WO2011140972A1 - 节能型行走式液压搬运机械 - Google Patents

节能型行走式液压搬运机械 Download PDF

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Publication number
WO2011140972A1
WO2011140972A1 PCT/CN2011/073890 CN2011073890W WO2011140972A1 WO 2011140972 A1 WO2011140972 A1 WO 2011140972A1 CN 2011073890 W CN2011073890 W CN 2011073890W WO 2011140972 A1 WO2011140972 A1 WO 2011140972A1
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WO
WIPO (PCT)
Prior art keywords
oil
energy
hydraulic
oil pump
motor
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Application number
PCT/CN2011/073890
Other languages
English (en)
French (fr)
Inventor
江绍成
白瑞海
姚航
张桂珍
Original Assignee
济南谨恒节能技术有限公司
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Filing date
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Application filed by 济南谨恒节能技术有限公司 filed Critical 济南谨恒节能技术有限公司
Priority to JP2013509440A priority Critical patent/JP2013526468A/ja
Priority to EP11780193.6A priority patent/EP2570381A4/en
Priority to KR1020127032257A priority patent/KR20130010024A/ko
Priority to US13/696,795 priority patent/US20130133966A1/en
Publication of WO2011140972A1 publication Critical patent/WO2011140972A1/zh

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60KARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K6/00Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
    • B60K6/08Prime-movers comprising combustion engines and mechanical or fluid energy storing means
    • B60K6/12Prime-movers comprising combustion engines and mechanical or fluid energy storing means by means of a chargeable fluidic accumulator
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B66HOISTING; LIFTING; HAULING
    • B66FHOISTING, LIFTING, HAULING OR PUSHING, NOT OTHERWISE PROVIDED FOR, e.g. DEVICES WHICH APPLY A LIFTING OR PUSHING FORCE DIRECTLY TO THE SURFACE OF A LOAD
    • B66F9/00Devices for lifting or lowering bulky or heavy goods for loading or unloading purposes
    • B66F9/06Devices for lifting or lowering bulky or heavy goods for loading or unloading purposes movable, with their loads, on wheels or the like, e.g. fork-lift trucks
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B66HOISTING; LIFTING; HAULING
    • B66FHOISTING, LIFTING, HAULING OR PUSHING, NOT OTHERWISE PROVIDED FOR, e.g. DEVICES WHICH APPLY A LIFTING OR PUSHING FORCE DIRECTLY TO THE SURFACE OF A LOAD
    • B66F9/00Devices for lifting or lowering bulky or heavy goods for loading or unloading purposes
    • B66F9/06Devices for lifting or lowering bulky or heavy goods for loading or unloading purposes movable, with their loads, on wheels or the like, e.g. fork-lift trucks
    • B66F9/075Constructional features or details
    • B66F9/20Means for actuating or controlling masts, platforms, or forks
    • B66F9/22Hydraulic devices or systems
    • EFIXED CONSTRUCTIONS
    • E02HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02FDREDGING; SOIL-SHIFTING
    • E02F9/00Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
    • E02F9/20Drives; Control devices
    • E02F9/22Hydraulic or pneumatic drives
    • E02F9/2217Hydraulic or pneumatic drives with energy recovery arrangements, e.g. using accumulators, flywheels
    • EFIXED CONSTRUCTIONS
    • E02HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02FDREDGING; SOIL-SHIFTING
    • E02F9/00Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
    • E02F9/20Drives; Control devices
    • E02F9/22Hydraulic or pneumatic drives
    • E02F9/2246Control of prime movers, e.g. depending on the hydraulic load of work tools
    • EFIXED CONSTRUCTIONS
    • E02HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02FDREDGING; SOIL-SHIFTING
    • E02F9/00Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
    • E02F9/20Drives; Control devices
    • E02F9/22Hydraulic or pneumatic drives
    • E02F9/2278Hydraulic circuits
    • E02F9/2292Systems with two or more pumps
    • EFIXED CONSTRUCTIONS
    • E02HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02FDREDGING; SOIL-SHIFTING
    • E02F9/00Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
    • E02F9/20Drives; Control devices
    • E02F9/22Hydraulic or pneumatic drives
    • E02F9/2278Hydraulic circuits
    • E02F9/2296Systems with a variable displacement pump
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B1/00Installations or systems with accumulators; Supply reservoir or sump assemblies
    • F15B1/02Installations or systems with accumulators
    • F15B1/024Installations or systems with accumulators used as a supplementary power source, e.g. to store energy in idle periods to balance pump load
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B11/00Servomotor systems without provision for follow-up action; Circuits therefor
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B21/00Common features of fluid actuator systems; Fluid-pressure actuator systems or details thereof, not covered by any other group of this subclass
    • F15B21/14Energy-recuperation means
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B2211/00Circuits for servomotor systems
    • F15B2211/20Fluid pressure source, e.g. accumulator or variable axial piston pump
    • F15B2211/205Systems with pumps
    • F15B2211/20507Type of prime mover
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B2211/00Circuits for servomotor systems
    • F15B2211/20Fluid pressure source, e.g. accumulator or variable axial piston pump
    • F15B2211/205Systems with pumps
    • F15B2211/2053Type of pump
    • F15B2211/20546Type of pump variable capacity
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B2211/00Circuits for servomotor systems
    • F15B2211/20Fluid pressure source, e.g. accumulator or variable axial piston pump
    • F15B2211/205Systems with pumps
    • F15B2211/2053Type of pump
    • F15B2211/20569Type of pump capable of working as pump and motor
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B2211/00Circuits for servomotor systems
    • F15B2211/20Fluid pressure source, e.g. accumulator or variable axial piston pump
    • F15B2211/205Systems with pumps
    • F15B2211/20576Systems with pumps with multiple pumps
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/62Hybrid vehicles

Definitions

  • the invention relates to the technical field of hydraulic machinery design, and in particular relates to an energy-saving walking type hydraulic conveying machine.
  • walking hydraulic handling machinery refers to vehicles that use heavy cylinders to lift and lower heavy objects. They are widely used in the loading and unloading operations of seaport terminals, highway and railway freight yards, construction machinery and factories, and warehouses, such as forklifts, container front hoists, Empty container stackers, hydraulic excavators, partial rail cranes and truck cranes. They rely on power machinery (diesel, electric motors, etc.) to drive the oil pump to push the cylinders and lift the heavy objects and drive the vehicles through mechanical transmission to their mechanical energy (potential and kinetic energy).
  • power machinery diesel, electric motors, etc.
  • the oil returning of the oil cylinder through the narrow opening of the control valve controls the speed at which the heavy object descends, and the potential energy of the heavy object is converted into the thermal energy generated by the hydraulic throttling.
  • the cooler water-cooled or air-cooled
  • the cooler is released into the atmosphere; using mechanical friction braking, the vehicle's kinetic energy is transferred into the surrounding environment. A lot of energy is lost in vain. If it can recover the potential energy of the walking hydraulic handling machinery during the heavy object's take-off and the kinetic energy before braking and use it for the next lift and start, it will become an energy-saving machine, which is a contribution to energy saving and emission reduction.
  • the patent application number is 200710120715.0, which is called the power generation state energy re-utilization electro-hydraulic energy-saving beam pumping unit. It will reduce the amount of potential energy when the motor is in the power generation condition during the process of lowering the "head", and directly store it through the descending cylinder. In the hydraulic accumulator, it is directly applied to the cylinder for lifting when lifting. It is only suitable for machines with basically the same potential energy, and can not adapt to the ordinary hydraulic handling machinery with variable potential energy.
  • the existing walking hydraulic handling machine is a device that repeatedly circulates, lifts or lowers, advances or retreats, brakes or starts.
  • the driving mode of the lifting operation is a power machine (diesel or electric motor). 8 drives the oil pump 9.
  • the pressure oil outputted by the oil pump 9 passes through the control valve group (KF) 20 to the lower chamber of the lifting cylinder 19, and the lifting weight is converted into a heavy object.
  • KF control valve group
  • the oil return of the cylinder must be controlled by a narrow opening in the control valve block 20 or a balancing valve (substantially automatically adjusted throttle) to control the speed at which the heavy object descends;
  • the transmission mode of the vehicle forward and backward operation is a power machine (
  • the diesel engine or the electric motor 8 drives the vehicle through the reduction gear box 5 with the clutch and the rear axle 6 to drive the vehicle, and the kinetic energy is consumed by the mechanical friction of the brake during braking.
  • the energy-saving walking hydraulic conveying machine of the invention provides a hydraulic transmission system without modifying the original mechanical transmission system, and only adds a part of the hydraulic components in the original hydraulic system, so that at least one hydraulic pump/motor and at least one energy storage are formed in the new hydraulic system formed.
