WO2014048026A1 - 泵车疏导控制系统、泵车疏导控制方法和泵车 - Google Patents

泵车疏导控制系统、泵车疏导控制方法和泵车 Download PDF

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Publication number
WO2014048026A1
WO2014048026A1 PCT/CN2012/085847 CN2012085847W WO2014048026A1 WO 2014048026 A1 WO2014048026 A1 WO 2014048026A1 CN 2012085847 W CN2012085847 W CN 2012085847W WO 2014048026 A1 WO2014048026 A1 WO 2014048026A1
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Prior art keywords
pumping
current
pressure
pump truck
threshold
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PCT/CN2012/085847
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English (en)
French (fr)
Inventor
魏志魁
武利冲
吴名陵
Original Assignee
湖南三一智能控制设备有限公司
三一重工股份有限公司
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Application filed by 湖南三一智能控制设备有限公司, 三一重工股份有限公司 filed Critical 湖南三一智能控制设备有限公司
Publication of WO2014048026A1 publication Critical patent/WO2014048026A1/zh

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B15/00Pumps adapted to handle specific fluids, e.g. by selection of specific materials for pumps or pump parts
    • F04B15/02Pumps adapted to handle specific fluids, e.g. by selection of specific materials for pumps or pump parts the fluids being viscous or non-homogeneous
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04GSCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G21/00Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/02Conveying or working-up concrete or similar masses able to be heaped or cast
    • E04G21/04Devices for both conveying and distributing
    • E04G21/0418Devices for both conveying and distributing with distribution hose
    • E04G21/0436Devices for both conveying and distributing with distribution hose on a mobile support, e.g. truck
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04GSCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G21/00Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/02Conveying or working-up concrete or similar masses able to be heaped or cast
    • E04G21/04Devices for both conveying and distributing
    • E04G21/0418Devices for both conveying and distributing with distribution hose
    • E04G21/0445Devices for both conveying and distributing with distribution hose with booms
    • E04G21/0463Devices for both conveying and distributing with distribution hose with booms with boom control mechanisms, e.g. to automate concrete distribution

Definitions

  • the present invention relates to the field of construction machinery, and in particular to a pump vehicle grooming control system, a pump truck having the pumping vehicle grooming control system, and a pumping vehicle grooming control method. Background technique
  • a pump grooming control system including: a discharge height collecting unit, a pumping state collecting unit, a processor, and a control component, wherein the discharge height collecting unit collects a pumping vehicle Current discharge height information, and transmitting the collected current discharge height information to the processor; the pumping state collection unit collects current pumping state information of the pump truck, and collects current pumping state information Transmitting to the processor; the processor is pre-set with a pumping state threshold corresponding to the discharge height, and determining a current pumping state threshold according to the current discharge height information of the pumping vehicle, And comparing the current pumping state information with the current pumping state threshold, and determining a pipe plugging fault to the control when the current pumping state information is greater than or equal to the current pumping state threshold
  • the component sends an action signal; the control component is connected to the processor, and performs a corresponding operation according to the action signal to exclude the blocked pipe .
  • the ideal pumping state threshold corresponding to various discharge heights is preset in the system database, so firstly, the current discharge height and the current pumping state are collected, and the corresponding pumping state threshold is found according to the current discharge height.
  • the current pumping state is compared with a corresponding pumping state threshold to determine whether a plugging fault has occurred, and an action signal is sent to the control component to accurately and timely eliminate the plugging fault.
  • a pump truck provided with the pump grooming control system described in any of the above aspects.
  • a pump grooming control method including the following Step: collecting current discharge height information and current pumping state information of the pump truck; presetting a pumping state threshold corresponding to the discharge height, and determining current current according to the current discharge height information of the pump truck Pumping a state threshold, and comparing the current pumping state information with the current pumping state threshold, determining that the pipe is blocked when the current pumping state information is greater than or equal to the current pumping state threshold
  • the fault sends an action signal to the control element; the control element performs a corresponding operation according to the action signal to eliminate the plugging fault.
