydraulic circuit from the hydraulic pump 2 to the hydraulic cylinder 3. The flow rate control valve 4 changes the flow area of the pressure oil discharged from the hydraulic pump 2 by changing the opening area according to the spool stroke position, and the pressure oil whose flow rate has been changed is supplied to the hydraulic cylinder 3. It is configured to supply, and is operated by supplying a pilot pressure corresponding to the operation position of the operation lever 5 to the input port of the flow rate control valve 4 via the pilot line 6. The hydraulic pump 2 is provided with a swash plate drive mechanism 7 that changes the flow rate of the pressure oil discharged from the hydraulic pump 2 by changing the position (tilt angle position) of the swash plate 2a. Yes. In FIG. 2, only one hydraulic cylinder 3, flow control valve 4, and operation lever 5 are shown, but actually, the hydraulic excavator has various working machines such as a boom, an arm, and a bucket. These hydraulic cylinders 3 and the like are provided for each of these work machines.
[0017]
The engine 1 is provided with a governor 8 of a fuel injection pump for supplying fuel to the engine 1. The governor 8 is driven by a drive position (control lever position) of the governor 8, in other words, a motor for driving the governor 8. A governor position sensor 9 is provided as a potentiometer for detecting the rotation angle. An engine speed sensor 10 that detects the actual speed Na of the engine 1 is provided on the output shaft of the engine 1. The governor position sensor 9 detects the rotational speed of the engine 1 when there is no load.
[0018]
Detection signals from the governor position sensor 9 and the engine speed sensor 10 are input to the controller 11 as data indicating the load state of the engine 1. The controller 11 processes these input data to create and store a load map, which will be described later, and displays the load map and the like on the external monitor 12 as necessary. The monitor 12 is provided with a mode switch 12a for selecting and instructing an appropriate work mode corresponding to various work.
[0019]
FIG. 3 shows a functional block diagram in the present embodiment.
[0020]
The controller 11 includes an input unit 13, a calculation unit 14, a load map setting unit (load map setting means) 15, and a storage unit 16. The input unit 13 receives an actual engine speed detection signal of the engine 1 from the engine speed sensor 10 and an unloaded engine speed detection signal of the engine 1 from the governor position sensor 9. 14, based on these input signals, a required calculation as described later is executed for each region of the load map set by the load map setting unit 15, and the calculation result is stored in the storage unit 16. The contents are displayed on the display unit 18 such as the monitor 12 described above via the reading unit 17. In addition, the calculating part 14 and the memory | storage part 16 in a present Example respond | correspond to the calculating and memory | storage means in this invention.
[0021]
Next, the procedure of data processing executed in the controller 11 will be described sequentially.
[0022]
First, based on the actual engine speed detection signal of the engine 1 and the no-load engine speed detection signal input to the input unit 13, the load map setting unit 15 sets the no-load engine speed (N ₀ ) to the first _value . 1 parameter value, the difference (N ₀ −Na = N ₁ ) between the no-load rotation speed (N ₀ ) and the actual rotation speed (Na) as the second parameter value, the first parameter value as the horizontal axis, A load map C having a parameter value as a vertical axis is created. As shown in FIG. 4, in the load map C, the first parameter value and the second parameter value are divided into a plurality of regions. That is, in the example of FIG. 4, the first parameter value is divided into nine levels of N ₀₁ , N ₀₂ , N ₀₃ ,... N ₀₉ and the second parameter value is N ₁₁ , N _12. , N ₁₃ ,... N ₁₉ are divided into nine levels, and a region of 9 × 9 = 81 is determined by a combination of these levels. Note that the number of divisions of the load map can be set as appropriate.
[0023]
Next, when it is determined that the engine 1 is in operation, the first parameter value (N ₀ ) and the second parameter value (N ₀ -Na = N ₁ ) are calculated at a predetermined interval (for example, 1 s) in the calculation unit 14. Every time it is detected and calculated. Next, based on the detected values of the first parameter value and the second parameter value, the number of detections (detection time) of each parameter value belonging to these regions is counted for each region of the load map until a predetermined time elapses. .
[0024]
In this way, by calculating the detection accumulated time (H) of each parameter value until a certain time elapses, as shown in FIG. 4, the load state of the engine 1 is used as a pattern. Can be recognized as.
[0025]
The calculation result in the calculation unit 14 is stored in the storage unit 16, and the stored content is displayed on the external display unit 18 through the reading unit 17 as necessary. By looking at the display data, it can be seen at a glance how the engine 1 is used, and this data can be used as prediction data for the damage amount of the engine 1.