  • the new hydraulic system also has the ability to automatically carry out heavy objects during the process of lowering, lifting heavy objects or braking, and starting the vehicle, while retaining all the functions and control methods of the machine. Partial recovery and regeneration of the front potential energy and kinetic energy of the vehicle before braking.
  • Energy-saving walking hydraulic handling machinery including lifting and traveling drive systems and control systems And a part of the hydraulic component is added to the original hydraulic system, so that the formed new hydraulic system has at least one oil pump/oil motor and at least one accumulator, and the oil is discharged from the oil passage of the at least one oil pump/oil motor.
  • the reversing valve of the energy device or the working cylinder can realize some or all of the functions of the heavy energy potential recovery and regeneration and the vehicle kinetic energy recovery and regeneration in at least one oil pump/oil motor.
  • the oil pump/oil motor in the hydraulic system may be: a combination of a variable oil pump/oil motor and a metering oil pump/oil motor; a combination of a metering oil pump/oil motor; a combination of a variable oil pump/oil motor.
  • the working condition of the oil pump/oil motor of the hydraulic system may be one of the following three states: oil pump working condition; oil motor working condition; unloading working condition.
  • the drive oil motor 27 drives the oil pump 9 to operate, and hydraulically loads the oil into the accumulator 15 to realize partial recovery of the potential energy of the heavy object;
  • the pressure oil in the accumulator 15 is passed to the oil suction port of the oil pump 9 and the oil motor 27 (in this case, the oil pump working condition), and the pressure oil is applied thereto to reduce the actual power machinery during the lifting process.
  • the output power is used to achieve partial regeneration of the potential energy of the weight.
  • An oil motor 27 is arranged in parallel in the original hydraulic system, which is coaxially mounted or mechanically linked with the oil pump 9. (Some large hydraulic lifting machines often have two or several oil pumps operating in parallel, such as an empty container. Stacker, front hoist, etc., because the general oil motor can be used as an oil pump, all or part of the oil pump can be changed to the model of the oil motor 27, without adding.)
  • the oil connection route of the system is, the fuel tank 1
  • the check valve 3 is connected to the oil inlet of the oil pump 9, and the outlet thereof is connected to the H port of the two-position four-way electromagnetic reversing valve 11 via the check valve 22, and the I, Z and the two-way four-way electromagnetic reversing valve 11 Port D leads to the oil inlet of the oil pump 9, the pressure oil inlet P A through the shutoff valve 14 to the accumulator 15 and the control valve group 20, and the parallel connection between the Z and I ports of the two-position four-way electromagnetic reversing valve 11 A small two-way two-way
  • the system is suitable for both quantitative pumps and variable pumps, and the control method for the weight drop rate:
  • the two-position three-way electromagnetic reversing valve 23 is reversed, and the return oil is returned to the fuel tank 1 through the return filter 34 through the return filter 2, and the lowering speed is controlled by the throttle valve 34, and at the same time
  • the three-way electromagnetic reversing valve 33 is energized and commutated, and both the oil pump 9 and the oil motor 27 are in an unloaded state.
  • variable oil pump/quantitative oil motor system only the fixed oil pump responsible for charging the accumulator can be changed to the variable oil pump 9, leaving a quantitative oil motor 27 connected coaxially or mechanically; or only in the original system
  • a lifting machine for a fixed oil pump it can be changed to a variable oil pump 9, and a fixed oil motor 27 connected coaxially or mechanically thereto is added.
  • the dedicated controller 31 ( ) processes the collected pressure P, the flow rate Q of the accumulator and the rotational speed ⁇ of the pump, and then adjusts the displacement of the variable oil pump in time to unload the power machine after the lifting is completed. Or control the speed and smoothness of heavy objects during the landing process.
  • the instantaneous speed at which the heavy object is lowered depends on the flow rate Q of the quantitative oil motor 27 (
  • is the angular velocity of the fixed oil motor 27, and is the displacement (which is a constant) of the fixed oil motor 27.
  • the speed of the heavy object is controlled by controlling the rotational speed of the fixed oil motor 27.
  • the rotational speeds of the dosing oil motor 27 and the variable oil pump 9 are the same, and the increase or decrease of the angular velocity ⁇ depends on the balance between the output torque of the dosing oil motor 27 and the variable oil pump 9 input torque M 2 .
  • variable displacement piston pumps In large hydraulic handling machinery, multiple variable displacement piston pumps are often used (such as three load-sensitive variable displacement piston pumps with large flow rates on the front), which can be replaced by variable piston oil motors in whole or in part. Let the return oil from the telescopic oil rainbow and the variable amplitude oil rainbow pass to different oil motors, and set the speed sensor 28 on the pump shaft. Similarly, the dedicated controllers 31 ( ) and 29 (K 2 ) will collect the respectively. After the data of the accumulator pressure ⁇ , flow rate Q and pump speed ⁇ are processed, the displacements of the variable oil pump 9 and the variable oil motor 27 are adjusted in time to unload or release the power machine after the lift is completed. Control the speed and stability of heavy objects during the descent.
  • the instantaneous speed at which the heavy object is lowered depends on the flow rate Q of the variable oil motor 27 (
  • is the angular velocity of the variable oil motor 27, which is the instantaneous displacement of the variable oil motor 27.
  • the speed of the heavy object can be controlled by simply adjusting the rotational speed and variable displacement mechanism of the variable oil motor 27 in time and effectively. .
  • the rotational speeds of the variable oil motor 27 and the variable oil pump 9 are the same, and the increase and decrease of the angular velocity ⁇ depends on the balance between the output torque of the variable oil motor 27 and the input torque ⁇ 2 of the variable oil pump 9.
  • variable oil motor 27 is the inlet pressure of the variable oil motor 27 (it depends on the weight of the weight, which is basically unchanged during the one-time lowering), 9 is the displacement of the variable oil motor 27; M 2 oc p 2 xq 2 , P 2 is The pressure of the accumulator 15 (from small to large during the energy storage process), q 2 is the displacement of the variable oil pump 9.
  • the regeneration process of the potential energy is to release the pressure oil in the accumulator 15 to the oil inlet of the oil pump 9 through the small two-way two-way electromagnetic reversing valve 10 having the orifice.
  • the hydraulic shock is reduced or eliminated, and the accumulator 15 applies pressure to the oil pump 9, thereby reducing the output power of the power machine 8.
  • the oil from the oil pump 9 lifts the weight through the control valve group 20 to the lift cylinder 19.
  • a two-position three-way electromagnetic reversing valve 33 is added, one of which is connected to the outlet of the oil pump 9 via the check valve 26, and the other inlet path is
  • the D port of the two-way four-way electromagnetic reversing valve 11 is connected, the outlet of the two-position three-way electromagnetic reversing valve 33 is connected to the 0 port of the two-position five-way electromagnetic reversing valve 32, and the other is connected to the outlet of the oil pump 27.
  • a two-position two-way electromagnetic reversing valve 4 is required before the pressure oil inlet P A of the original mechanical control valve group KF.
  • the two-position two-way electromagnetic reversing valve 4 When the vehicle brakes, the two-position two-way electromagnetic reversing valve 4 is energized and disconnected, and the vehicle inertia kinetic energy reversely drives the oil pump 9 and the oil pump 27 to rotate through the deceleration box 5 with the clutch, and the oil is charged from the oil tank 1 into the accumulator 15 Internally, the oil pump 9 and the oil pump 27 act together as a resisting torque formed by the load to cooperate with the mechanical brake to decelerate and stop the vehicle, thereby improving the braking force of the vehicle; when the vehicle is started, the two-way four-way electromagnetic reversing valve 11 is de-energized, two-fifth The electromagnetic reversing valve 32 is energized, and the pressure oil in the accumulator 15 drives the oil pump 9 and the oil pump 27 (at this time, the oil motor working condition), and through the gearbox 5 with the clutch, the power machinery is started to help the vehicle to start.
  • the technical solution for transforming them is to change the quantitative oil pump to the same-displacement quantitative oil motor 9, and the inlet of the quantitative oil motor 9 is connected to the oil tank 1 via the check valve 3, and the outlet of the quantitative oil motor 9 passes through two two
  • the electromagnetic reversing valve 21 is directly connected to the oil return filter 1, and the other path is connected to the H port of the two-way four-way electromagnetic reversing valve 11 via the check valve 22, and the I and Z of the two-position four-way electromagnetic reversing valve 11 And the D port respectively lead to the oil inlet of the dosing pump 9, the shutoff valve 14 to the accumulator 15 and the pressure oil inlet P A leading to the control valve group 20, the Z and I of the two-position four-way electromagnetic reversing valve 11
  • a small two-position two-way electromagnetic reversing valve 10 having an orifice is connected in parallel between the ports, and a safety valve 12 and a pressure measuring point 13 are arranged on the bypass of the accumulator 15, and the control valve group 20 leads
  • two-position two-way electromagnetic reversing valve 25 when the potential energy is regenerated, two-position two-way electromagnetic reversing valve 25 must be installed in the scheme of two or more pumps to avoid overspeed due to the loss of load of the diesel engine due to the weight of the heavy object.