  • the pumping state of the information quantification can be obtained, so that the customer or the operator can know the pumping operation state in time; the plugging tube can be accurately determined according to the control strategy; and the functions such as sound, text, animation, etc. can be used.
  • Fault grading warning prompt Ability to select fault resolution control scheme through automatic/manual mode, timely and effectively solve the plugging fault, and the flexibility and reliability are greatly improved.
  • FIG. 1 is a schematic view of a pumping vehicle grooming control system in accordance with an embodiment of the present invention
  • FIG. 2 is a schematic diagram of a control process of a pumping vehicle grooming control system in accordance with an embodiment of the present invention
  • FIG. 3 is a pump in accordance with an embodiment of the present invention. Schematic diagram of the vehicle grooming control system
  • FIG. 4 is a schematic illustration of a discharge height acquisition in accordance with an embodiment of the present invention.
  • Figure 5 is a flow chart of a pump grooming control method in accordance with an embodiment of the present invention.
  • FIG. 6 is a flow chart of a pumping grooming control logic strategy in accordance with an embodiment of the present invention.
  • DETAILED DESCRIPTION OF THE INVENTION The present invention will be further described below in conjunction with the accompanying drawings and embodiments. It should be noted that, in the case of no conflict, the features in the embodiments and the embodiments of the present application may be combined with each other.
  • the pumping and grooming control system includes a discharge height collecting unit 101, a pumping state collecting unit 102, a processor 104 and a control element 106, wherein the discharge height collecting unit 101 Collecting the current discharge height information of the pump truck, and transmitting the collected current discharge height information to the processor 104; the pumping state collection unit 102 collecting the current pumping state information of the pump truck, and collecting the current pumping state information Transfer to the processor 104; the processor 104 is pre-set with a pumping state threshold corresponding to the discharge height, determining a current pumping state threshold based on the current discharge height information of the pump truck, and the current pumping state information Comparing with the current pumping state threshold, when the current pumping state information is greater than or equal to the current pumping state threshold, determining a plugging fault, sending an action signal to the control component 106; the control component 106
  • the current pumping state information collected by the pumping state collecting unit 102 may be the commutation period of the pumping cylinder of the pumping truck, the pressure of the main cylinder, the pressure of the pumping main system, or the above two or With more than two types of information, these main parameters can be used to determine the current pumping status.
  • the pumping state collecting unit 102 includes a commutating collecting instrument configured to collect the commutation period of the conveying cylinder; when the current pumping state information is dominant
  • the pumping state collection unit 102 includes a first pressure sensor configured to collect the pressure of the master cylinder; when the current pumping state information is the pressure of the pumping main system, the pumping state collection unit 102 includes a configuration for collecting A second pressure sensor that pumps the pressure of the main system.
  • the pumping state threshold corresponding to various discharge heights is preset in the system database, so firstly, the current discharge height and the current pumping state are collected, and the corresponding pumping state threshold is found according to the current discharge height, The current pumping state is compared to a corresponding pumping state threshold to determine if a plugging fault has occurred and an action signal is sent to the control component 106 to accurately and timely eliminate the plugging fault.
  • the main system pressure threshold corresponding to the current discharge height is preset. When the collected main system pressure is greater than or equal to the main system pressure threshold corresponding to the current discharge height, it indicates that a pipe blockage has occurred.
  • the discharge height collecting unit 101 may specifically include an angle sensor configured to detect a rotation angle of each section of the pump truck, and the discharge height collecting unit 101 is configured according to each section of the pumping vehicle.
  • the rotation angle of the boom and the length of each boom of the pump truck are used to obtain the current discharge height information of the pump truck.
  • the processor 104 determines that the pressure of the pumping main system continues for a predetermined first period of time or greater.
  • pumping the pressure threshold of the main system continue to determine whether the pressure of the main cylinder continues for a predetermined period of time.
  • the second time period is greater than or equal to the pressure threshold of the main cylinder. If there is no pressure threshold greater than or equal to the main cylinder, a first-level warning is performed, otherwise, the judgment is continued. Whether the commutation period of the transport cylinder is greater than or equal to the commutation period threshold of the transport cylinder, and if it is greater than or equal to the commutation period threshold, a secondary alarm is performed. In this way, the operator can be alarmed according to the severity of the fault, and the operator can be alerted by sound, text, image, etc., and in the second-level early warning, the warning sound can be played through the speaker to remind.