[0026]
According to the present embodiment, the first parameter value and the second parameter value can be obtained using the existing engine speed sensor and governor position sensor, and the load state of the engine 1 is detected using these parameter values. Therefore, it is not necessary to add a rack position sensor, a pump swash plate sensor, or the like in order to detect the output torque of the engine 1 as in the prior art, and cost increase can be suppressed. In addition, the load map is not the absolute value of the engine load (output horsepower), but the no-load speed (N ₀ ) and the difference between the no-load speed (N ₀ ) and the actual speed (Na) (N ₀₋ Na = N ₁ ) is stored, so that the engine load state can be stored without being affected by the detection accuracy, thereby detecting even when the engine output torque varies. It is possible to avoid reversing the value and the actual load.
[0027]
Next, a second embodiment of the present invention will be described. FIG. 5 shows a functional block diagram of the second embodiment.
[0028]
In the present embodiment, the configuration of the controller (construction machine controller) 11 and the processing content thereof are the same as those in the first embodiment. Therefore, the same reference numerals are given to the parts common to the first embodiment, and the detailed description thereof will be omitted, and only the points peculiar to the present embodiment will be described below.
[0029]
In the present embodiment, a data communication controller 19 and a construction machine side transmitter / receiver (first transmitter / receiver) 20 provided on the construction machine controller 11 are provided on the vehicle body side of the construction machine, and are separated from the construction machine. A base station controller 11A is provided at the location, and a data communication controller 21 and a base station side transceiver (second transceiver) 22 are also provided in association with the base station controller 11A. Further, the base station controller 11A is provided with a calculation unit (data processing means) 14A and a storage unit 16A, and the storage contents stored in the storage unit 16A are read by the reading unit 17 to be monitored, etc. It is displayed on the display unit 18.
[0030]
In such a configuration, data relating to the engine load state stored in the storage unit 16 of the construction machine controller 11 is transmitted from the construction machine side transceiver 20 to the base station side transceiver 22 via the data communication controller 19, The data is taken into the storage unit 16A in the base station controller 11A via the data communication controller 21 on the base station side, and data processing is performed in the arithmetic unit 14A. Thus, the stored contents of the storage unit 16A of the base station controller 11A are displayed on the display unit 18 via the reading unit 17. Therefore, by looking at the data displayed on the display unit 18 of the base station, it is possible to clearly understand how the engine 1 is used, and this data can be used as prediction data for the damage amount of the engine 1.
[0031]
According to the present embodiment, even when a plurality of construction machines are interspersed in a wide range of work, the data relating to the engine load state in each construction machine is separated from the construction machines. It can be processed, stored and displayed in a batch at the base station. Therefore, there is an advantage that load data of a plurality of construction machines can be obtained while staying at the base station even if an operator or a maintenance manager who maintains the construction machine does not go to the construction machine. .
[0032]
In the present embodiment, the data transfer from the construction machine to the base station is performed using the communication means, but of course, an embodiment in which the data transfer is performed to an IC card, an IC memory or the like is also possible.
[0033]
Next, a third embodiment of the present invention will be described. In each of the above embodiments, the data processing for calculating the detection accumulated time of each parameter value for each region of the load map and storing the calculated value has been described. From the calculated value thus obtained, the engine The actual damage amount of 1 can be digitized, and the engine life corresponding to the damage amount can be digitized and output.
[0034]
FIG. 6 shows a functional block diagram of the third embodiment. In this embodiment, a weight setting unit 23 and a life curve setting unit 24 are added in the controller 11B. Other parts are the same as in the first embodiment. Therefore, the same reference numerals are given to the parts common to the first embodiment, and the detailed description thereof is omitted.
[0035]
In this embodiment, based on the detection accumulated time of each parameter value calculated as described above, the calculation unit (damage amount calculation means) 14 adds to the engine 1 until the predetermined time elapses. In order to obtain the actual damage amount, the weight setting unit 23 weights the detection accumulated time for each region of the load map. As shown in FIG. 7 (relationship between load map and weight), the weight k _i is set according to the load applied to the engine 1. As examples of specific numerical values of the weights k _i , numerical values of k ₀ = 0, k ₁ = 1, k ₂ = 2, k ₃ = 3, k ₄ = 4, and k ₅ = 5 are employed. Thus, when the value of the weight k _i is determined, the actual damage amount (average load factor) applied to the engine 1 by multiplying the detection accumulated time H _i by the weight k _i as shown in the following equation. δ is determined.
δ = Σk _i · H _i
[0036]
On the other hand, at the time of engine development, a durability curve and parts inspection after the test are performed in advance, and a life curve indicating the correspondence between the amount of damage δ and the average life length L of the engine for each engine type (See FIG. 8) is set in advance in the life curve setting unit (correspondence setting means) 24.