  • the driver can control the opening of the lift valve or install a speed control valve on the oil line to keep the lift speed stable.
  • the fuel tank can be used with a template piston closed oil tank (patent number 200720068995.0) that maintains normal pressure to ensure the reliability and service life of the system.
  • a template piston closed oil tank (patent number 200720068995.0) that maintains normal pressure to ensure the reliability and service life of the system.
  • the hydraulic system of the energy-saving walking hydraulic handling machine can be equipped with various standard oil pumps/oil horses.
  • the combination of hydraulic components such as hydraulic valve and hydraulic valve shall be matched with the original hydraulic system.
  • the system shall be integrated into the overall design of the hydraulic lifting machine.
  • Specialized integrated valves are manufactured to reduce volume and reduce costs.
  • the power machinery diesel or electric motor
  • it can charge the accumulator for the next lift and start the full force.
  • the power of the power machinery should be reduced. Small, to obtain better technical and economic benefits and energy saving and emission reduction effects.
  • the hydraulic system of the energy-saving walking hydraulic handling machine utilizes and develops the functions of the original hydraulic system to realize the recovery and regeneration of heavy potential energy and vehicle kinetic energy, and reduces the temperature rise of the hydraulic system.
  • Energy-saving walking hydraulic handling machinery power machinery (diesel or electric motor) can charge the accumulator when it is idle (or non-lifting condition), in order to prepare for the next lift. In this way, when designing a new model, the power of the power machine can be reduced, thereby further improving the energy saving and emission reduction effect.
  • the hydraulic system of the energy-saving walking hydraulic handling machine can be used simultaneously with the original mechanical brake to improve the braking effect and extend the service life of the mechanical brake components.
  • the hydraulic system of the energy-saving walking hydraulic handling machine can recover kinetic energy and potential energy at the same time, and allow multiple joint movements of the forklift.
  • the hydraulic system of the double-pump or multi-pump of the energy-saving walking hydraulic handling machine can combine the braking or starting action, thereby increasing the braking force or starting power of the vehicle and improving the working efficiency of the vehicle.
  • Figure 1 Hydraulic schematic of an energy-saving walking hydraulic handling machine (combined with variable pump and quantitative motor).
  • FIG. 1 Hydraulic schematic of an energy-saving walking hydraulic handling machine (combined with a fixed pump and a quantitative motor).
  • FIG. Hydraulic schematic of an energy-saving walking hydraulic handling machine (combined with variable pump and variable motor).
  • Figure 5 Hydraulic schematic of an energy-efficient universal forklift.
  • FIG. 7 Hydraulic schematic of an energy-saving walking hydraulic handling machine (an alternative to a dual pump/motor).
  • Figure 8 Hydraulic schematic diagram of the potential and kinetic energy combination scheme of the energy-saving universal forklift.
  • Fig. 1 The combination system of the variable pump and the quantitative motor is shown in Fig. 1. It is a better adaptive scheme, which can automatically adapt to potential energy recovery under different working conditions, when the driver uses the power machinery. (Diesel engine or electric motor) 8 Drive the variable oil pump 9 to drive the lift cylinder 19 to lift the heavy object. If the control machine is used for the lowering operation, during the heavy lifting, the oil in the lower chamber (the rodless chamber) of the lift cylinder 19 is lifted.
  • Diesel engine or electric motor Drive the variable oil pump 9 to drive the lift cylinder 19 to lift the heavy object. If the control machine is used for the lowering operation, during the heavy lifting, the oil in the lower chamber (the rodless chamber) of the lift cylinder 19 is lifted.
  • the pressure of the potential energy converted into the fluid can be stored in the accumulator 15, and the safety valve 12 acts as a pressure limiting protection.
  • 4DT is energized first, and the pressure oil in the accumulator 15 is throttled by the two-position two-way electromagnetic reversing valve 10 to the two-position four-way electromagnetic reversing valve.
  • the I port of 11 and the oil inlet of the variable oil pump 9 increase the pressure at this point.
  • Both 1DT and 5DT are de-energized, the reversing valve 11 and the reversing valve 32 are reset, the pressure oil in the accumulator 15 is supplied to the inlet of the variable oil pump 9, and the pressure supply is performed, and the power machine 8 drives the variable oil pump 9 and the quantitative oil motor.
  • the pressure oils at the outlets thereof pass through the check valves 22 and 30, respectively, and are respectively passed through the electromagnetic reversing valves 11 and 32 to the pressure oil inlet P A of the control valve group 20, and
  • the valve block 20 is controlled to lift the oil rainbow 19.
  • the pressure in the accumulator 15 is smaller than the outlet pressure P A of the pump group, the two-position two-way electromagnetic reversing valve 25 is energized to open, and the pressure oil in the accumulator 15 is passed through the reversing valve 11
  • the inlets of the Z port and the I port to the variable oil pump 9 and the pressure supply of the two pumps through the two-way two-way electromagnetic reversing valve 25 to the inlet of the metering oil motor 27 of the pump operating condition greatly reduce the oil pump
  • the inlet and outlet pressure difference of the group, when the flow rate is constant, the power of the oil pump is proportional to the pressure difference between the inlet and outlet ( ⁇ ), thereby greatly reducing the energy consumption of the power machine until the pressure oil in the accumulator 15 is discharged.
  • the power machinery began to fully drive the oil pump set; (2) the pressure in the accumulator 15 is greater than the outlet pressure of the pump set ⁇ ⁇ , the two-position two-way electromagnetic reversing valve 25 is closed, and the pressure oil in the accumulator 15 is only Arriving at the inlet of the variable oil pump 9, only the variable oil pump 9 is subjected to pressure supply, and the quantitative oil motor 27 of the pump operating condition is driven by the power machine full force, which causes the power machine to avoid overload and overspeed, with the pressure in the accumulator 15 When it is reduced to less than the outlet pressure P A of the pump set, the two-position two-way electromagnetic reversing valve 2 When 5 is turned on, pressure is supplied to the two pumps at the same time to reduce the energy consumption of the power machine.
  • the controller 31( ) processes the collected pressure P of the accumulator, the flow rate Q and the rotational speed ⁇ of the pump, and then adjusts the displacement of the variable oil pump in time to unload the power machine after the lifting is completed or Control the speed and smoothness of heavy objects during the landing process.
  • the instantaneous speed at which the weight is lowered depends on the flow rate Q i of the metering oil motor 27.
  • is the angular velocity of the fixed oil motor 27, and is the displacement of the fixed oil motor 27, which is a constant, and it is only necessary to control the rotational speed of the fixed oil motor 27 to control the speed at which the weight is lowered.
  • the rotational speeds of the dosing oil motor 27 and the variable oil pump 9 are the same, and the increase or decrease of the angular velocity ⁇ depends on the balance between the output torque of the dosing oil motor 27 and the variable oil pump 9 input torque M 2 .
  • M 2 P 2 xq 2 P 2 is the pressure of the accumulator 15 (small during the energy storage process) It becomes larger)
  • q 2 is the displacement of the variable oil pump 9.
  • the two-position three-way electromagnetic reversing valve 23 When the accumulator is full, the two-position three-way electromagnetic reversing valve 23 is reversed, and the return oil passes through the adjustable flow valve 34 and then returns.
  • the oil filter 2 is returned to the tank 1, and the lowering speed is controlled by the throttle valve 34, while the two-position three-way electromagnetic reversing valve 33 is energized and reversed, and both the oil pump 9 and the oil motor 27 are in an unloaded state.
  • the instantaneous speed at which the heavy object is lowered depends on the flow rate Q (Q ⁇ xq l ) of the variable oil motor 27, where ⁇ is the angular velocity of the variable oil motor 27, which is the instantaneous displacement of the variable oil motor 27, which needs to be adjusted in time and effectively
  • the speed and variable displacement mechanism of the variable oil motor 27 can control the speed at which the weight is lowered.
  • the rotational speeds of the variable oil motor 27 and the variable oil pump 9 are the same, and the increase or decrease of the angular velocity ⁇ depends on the balance between the output torque of the variable oil motor 27 and the variable oil pump 9 input torque M 2 .