  • the pumping and grooming control system may further include a display device 108 connected to the processor 104, displaying the information collected by the pumping state collecting unit 102, and displaying the warning information corresponding to the first level warning and the warning information corresponding to the second level warning, and Play the warning information corresponding to the secondary alarm.
  • the operator can intuitively and clearly understand the current status information of the pumping device through the display device 108, and timely notice whether a pipe plugging failure has occurred.
  • the database also stores pumping material information, work displacement and output.
  • the pressure threshold of the pumping main system corresponding to the material height, the pressure threshold of the main cylinder, and the commutation period threshold of the delivery cylinder, the display device 108 is configured to input the current pumping material information and transmit the input pumping material information to the processing.
  • the processor 104 retrieves a corresponding pumping state threshold from the database, and the current pumping state to be collected (for example, the main The system pressure, the master cylinder pressure) is compared with the found pumping state threshold, and the blockage fault is determined when the pumping state threshold is greater than or equal to.
  • a corresponding pumping state threshold for example, the main The system pressure, the master cylinder pressure
  • the control element 106 shown in FIG. 1 may include a first control
  • the first control device 1062 includes a solenoid valve on the reverse pump oil line, a proportional solenoid valve of the main oil pump, and an engine speed control unit.
  • the proportional solenoid valve of the main oil pump and the engine speed control unit respectively receive the first from the processor 104. Controlling the signal and performing a displacement change operation according to the first control signal; after the first control device 1062 performs the displacement change operation, the processor 104 sends the reverse pump oil to the first control device 1062 if the plugging fault is still not eliminated.
  • the solenoid valve on the road, the proportional solenoid valve of the main oil pump, and the engine speed control unit respectively transmit a second control signal, and the first control device 1062 performs a reverse pump operation according to the second control signal.
  • Both the displacement change operation and the back pump operation are a preferred way to eliminate the blockage failure.
  • the displacement change operation means increasing the displacement of the main oil pump or reducing the displacement of the main oil pump without changing the oil passage.
  • the control element 106 shown in FIG. 1 may further include a second control device 1064.
  • the processor proceeds to the second control device 1064.
  • the second control device 1064 includes a solenoid valve on the high pressure oil line, a proportional solenoid valve of the main oil pump, and an engine speed control unit, respectively receiving a third control signal from the processor and performing high pressure pumping according to the three control signals operating.
  • High-pressure pumping is also a way to troubleshoot tube plugging, but to ensure system safety, this method is only used when the counter pump operation is unsuccessful.
  • the processor 104 transmits a third control signal to the second control device upon receiving the acknowledgment signal from the user.
  • the processor 104 determines whether it is currently in the automatic mode according to the setting data of the user, and if it is in the automatic mode, preferentially sends the first control signal to the first control device, and if in the manual mode, performs manual operation according to the prompt.
  • the specific interaction process between the control element 106 and the processor 104 is shown in FIG. 2.
  • the first control device 1062 includes a corresponding solenoid valve, a displacement control valve, and a starting valve for controlling the operation of the cylinder on the reverse pump oil path.
  • the machine speed control output device when determining the pipe plugging fault, the processor 104 first sends a displacement control signal to the displacement control valve (ie, the proportional solenoid valve of the main oil pump) in the first control device 1062 to control the displacement change thereof. operating.
  • the second control device 1064 includes a corresponding solenoid valve for controlling the operation of the cylinder on the high pressure oil passage, a displacement control valve for controlling the main oil pump, and an engine speed control output device. After receiving the action signal of the processor 104, the high pressure pumping operation is realized. . After the second control device 1064 is activated, the high pressure confirmation function is first performed. After the confirmation is completed, a high pressure pumping operation is performed, that is, the main cylinder and the swing cylinder are alternately operated in sequence to realize the high pressure pumping operation, and the processor is controlled according to the feedback state. 104 determines the next action signal.