[0037]
Here, the lifetime curve is set as follows. That is, the load factor δ ₀ of 100% is associated with the time H ₀ when the predetermined durability test is performed. Then, plot the point D plus a predetermined margin Δδ this load factor [delta] _0. Next, the load factor δ _L under general operating conditions and the life _HL under general operating conditions are empirically obtained from inspection of part wear and damage after the durability test. Plot the corresponding point E. Thus, as a curve connecting the point D and the point E, a correspondence relationship (average life curve) between the magnitude δ of the damage amount and the average life length H of the engine is obtained. Note that this average life curve is average for all engines, and actually has a range due to variations in manufacturing of individual engines. In addition, this average life curve is different for each type of engine and the type of parts constituting the engine.
[0038]
As described above, the calculation unit (life prediction means) 14 calculates the damage amount δ determined as described above based on the correspondence between the magnitude of the damage amount set by the life curve setting unit 24 and the engine life. The predicted life L of the engine 1 corresponding to is calculated, and this calculated value is stored in the storage unit 16 and displayed on the display unit 18 via the reading unit 17. The predicted value of the engine life is recalculated every time a fixed time elapses, and the calculation result is corrected even when the operating condition of the engine 1 is changed.
[0039]
Also in the present embodiment, the data calculated by the construction machine controller can be taken into the base station controller via the data communication controller or the like to perform data processing.
[0040]
In each of the above embodiments, the engine no-load rotation speed is detected by the governor position sensor. However, the engine no-load rotation speed is detected from the actual engine rotation speed when the operation lever is neutral. Also good.
[0041]
In each of the above-described embodiments, the description has been given of the application to a hydraulic excavator, but it goes without saying that the present invention can also be applied to other construction machines.
[Brief description of the drawings]
FIG. 1 is a diagram showing a concept of data processing in the present invention.
FIG. 2 is a system configuration diagram of a data processing apparatus for a construction machine according to a first embodiment of the present invention.
FIG. 3 is a functional block diagram of the first embodiment.
FIG. 4 is a diagram illustrating a load map;
FIG. 5 is a functional block diagram in a second embodiment of the present invention.
FIG. 6 is a functional block diagram in a third embodiment of the present invention.
FIG. 7 is a diagram illustrating a relationship between a load map and weights.
FIG. 8 is a diagram illustrating a relationship between an average load factor and a lifetime.
FIG. 9 is a diagram for explaining a problem of conventional engine load detection.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Engine 2 Hydraulic pump 8 Governor 9 Governor position sensor 10 Engine speed sensor 11, 11A, 11B Controller 12 Monitor 13 Input part 14, 14A Calculation part 15 Load map setting part 16, 16A Storage part 17 Reading part 18 Display part 19, 21 Data communication controller 20 Construction machine side transceiver (first transceiver)
22 Base station side transceiver (second transceiver)
23 Weight setting unit 24 Life curve setting unit

Claims (4)

A data processing apparatus for a construction machine that collects and processes data relating to the engine load state in the construction machine,
(A) detecting means for detecting an actual rotation speed of the no-load Rotational speed and the engine of the engine,
(B) The first parameter value consisting of the value of the engine's no-load speed is on the horizontal axis, and the second parameter value consisting of the difference between the engine's no-load speed and the actual speed is on the vertical axis, create a load map, from said no-load speed and detected by the detecting means and the actual rotational speed, the a first parameter value, a plurality of the created load map a combination of the second parameter value Load map setting means for setting the load map by allocating to the area, and (c) the first parameter value and the second time until a predetermined time elapses for each area of the load map set by the load map setting means. A data processing method for a construction machine, characterized by comprising calculation / storage means for calculating the parameter value detection time and storing the calculation result for each area of the load map. Apparatus.   Further, for each area of the load map, the accumulated time calculated by the calculating / storing means is weighted, and the engine is processed until the predetermined time elapses based on the weighted accumulated time. Damage amount calculating means for calculating the actual damage amount applied to the above, correspondence setting means for presetting the correspondence between the magnitude of the damage amount and the engine life, and the correspondence set by the correspondence setting means The construction machine data processing device according to claim 1, further comprising: a life prediction means for obtaining an engine life corresponding to an actual damage amount calculated by the damage amount calculation means.   The construction machine data processing apparatus according to claim 1 or 2, wherein data stored in the calculation / storage means can be read from outside.   Furthermore, data is exchanged between the first transmission / reception means for transmitting / receiving data stored in the calculation / storage means and the first transmission / reception means provided at a position separated from the first transmission / reception means. 3. A second transmission / reception unit for performing data processing, a data processing unit for processing data received by the second transmission / reception unit, and a display unit for displaying data processed by the data processing unit. A data processing device for a construction machine as described in 1.

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