  • P A is the inlet pressure of the variable oil motor 27 (it depends on the weight of the weight, which is basically unchanged during the one-time take-off process),
  • Qi is the displacement of the variable oil motor 27;
  • M 2 oc pxq 2 which is the pressure of the accumulator 15 (from small to large during the energy storage process), and
  • q 2 is the displacement of the variable oil pump 9.
  • the kinetic energy recovery and regeneration of the vehicle is in the above hydraulic system capable of recovering and regenerating the potential energy, and a two-position three-way electromagnetic reversing valve 33 is added, wherein a diverting oil passage is connected to the outlet of the oil pump 9 via the check valve 26, The other inlet passage is connected to the D port of the two-position four-way electromagnetic reversing valve 11, the outlet of the two-position three-way electromagnetic reversing valve 33, and one way is connected to the zero port of the two-position five-way electromagnetic reversing valve 32, and One way is connected to the outlet of the oil pump 27, and a two-position two-way electromagnetic reversing valve 4 is additionally installed before the pressure oil inlet P A of the original mechanical control valve group KF.
  • the two-position two-way electromagnetic reversing valve 4 When the vehicle brakes, the two-position two-way electromagnetic reversing valve 4 is energized and disconnected, and the vehicle inertia kinetic energy reversely drives the oil pump 9 and the oil pump 27 to rotate through the deceleration box 5 with the clutch, and the oil is charged from the oil tank 1 into the accumulator 15
  • the oil pump 9 and the oil pump 27 have a total braking force; when the vehicle is started, the two-position four-way electromagnetic reversing valve 11 is de-energized, the two-position five-way electromagnetic reversing valve 32 is energized, and the pressure oil in the accumulator 15 drives the oil pump 9 And the oil pump 27 (in this case, the oil motor working condition), through the gearbox with the clutch 5, together to help the power machinery start the vehicle, increase the starting power of the vehicle.
  • the system can realize the recovery and regeneration of heavy potential energy and vehicle kinetic energy on the basis of maintaining all the original functions of the mobile hydraulic lifting machine.
  • FIG. 4 is a schematic diagram of the hydraulic system of the energy-saving mobile hydraulic lifting machine of a single metering pump/quantitative oil motor. It is easy to use. It is generally suitable for medium and small hydraulic lifting machines.
  • the hydraulic system is simple, only A quantitative oil pump, the technical solution for improving them is to change the quantitative oil pump to the same displacement quantitative oil motor 9, the inlet of the oil motor 9 is connected to the oil tank 1 via the check valve 3, and the outlet of the oil motor 9 passes through two
  • the two-way electromagnetic reversing valve 21 is directly connected to the return filter 1 , and the other pass through the check valve 22 to the H port of the two-way four-way electromagnetic reversing valve 11
  • the ports I, Z and D of the magnetic reversing valve 11 are respectively led to the oil inlet of the oil pump 9 via the check valve 4, the shutoff valve 14 to the accumulator 15 and the pressure oil inlet P A leading to the control valve group 20,
  • the control valve group 20 leads to the lift oil rainbow 19, and the oil return when the lift oil rainbow 19 descends through the outlet T of the control valve group 20 to the inlet of the two-position three-way electromagnetic reversing valve 23, two-position three-way electromagnetic exchange
  • the outlet to the valve 23 is passed all the way to the inlet of the oil pump 9, and the other is passed through the adjustable flow valve 34 to the return filter 2.
  • FIG. 5 is a hydraulic schematic diagram of the current general-purpose forklift retrofit.
  • the dotted line frame of 16 is the steering system of the original forklift
  • the dotted line frame of 20 is the control valve group of the original forklift
  • the 20-2 is the diverter valve, which divides the flow of the oil pump 9 into the lift, Tilting cylinder and steering mechanism
  • 20-1 is the regulating valve for lifting and tilting oil circuit
  • 20-3 is the regulating valve for steering oil line
  • 20-4 is the operating valve for lifting cylinder
  • 20-5 is the operation of inclined cylinder valve.
  • the oil of the oil pump 9 is first diverted by the diverter valve 20-2 in the control valve group 20, then to the H port of the two-way four-way electromagnetic reversing valve 11, and returned to the control via the two-way four-way electromagnetic reversing valve 11.
  • the valve block 20 leads to the control valve, and 17 is the shut-off valve of the oil passage to prevent the heavy objects from falling off. Its working principle is the same as that of Figure 3. Electromagnet action and working condition table of forklift
  • FIG. 6 is the hydraulic principle diagram of the energy-saving front hoist.
  • B6, B7, B12, B23 and B25 in the dotted line frame are the original front-mounted hydraulic control valve group, which recovers in potential energy.
  • the oils of the telescopic cylinders with different pressures and the lower chamber of the luffing cylinder are respectively led to the inlets of the two variable oil motors, and the combined torque is used to drive the oil pump to charge the accumulator.
  • the working principle is the same as that of FIG.
  • Figure ⁇ is another solution of two hydraulic pump / hydraulic motor, which eliminates the check valve 26 and the two-position two-way electromagnetic reversing valve 4, and changes the two-position three-way electromagnetic reversing valve 33 to two Two-way electromagnetic reversing valve, and can change the two-position two-way electromagnetic reversing valve 25 into a hydraulically controlled reversing valve.
  • the system is simpler than the schemes of Fig. 1, Fig. 2 and Fig. 3, it is difficult to achieve the simultaneous braking or starting action of the dual pump.
  • a potential and kinetic energy combination scheme of the energy-saving universal forklift which is characterized in that a double-quantity metering pump 9 is connected to the output shaft of the diesel engine 8 through a one-way overrunning clutch 41; and an output shaft of the gearbox 5 is attached
  • the dosing pump 37 enables the retraction of potential energy and kinetic energy to be completed by different oil pump/oil motors.
  • the clutch 42 of the diesel engine can be disengaged, and the speed of the descent clutch 41 makes the descending speed of the accumulative energy and the idle speed of the diesel engine. None.
  • a large-diameter hydraulic two-way four-way reversing valve 38 is added to the inlet and outlet ports of the oil pump 37, which can maintain the flow of the output of the oil pump 37 during the forward or reverse operation.
  • the two-position two-way electromagnetic reversing valve 39 is kinetic energy regenerative operation when it is turned on, and the potential energy regeneration operation can be performed when the valve is turned off.
  • the clutch 42 is combined, the two sets of pumps (9 and 37) can be combined to participate in kinetic energy recovery or kinetic energy regeneration, which can increase the braking torque or starting torque of the vehicle and improve the working efficiency of the carrier.
  • the other parts work in the same way as in Figure 5.
  • the present invention can be applied not only to a traveling hydraulic handling machine, but also to the principle of recovery and regeneration of potential energy for use in a stationary hydraulic lifting machine.
  • the above embodiments are merely examples and do not limit the scope of protection of the patent.

Description

节能型行走式 ί½搬运 w¾ 本申请要求下列三个中国专利申请的优先权, 三者的全部内容均通过 引用结合在本申请中。
1、 2010年 9月 26日提交中国专利局、 申请号为 201010297795.9、 发 明名称为"节能型行走式液压搬运机械"的中国专利申请。
2、 2010年 7月 8 日提交中国专利局、 申请号为 201010228190.4、 发 明名称为"节能型行走式液压搬运机械"的中国专利申请。
3、 2010年 5月 13 日提交中国专利局、 申请号为 201010174436.4、 发 明名称为"液压升降机械的势能回收再生系统"的中国专利申请。 技术领域
本发明涉及液压机械设计技术领域, 特别涉及一种节能型行走式液压 搬运机械。
背景技术
本文中, 行走式液压搬运机械是泛指用油缸升降重物的车辆, 它们广 泛地应用在海港码头、 公路铁路货场、 工程机械和工厂、 仓储的运输装卸 作业中, 如叉车, 集装箱正面吊、 空箱堆高机、 液压挖掘机、 部分轨道起 重机和汽车起重机等。 它们均是靠动力机械(柴油机、 电机等)驱动油泵 推动油缸而举升重物和通过机械传动驱动车辆, 转变为它们的机械能(势 能和动能)。 目前, 该类机械在重物的放降过程中, 使油缸的回油通过控制 阀的狭小的开度来操控重物下降的速度, 重物的势能转换成液压节流而产 生的热能, 通过冷却器(水冷或风冷)散发到大气中; 利用机械摩擦制动, 使车辆动能变成热能散发到周围环境中。大量的能量就这样白白地流失了。 如能回收行走式液压搬运机械在重物放降过程中的势能和制动前的动能并 用于下次举升和起动, 使其成为节能型机械, 是对节能减排的贡献。 节能 型液压搬运机械已成为用户的要求并引领生产厂商的研发方向。 近期的一 些信息和报道也反映出该种趋势, 如专利申请号为 200810143874.7的名为 "一种液压挖掘机动臂势能回收方法及装置"等, 这些技术方案的共同点是 将重物的势能在放降过程中通过发电机转换为电能储存在电池或超级电容 中, 它们的问题是: 放降过程时间很短, 普通电池来不及充电, 回收的势 能有限; 而超级电容和大容量锂电池在经济、 技术和寿命上都存在不少瓶 颈难题,目前离广泛实际应用尚有较大距离。专利申请号为 200710120715.0 的名为发电态能量再利用电液压节能游梁式抽油机, 它将"驴头"下降过程 中, 电动机处于发电工况时的少部分势能, 通过下降的油缸直接储存到液 压蓄能器中, 在举升时直接放至油缸而助力, 它只适用于势能基本不变的 机械, 无法适应势能大小变化无常的普通液压搬运机械中。
现有的行走式液压搬运机械是动作反复循环的设备, 举升或放降、 前 进或后退、 制动或起动。 升降操作的传动方式是动力机械(柴油机或电动 机) 8带动油泵 9, 油泵 9输出的压力油经控制阀组(KF ) 20到升降油缸 19的下腔, 举升重物做功而转换为重物的势能; 放降重物时, 油泵 9处于 卸荷状态, 升降油缸 19下腔的液压油, 被重物的重力通过控制阀组 20压 回油箱, 为使重物以一定速度平稳放降, 必须使油缸的回油通过控制阀组 20 中的狭小的开度或设置平衡阀(实质为自动调整的节流阀), 来操控重物 下降的速度; 车辆进退操作的传动方式是动力机械(柴油机或电动机) 8通 过带离合器的减速箱 5及后桥 6带动车轮 7而驱动车辆, 制动时靠刹车的 机械摩擦来消耗动能。 发明内容
本发明节能型行走式液压搬运机械, 提供了一个不改动原机械传动系 统, 仅在原液压系统中附加部分液压元件, 使形成的新的液压系统中具有 至少一个液压泵 /马达和至少一个蓄能器, 同时新的液压系统还具有在保留 该机械原有的全部功能和操控方式的基础上,可在放降、举升重物或制动、 起动车辆的过程中, 自动实现重物放降前的势能和车辆制动前的动能的部 分回收和再生。
本发明的技术方案概述如下:
节能型行走式液压搬运机械, 包括起重和行走的驱动系统和控制系统 等, 在原液压系统中附加部分液压元件, 使形成的新的液压系统中具有至 少一个油泵 /油马达和至少一个蓄能器,在至少一个油泵 /油马达的出油路上 有控制出油去蓄能器或去工作油缸的换向阀,在至少一个油泵 /油马达的进 有能实现重物势能回收与再生和车辆动能回收与再生两者的部分或全部功 能。所述的液压系统中的油泵 /油马达可以是: 变量油泵 /油马达与定量油泵 /油马达的组合; 定量油泵 /油马达的组合; 变量油泵 /油马达的组合。 该液 压系统的油泵 /油马达的工况可以是下述三种状态之一: 油泵工况; 油马达 工况; 卸荷工况。
一、 重物势能的回收与再生: 在重物下降回收势能的过程中, 部分油 泵 /油马达进入油马达工况, 被工作油缸的压力回油所驱动, 输出转矩; 另 有部分油泵 /油马达进入油泵工况, 被前者所输出的转矩所驱动, 将油从油 箱压入蓄能器中。 以双油泵 /油马达为例(图 1 ), 在原只有一个油泵 9的液 压系统中并联增设一个油马达 27, 它与原液压系统的油泵 9同轴安装或机 戈连动, 重物放降时, 重物的重力将升降油缸 19的回油压至油马达 27的 进口, 驱动油马达 27带动油泵 9工作, 将油液压入蓄能器 15中, 实现重 物势能的部分回收;举升重物时,蓄能器 15内压力油先后通到油泵 9和油 马达 27(此时为油泵工况)的吸油口, 对其实施压力供油, 减小了举升过程 中动力机械的实际输出功率, 实现重物的势能的部分再生。
具体叙述如下: 在原液压系统中并联设置一个油马达 27, 它与油泵 9 同轴安装或机械连动,(有些大型液压升降机械常设有两个或数个并联同时 工作的油泵, 如集装箱空箱堆高机、 正面吊等, 因一般的油马达可当油泵 使用, 可将其全部或部分油泵改为油马达 27的型号, 而不需增设。)该系 统的油路连结途径是, 油箱 1经单向阀 3通向油泵 9的进油口, 其出口经 单向阀 22与两位四通电磁换向阀 11的 H口相连,两位四通电磁换向阀 11 的 I、 Z和 D口分别通向油泵 9的进油口、 经截止阀 14到蓄能器 15和控 制阀组 20的压力油进口 PA, 两位四通电磁换向阀 11的 Z与 I口之间并联 了一个有节流孔的小两位两通电磁换向阀 10, 蓄能器 15的旁路上设有安 全阀 12和测压点 13; 增设的与原液压系统的油泵 9同轴安装或机械连动 的油马达 27的进油口经单向阀 24与油箱 1连接, 并在油马达 27与油泵 9 的进油口之间的通道上设有两位二通电磁换向阀 25 , 油马达 27的出口经 单向阀 30与两位五通电磁换向阀 32的 F口相连, 两位五通电磁换向阀 32 的 G、 A、 B和 0口分别通向油马达 27的进油口、 控制阀组 20的压力油 进口 PA、 控制阀组 20的回油口 T和回油过滤器 2; 原液压系统中的控制 阀组 20通向升降油缸 19的油路不变,但应将控制阀组 20的回油通道上的 流阻变小。
该系统适用于定量泵也适用于变量泵, 重物放降速度的控制方法:
A、 在定量油泵 /定量油马达的系统中, 在重物放降的蓄能过程中, 回 油经两位三通电磁换向阀 23到油马达 27的进口,随着蓄能器 15内压力的 升高, 放降速度也减慢, 当蓄能器 15内压力与升降油缸 19下腔压力相等 时, 重物将不再下降。 因此当重物放降速度低于要求值时, 处于怠速工况 的动力机戈 8可继续驱动油泵 9和油马达 27转动, 在向蓄能器 15继续充 能的同时, 转动的油马达 27可使重物在要求速度下继续放降至需要高度。 当蓄能器已满, 两位三通电磁换向阀 23换向, 回油经节流阀 34再经回油 过滤器 2回到油箱 1 , 放降速度由节流阀 34控制, 同时两位三通电磁换向 阀 33通电换向, 油泵 9和油马达 27均在卸荷状态。
B、 在变量油泵 /定量油马达的系统中, 可只将负责给蓄能器充能的定 量油泵改换为变量油泵 9, 保留与其同轴或机械相连一个定量油马达 27; 或在原系统中只有一个定量油泵的升降机械中, 可将其改换为变量油泵 9, 并增设一个与其同轴或机械相连一个定量油马达 27。 专用控制器 31( )将 采集的蓄能器的压力 P、 流量 Q和泵的转速 ω等数据处理后, 对变量油泵 的排量作适时的调节, 以便在举升完成后使动力机械卸荷或在放降过程中 控制重物放降的速度和平稳性。 重物放降的即时速度取决于定量油马达 27 的流量 Q (
Figure imgf000006_0001
式中 ω为定量油马达 27的角速度, 是定量油马 达 27的排量(是常数), 只需控制定量油马达 27的转速, 就能控制重物放 降的速度。 定量油马达 27和变量油泵 9的转速是相同的, 角速度 ω的增 减取决于定量油马达 27的输出转矩 和变量油泵 9输入转矩 M2之间的 平衡。
Figure imgf000006_0002
, 为定量油马达 27进口压力(它取决于重物的重量, 在 该一次放降过程中基本不变), 9为常量, 因此 Mi也是常量; M2 P2xq2, P2为蓄能器 15的压力 (在蓄能过程中由小变大), q2为变量油泵 9的排量。
当 Mi > M2时, ω增大, 放降速度加快; 当 Mi < M2, ω减小, 放降速 度减慢。 检测角速度 ω数值并输入至控制器 31( )与设定的 ω比对, 调整 变量油泵 9的排量 q2,就可改变 M2,若不考虑机械传动和液压系统的效率, 在理论上就可在不发生节流发热损耗的情况下, 迅速有效地控制重物的放 降速度并最大限度地回收重物的势能。 重物落地前的緩速或中间悬停, 仍 由司机操作完成。
C、 在大型液压搬运机械中, 常使用多台变量柱塞油泵(如正面吊有 三台流量较大的负载敏感型变量柱塞油泵 ),可将其全部或部分改换为变量 柱塞油马达, 让分别来自伸缩油虹和变幅油虹的回油通向不同的油马达, 并在泵轴上设置转速传感器 28, 同理, 专用控制器 31( )和 29(K2)分别将 采集的蓄能器的压力 Ρ、 流量 Q和泵的转速 ω等数据处理后, 对变量油泵 9和变量油马达 27的排量作适时的调节, 以便在举升完成后使动力机械卸 荷或在放降过程中控制重物放降的速度和平稳性。 重物放降的即时速度取 决于变量油马达 27的流量 Q (
Figure imgf000007_0001
), 式中 ω为变量油马达 27的角速 度, 是变量油马达 27的即时排量, 只需及时有效地调整变量油马达 27 的转速和变排量机构,就能控制重物放降的速度。 变量油马达 27和变量油 泵 9的转速是相同的, 角速度 ω的增减取决于变量油马达 27的输出转矩 和变量油泵 9输入转矩 Μ2之间的平衡。
Figure imgf000007_0002
, 为变量油马达 27进口压力(它取决于重物的重量, 在该一次放降过程中基本不变), 9 为 变量油马达 27的排量; M2oc p2xq2, P2为蓄能器 15的压力 (在蓄能过程中 由小变大), q2为变量油泵 9的排量。
当 Mi > M2时, ω增大, 放降速度加快; 当 Mi < M2, ω减小, 放降速 度减慢。 检测角速度 ω数值并输入至专用控制器 31( )和 29(Κ2)与设定的 ω比对, 分别调整变量油马达 27的排量 和变量油泵 9的排量 q2, 就可 同时改变 和 Μ2 , 若不考虑机械传动和液压系统的效率, 在理论上就可 在不发生节流发热损耗的情况下, 迅速有效地控制重物的放降速度并最大 限度地回收重物的势能。 重物落地前的緩速或中间悬停, 仍由司机操作完 成。
上述的几种系统中, 势能的再生过程是将蓄能器 15内的压力油,先经 有节流孔的小两位两通电磁换向阀 10释放至油泵 9的进油口,提高了该处 压力, 两位四通电磁换向阀断电复位大流量放能时, 以减少或消除液压沖 击, 蓄能器 15对油泵 9实施压力供油, 减少了动力机械 8的输出功率, 油 泵 9的出油经控制阀组 20到升降油缸 19举升重物。
二、 车辆制动前动能的回收与再生:
在上述能完成势能回收与再生的液压系统中, 再加一个两位三通电磁 换向阀 33 , 其中一个进油路经单向阀 26与油泵 9的出口相连, 另一进油 路则与两位四通电磁换向阀 11的 D口相连, 两位三通电磁换向阀 33的出 口, 一路与两位五通电磁换向阀 32的 0口连接, 另一路与油泵 27的出口 相连, 此外还需在原机械控制阀组 KF的压力油进口 PA之前加装一个两位 二通电磁换向阀 4。 车辆制动时, 两位二通电磁换向阀 4通电断开, 车辆 惯性动能反过来通过带离合器的减速箱 5带动油泵 9和油泵 27转动,将油 液自油箱 1充入蓄能器 15内, 油泵 9和油泵 27共同作为负载形成的阻力 矩配合机械刹车使车辆减速以至停下,提高了车辆的制动力; 车辆起动时, 两位四通电磁换向阀 11 失电、 两位五通电磁换向阀 32得电, 蓄能器 15 内的压力油驱动油泵 9和油泵 27 (此时均为油马达工况), 通过带离合器的 减速箱 5 , 共同帮助动力机械起动车辆, 加大了车辆的起动力。 车辆前进 或后退, 动力机械和油泵的转向不变, 都能正常进行动能的回收与再生。 这样, 该系统就能在保持该行走式液压搬运机械原有全部功能的基础上, 实现重物势能和车辆动能的回收与再生。 变量油泵系统电磁铁动作与工况表: 复原 放降蓄势能 助升生势能 制动蓄动能 起动生动能 离合器状态 (+ -) - - + +
1 DT - + 延时- + 延时-
5 DT - + - - + 6 DT - - - - +
4 DT - - 先 + - 先 +
8 DT - - - + + 三、 叉车等中小型行走式液压搬运机械的势能和动能的回收和再生: 它们一般是中、 小型行走式液压搬运机械, 液压系统较筒单, 一般只 有一个定量油泵, 改造它们的技术方案是, 将该定量油泵改为同排量的定 量油马达 9, 定量油马达 9的进口经单向阀 3与油箱 1相连, 定量油马达 9 的出口一路经两位二通电磁换向阀 21直接与回油过滤器 1相连,另一路经 单向阀 22通到两位四通电磁换向阀 11 的 H口, 两位四通电磁换向阀 11 的 I、 Z和 D口分别通向定量油泵 9的进油口、 经截止阀 14到蓄能器 15 和通向控制阀组 20的压力油进口 PA, 两位四通电磁换向阀 11的 Z与 I口 之间并联了一个有节流孔的小两位两通电磁换向阀 10, 蓄能器 15的旁路 上设有安全阀 12和测压点 13 , 控制阀组 20通向升降油缸 19, 升降油缸 19下降时的回油经控制阀组 20的出口 T到两位三通电磁换向阀 23的进口, 两位三通电磁换向阀 23的出口,一路到油泵 9的进口, 另一路经可调节流 阀 34与回油过滤器 1相连。 市场上 5-10吨的叉车, 虽然在液压系统中设 有两个定量泵, 但由于他们是同轴相连且机械联动的, 所以也可应用上述 方案。 因此可以总结出此方案的特点为在重物下降回收势能的过程中, 工 作油缸的压力回油在进入蓄能器前,所经过的油泵 /油马达均不为油马达工 况, 而是卸荷工况或被引擎所驱动的油泵工况, 并且势能和动能由相同的 油泵 /油马达来回丈或再生。
需要注意的是当势能再生时, 须在两个或多个泵的方案中加装两位两 通电磁换向阀 25, 避免有时因重物的重量太轻而造成柴油机失载致超速。 而在一个泵的方案中则可由司机控制升降阀的开度或在油路上安装调速阀 以保持升举速度的稳定。
为防止周围环境对油液的污染, 油箱可选用保持常压的模板活塞闭式 油箱(专利号为 200720068995.0), 以保证系统的可靠性和使用寿命。
节能型行走式液压搬运机械的液压系统,可选用各类标准的油泵 /油马 达和液压阀等液压元件组合而成, 所采用的液压元件的规格型号, 应和原 机液压系统相匹配, 在定型设计之后, 应将本系统融合在该液压举升机械 的整体设计中, 制造专用集成阀, 以减小体积并降低成本。 动力机械 (柴油 机或电动机)在原地怠速 (或非举升工况)时, 可向蓄能器充能, 以备下次举 升、 起动出全力, 此时动力机械选型之功率应可减小, 以获得更佳的技术 经济效益和节能减排效果。
有益效果:
1、节能型行走式液压搬运机械的液压系统, 它利用和发展了原液压系 统的功能来实现重物势能和车辆动能的回收和再生, 并降低了液压系统的 温升。
2、 节能型行走式液压搬运机械,势能和动能的回收和再生是筒单的 物理过程, 而非电化学过程, 能实现高速、 高效的势能和动能的回收和再 生。
3、 节能型行走式液压搬运机械, 动力机械 (柴油机或电动机)在原地 怠速 (或非举升工况)时, 可向蓄能器充能, 以备下次举升出全力。 这样, 在设计新的机型时, 可减小动力机械的功率, 从而进一步提高节能减排效 果
4、 节能型行走式液压搬运机械,所用的技术是成熟的液压技术,对 原机械传动系统和操作方法未作改变, 无论是新造还是旧设备改造, 都筒 便易行、 可靠性好、 寿命长, 且投入少、 经济性好。
5、 节能型行走式液压搬运机械,它的液压系统中的几个电磁换向阀 都断电时,不需任何改动就能恢复原机械液压系统原先的非节能工作模式。
6、 节能型行走式液压搬运机械的液压系统,与原机械制动可同时作 用, 可提高制动效果, 也可延长机械制动部件的使用寿命。
7、 节能型行走式液压搬运机械的液压系统, 可同时回收动能和势 能, 并允许叉车的多种联合动作。
8、 节能型行走式液压搬运机械的双泵或多泵的液压系统,可组合起 制动或起动作用,从而加大车辆的制动力或起动力,提高车辆的工作效率。 附图说明
图 1、 节能型行走式液压搬运机械的液压原理图(采用变量泵与定量马 达组合)。
图 2、 节能型行走式液压搬运机械的液压原理图(采用定量泵与定量马 达组合)。
图 3、 节能型行走式液压搬运机械的液压原理图(采用变量泵与变量马 达组合)。
图 4、 节能型行走式液压搬运机械的液压原理图(采用单个定量泵 /马 达)
图 5、 节能通用型叉车的液压原理图。
图 6、 节能型正面吊的液压原理图。
图 7、 节能型行走式液压搬运机械的液压原理图 (双泵 /马达的另一种 方案)。
图 8、 节能通用型叉车的势、 动能组合方案的液压原理图。
具体实施方式
现结合附图说明本发明的具体实施方案, 变量泵与定量马达的组合系 统见图 1 , 是较佳的自适应性方案, 它能自动适应不同工况下的势能回收, 当司机利用动力机械(柴油机或电动机) 8带动变量油泵 9驱动升降油缸 19举升重物后, 若操控机械进行放降作业, 在重物放降过程中, 升降油缸 19的下腔(无杆腔) 的油液, 被重物的重力压至控制阀组 20的畅通(流 阻调至最小) 的回油通道 T, 与此同时, 1DT和 5DT通电, 换向阀 11和 32换向, 带压力的回油经换向阀 32的 B口到 G至定量油马达 27的进口, 定量油马达 27的出油经单向阀 30回经换向阀 32的 0口至回油过滤器 1 到油箱 1 , 此时, 由重物的势能造成的回油压力, 形成的定量油马达 27的 转矩带动同轴或机械连动的变量油泵 9工作, 将油液自油箱 1经单向阀 3 抽出,再经单向阀 22至换向阀 11的 H口到 Z口经开启的截止阀 14 (维修 时可关断)通至蓄能器 15。 这样, 重物在放降过程中, 其势能部分转换为 流体的压力能储存在蓄能器 15中, 安全阀 12起限压保护作用。 需要再次举升作业时, 在操纵控制阀组 20的同时, 4DT先通电, 蓄 能器 15内的压力油经节流的两位二通电磁换向阀 10到两位四通电磁换向 阀 11的 I口, 再至变量油泵 9的进油口, 提高了该处压力, 两位四通电磁 换向阀 11 断电复位大流量放能时, 以减少或消除液压沖击, 延时后 1DT 和 5DT都断电, 换向阀 11和换向阀 32复位, 蓄能器 15内的压力油通到 变量油泵 9的进口, 实施压力供油, 动力机械 8带动变量油泵 9和定量油 马达 27 (此时为泵工况;), 它们出口的压力油分别经单向阀 22和 30, 再分 别经电磁换向阀 11和 32共同到控制阀组 20的压力油进口 PA, 并经控制 阀组 20至升降油虹 19。
此时分两种状况: (1 )蓄能器 15 内的压力小于泵组的出口压力 PA, 两位二通电磁换向阀 25通电开通,蓄能器 15内的压力油经换向阀 11的 Z 口和 I口至变量油泵 9的进口,并经两位二通电磁换向阀 25至泵工况的定 量油马达 27的进口,对两个泵实施压力供油, 大大减小了油泵组的进出口 压差, 当流量不变时, 油泵的功率与其进出口压差成正比(Ν^ΔΡ ), 从 而大大降低了动力机械的能耗, 直至蓄能器 15内的压力油放完,动力机械 才开始全力带动油泵组工作;(2 )蓄能器 15内的压力大于泵组的出口压力 ΡΑ, 两位二通电磁换向阀 25关闭, 蓄能器 15内的压力油只到达变量油泵 9的进口, 只对变量油泵 9实施压力供油, 泵工况的定量油马达 27由动力 机械全力驱动,这使动力机械避免失载而超速, 随着蓄能器 15内的压力降 至小于泵组的出口压力 PA时, 两位二通电磁换向阀 25开通, 则同时向两 个泵实施压力供油, 减少动力机械的能耗。
控制器 31( )将采集的蓄能器的压力 P、 流量 Q和泵的转速 ω等数据 处理后, 对变量油泵的排量作适时的调节, 以便在举升完成后使动力机械 卸荷或在放降过程中控制重物放降的速度和平稳性。 重物放降的即时速度 取决于定量油马达 27的流量 Q i
Figure imgf000012_0001
), 式中 ω为定量油马达 27的角 速度, 是定量油马达 27的排量, 是常数, 只需控制定量油马达 27的转 速,就能控制重物放降的速度。定量油马达 27和变量油泵 9的转速是相同 的, 角速度 ω的增减取决于定量油马达 27的输出转矩 和变量油泵 9输 入转矩 M2之间的平衡。
Figure imgf000012_0002
, 为定量油马达 27进口压力(它取决 于重物的重量, 在该一次放降过程中基本不变), 9 为常量, 因此 也是 常量; M2 P2xq2 , P2为蓄能器 15的压力 (在蓄能过程中由小变大), q2为 变量油泵 9的排量。
当 Mi > M2时, ω增大, 放降速度加快; 当 Mi < M2, ω减小, 放降速 度减慢。 检测角速度 ω数值并输入至控制器 31 ( )与设定的 ω比对, 调整 变量油泵 9的排量 q2,就可改变 M2 ,若不考虑机械传动和液压系统的效率, 在理论上就可在不发生节流发热损耗的情况下, 迅速有效地控制重物的放 降速度并最大限度地回收重物的势能。 重物落地前的緩速或中间悬停, 仍 由司机操作完成。
定量泵与定量油马达组合的系统如图 2所示, 势能回收和再生过程和 图 1完全一样。 在重物放降的蓄能过程中, 随着蓄能器 15内压力的升高, 放降速度也减慢, 当重物较轻时当蓄能器 15内压力与升降油缸 19下腔压 力相等时, 重物将不再下降, 因此当重物放降速度低于要求值时, 处于怠 速工况的动力机械 8可继续驱动油泵 9和油马达 27转动, 在向蓄能器 15 继续充能的同时,转动的油马达 27可使重物继续放降至需要高度, 当蓄能 器已满, 两位三通电磁换向阀 23换向, 回油经可调节流阀 34再经回油过 滤器 2回到油箱 1 , 放降速度由节流阀 34控制, 同时两位三通电磁换向阀 33通电换向, 油泵 9和油马达 27均在卸荷状态。
变量泵与变量油马达组合的系统如图 3所示, 势能回收和再生过程和 图 1完全一样。 可在泵轴上设置转速传感器 28 , 控制器 31 ( )和 29(K2)分 别将采集的蓄能器压力?、 流量 Q和泵的转速 ω等数据处理后, 对变量油 泵 9和变量油马达 27的排量作适时的调节,以便在举升完成后使动力机械 卸荷或在放降过程中控制重物放降的速度和平稳性。 重物放降的即时速度 取决于变量油马达 27的流量 Q ( Q^ωxql ), 式中 ω为变量油马达 27的角 速度, 是变量油马达 27 的即时排量, 只需及时有效地调整变量油马达 27的转速和变排量机构, 就能控制重物放降的速度。 变量油马达 27和变 量油泵 9的转速是相同的, 角速度 ω的增减取决于变量油马达 27的输出 转矩 和变量油泵 9输入转矩 M2之间的平衡。
Figure imgf000013_0001
PA为变量油 马达 27进口压力(它取决于重物的重量, 在该一次放降过程中基本不变), qi为变量油马达 27的排量; M2oc pxq2 , 为蓄能器 15的压力 (在蓄能过程中 由小变大), q2为变量油泵 9的排量。
当 Mi > M2时, ω增大, 放降速度加快; 当 Mi < M2, ω减小, 放降速 度减慢。检测角速度 ω数值并输入至控制器 31( )和 29(Κ2)与设定的 ω比 对, 分别调整变量油马达 27的排量 qi和变量油泵 9的排量 q2, 就可同时 改变 和 M2, 若不考虑机械传动和液压系统的效率, 在理论上就可在不 发生节流发热损耗的情况下, 迅速有效地控制重物的放降速度并最大限度 地回收重物的势能。 重物落地前的緩速或中间悬停, 仍由司机操作完成。
车辆动能回收和再生是在上述能完成势能回收与再生的液压系统中, 再加一个两位三通电磁换向阀 33 , 其中一亇进油路经单向阀 26与油泵 9 的出口相连, 另一进油路则与两位四通电磁换向阀 11 的 D口相连, 两位 三通电磁换向阀 33的出口, 一路与两位五通电磁换向阀 32的 0口连接, 另一路与油泵 27的出口相连,此外还需在原机械控制阀组 KF的压力油进 口 PA之前加装一个两位二通电磁换向阀 4。 车辆制动时, 两位二通电磁换 向阀 4通电断开, 车辆惯性动能反过来通过带离合器的减速箱 5带动油泵 9和油泵 27转动, 将油液自油箱 1充入蓄能器 15内, 油泵 9和油泵 27共 制动力; 车辆起动时, 两位四通电磁换向阀 11失电、 两位五通电磁换向阀 32得电, 蓄能器 15内的压力油驱动油泵 9和油泵 27 (此时均为油马达工 况), 通过带离合器的减速箱 5 , 共同帮助动力机械起动车辆, 加大车辆的 起动力。 车辆前进或后退, 动力机械和油泵的转向不变, 都能正常进行动 能的回收与再生。 这样, 该系统就能在保持该移动式液压升降机械原有全 部功能的基础上, 实现重物势能和车辆动能的回收与再生。
图 4是单个定量泵 /定量油马达的节能型移动式液压升降机械的液压系 统原理图, 是筒易型的, 它们一般适用于中、 小型的液压升降机械, 液压 系统较筒单, 一般只有一个定量油泵, 改进它们的技术方案是, 将该定量 油泵改为同排量的定量油马达 9, 油马达 9的进口经单向阀 3与油箱 1相 连,油马达 9的出口一路经两位二通电磁换向阀 21与回油过滤器 1直接相 连, 另一路经单向阀 22通到两位四通电磁换向阀 11的 H口, 两位四通电 磁换向阀 11的 I、 Z和 D口分别经单向阀 4通向油泵 9的进油口、 经截止 阀 14到蓄能器 15和通向控制阀组 20的压力油进口 PA, 两位四通电磁换 向阀 11的 Z与 I口之间并联了一个有节流孔的小两位两通电磁换向阀 10, 蓄能器 15的旁路上设有安全阀 12和测压点 13 , 控制阀组 20通向升降油 虹 19,升降油虹 19下降时的回油经控制阀组 20的出口 T到两位三通电磁 换向阀 23的进口, 两位三通电磁换向阀 23的出口,一路到油泵 9的进口, 另一路经可调节流阀 34到回油过滤器 2。
需要说明的是, 当重物放降时, 如果蓄能器容量已满, 则令 1DT (阀 11 )和 2DT (阀 21)得电, 此时, 柴油机将进入怠速工况, 油泵 9卸荷, 其 出油经两位二通电磁换向阀 21 回油箱; 而升降油缸的回油则经过阀 23、 节流阀 34, 并经回油过滤器 2回到油箱 1 , 从而可以继续控制重物的放降 速度。
图 5是目前常见的通用型叉车改造后的液压原理图。 16的点划线框内 是原叉车的转向随动系统, 20的点划线框内是原叉车的控制阀组, 20-2是 分流阀,它将油泵 9的流量按比例分流给升降、倾斜油缸和转向机构; 20-1 是升降、 倾斜油路的调压阀; 20-3是转向油路的调压阀; 20-4是升降油缸 的操纵阀; 20-5是倾斜油缸的操纵阀。 油泵 9的出油先经控制阀组 20里 的分流阀 20-2分流后, 再到两位四通电磁换向阀 11的 H口, 并经两位四 通电磁换向阀 11回到控制阀组 20通向操纵阀, 17为油路的切断阀, 防止 重物急落。 其工作原理与图 3相同。 叉车的电磁铁动作与工况表
复 放 降 放降蓄势 助升生 制动蓄 起动生 原 蓄 势 势能 动能 动能
能 满时)
离合器 (+ -) - - - + + 状态
1 DT - 十 + 延时- + 延时-
2 DT - - + - - + 3 DT - + - - - -
4 DT - - - 先 + - 先 + 图 6是节能型正面吊的液压原理图,点划线框内的 B6、 B7、 B12、 B23 和 B25是原正面吊液压控制阀组, 它在势能回收时, 分别将压力不同的伸 缩缸和变幅缸下腔的油液通向两个变量油马达的进口, 形成的合力矩带动 油泵向蓄能器充能, 其工作原理和图 3相同。
图 Ί是两个液压泵 /液压马达的另一种方案, 它省去了单向阀 26和两 位二通电磁换向阀 4, 并将两位三通电磁换向阀 33改为两位二通电磁换向 阀, 并可将两位二通电磁换向阀 25改为液控换向阀。 系统虽较图 1、 图 2 和图 3的方案筒单, 但难以实现双泵同时起制动或起动作用。
图 8是节能通用型叉车的势、 动能组合方案, 它的特点是一亇双联定 量泵 9通过单向超越离合器 41与柴油机 8的输出轴相连;在变速箱 5的输 出轴上加装一个定量泵 37 ,使势能和动能的收放可由不同的油泵 /油马达完 成, 制动回收动能时柴油机的离合器 42可脱开, 超越离合器 41使下降蓄 势能时的下降速度与柴油机怠速的转速无关。 为了适应叉车经常的倒车作 业, 在油泵 37 的进出油口上加装了一个较大通径的液动两位四通换向阀 38 , 它可在正或倒车作业时, 保持油泵 37的输出的流向不变。 其中的两位 二通电磁换向阀 39导通时实施动能再生操作,该阀关断时,可实施势能再 生操作。 该系统当离合器 42结合时, 两组泵( 9和 37 )组合起来都可参与 动能回收或动能再生, 这样可加大车辆的制动力矩或起动力矩, 提高搬运 机戈的工作效率。 其它部分工作原理同图 5。
本发明不仅可用于行走式液压搬运机械, 其势能回收和再生的原理也 可用于固定式液压升降机械, 上述的实施例只是几种选例, 并不限定本专 利的保护范围。

Claims

权 利 要 求
1、一种节能型行走式液压搬运机械, 包括起重和行走的驱动系统和控 制系统等, 在原液压系统中附加部分液压元件, 构成新的液压系统, 其特 征在于: 具有至少一个油泵 /油马达和至少一个液压蓄能器, 在至少一个油 泵 /油马达的出油路上有控制出油去蓄能器或去工作油缸的换向阀,在至少 一个油泵 /油马达的进油路上有控制工作油虹的回油去油泵 /油马达的入口 或回油箱的换向阀, 新液压系统在保留该机械原有的全部功能和操控方式 的基础上, 具有能实现重物势能回收与再生和车辆动能回收与再生两者的 部分或全部功能。
2. 如权利要求 1所述的节能型行走式液压搬运机械, 其特征在于: 所 述的液压系统中的油泵 /油马达可以是: 变量油泵 /油马达与定量油泵 /油马 达的组合; 定量油泵 /油马达的组合; 变量油泵 /油马达的组合。
3. 如权利要求 1或 2任一项所述的节能型行走式液压搬运机械,其特 征在于: 该液压系统的油泵 /油马达的工况可以是下述三种状态之一: 油泵 工况; 油马达工况; 卸荷工况。
4. 如权利要求 1-3任一项所述的节能型行走式液压搬运机械, 其特征 在于: 在重物下降回收势能的过程中, 部分油泵 /油马达进入油马达工况, 被工作油缸的压力回油所驱动, 输出转矩; 另有部分油泵 /油马达进入油泵 工况, 被前者所输出的转矩所驱动, 将油从油箱压入蓄能器中。
5. 如权利要求 1-3任一项所述的节能型行走式液压搬运机械, 其特征 在于: 在重物下降回收势能的过程中, 工作油缸的压力回油在进入蓄能器 前, 所经过的油泵 /油马达均不为油马达工况, 而是卸荷工况或被引擎所驱 动的油泵工况。
6. 如权利要求 1-5任一项所述的节能型行走式液压搬运机械, 其特征 在于: 势能和动能分别由不同的油泵 /油马达来回收或再生, 它们还可以组 合发挥功能。
7. 如权利要求 1-5任一项所述的节能型行走式液压搬运机械, 其特征 在于: 势能和动能由相同的油泵 /油马达来回收或再生。
8. 如权利要求 1-7任一项所述的节能型行走式液压搬运机械, 其特征 在于: 所述的液压系统中含有防止柴油机失载超速的控制阀。
9. 如权利要求 1-7任一项所述的节能型行走式液压搬运机械, 其特征 在于:两个或多个定量油泵 /油马达的组合和单个油泵 /油马达的液压系统中 含有可控制重物下降速度的可调节流阀。
10. 如权利要求 3所述的节能型行走式液压搬运机械, 其特征在于: 所述的含有变量油泵与油马达的组合, 配备有专用的控制器。
11. 如权利要求 1-7任一项所述的节能型行走式液压搬运机械, 其特 征在于: 所述液压系统中设有在能量再生过程中起緩沖作用的有节流孔的 两位两通电磁换向阀。
12. 如权利要求 1-11任一项所述的节能型行走式液压搬运机械, 其特 征在于: 所述的液压系统可选用各类标准的油泵 /油马达和液压阀等液压元 件组合而成, 也可设计制造专用集成阀。
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