  • the processor 104 can adopt the special mechanical controller of the engineering machinery, as shown in FIG. 3, the main system pressure sensor P1 is installed on the pumping system, and the pressure sensors P2 and P3 are installed on the main cylinder, and the collection is performed.
  • the main cylinder pressure, and the reversing collectors S1 and S2 are mounted on the delivery cylinder to collect the commutation period.
  • an embodiment of the present invention provides a pump truck including the pump grooming control system as described in any of the above aspects.
  • step 402 pumping status information and discharge height information of the system are collected, wherein the pumping status information includes pumping system pressure, main cylinder pressure, and commutation period.
  • the collected information is calculated and processed, and the database is called.
  • the factors affecting the main system pressure are related to the discharge height, concrete specification and displacement. Therefore, in the process of designing the pumping pressure threshold, taking into account the current working displacement, the current discharge height (determined by the boom attitude, the boom length and the end position), etc., set the corresponding pressure threshold under different working conditions or Other status thresholds.
  • the amount of information collected is compared with a corresponding threshold value found from the database according to the current state of the system, and the plugging fault is determined according to the comparison result.
  • step 406 when the plugging condition is satisfied, the process proceeds to step 408. If the plugging condition is not met, the process returns to step 402.
  • step 408 it is determined whether the first-level early warning condition is met. If yes, the process proceeds to step 410. If not, the process proceeds to step 409, where a first-level warning is presented to the user. For example, use images and animations to make a prompt.
  • a secondary alert is prompted to prompt the user, for example by voice.
  • step 412 it is judged whether or not the automatic mode is entered. If yes, the process proceeds to step 414. If not, the process proceeds to step 416.
  • adaptive control is performed to suppress the blockage, eliminate the fault, and place the system in a safe pumping state.
  • manual control is performed to suppress the blockage, eliminate the fault, and place the system in a safe pumping state. Therefore, the adaptive control suppression plugging function includes two parts functions. One is to select the automatic control mode or the manual control mode through the user setting; the other is to increase the second control function confirmed by the user, that is, the high pressure switching pump in the automatic control mode. Send function.
  • the processor preferentially selects the first control device for the control output, at the first When the control device is running, it will adjust the control time, displacement, engine speed, etc. according to the state feedback; if the user starts the second control device at the same time, the first control device is preferred when controlling the output, if after the time t is maintained (Invoking the database threshold, the value is different under different working conditions), if the fault still cannot be eliminated, the second control device is started, and the user confirmation function is added to avoid the safety problem.
  • step 502 the pumping state information of the system and the current discharge height and the current displacement are collected, wherein the pumping state information includes the main system pressure, the main cylinder pressure, the commutation period, and the like, and the boom attitude determines the discharge height.
  • the phase is picked from the database based on the current discharge height and the current displacement.
  • the pumping status threshold should be.
  • step 506 it is determined whether the collected main system pressure continues to exceed the set main system pressure threshold P_M, and if so, proceeds to step 508, and if not, returns to step 502.
  • step 508 it is determined whether the collected master cylinder pressure continues to exceed the set master cylinder pressure threshold P_C, and if so, proceeds to step 510, and if not, performs an early warning and performs a corresponding drain operation, and then returns to step 502.
  • step 510 it is determined whether the collected commutation period continues to exceed the set commutation period threshold T. If yes, the output is controlled, and after the fault is discharged, the routine proceeds to step 512, and the system is in the safe pumping state. If no, go back to step 502.
  • the pressure sensor or the angle sensor may not be installed, and the tube failure judgment and control may be performed only through the commutation period.
  • the utility model provides a pump truck grooming control system, a pump truck grooming control method and a pump truck, which can obtain the pumping state of information quantification, so that the customer or the operator can know the pumping operation state in time; the plugging can be accurately determined according to the control strategy
  • the tube is faulty; it can use the functions of sound, text, animation, etc. to perform fault grading warning prompts; it can select fault resolution through automatic/manual modes.
  • the control plan solves the pipe plugging fault in a timely and effective manner. Therefore, the invention has industrial applicability

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Control Of Positive-Displacement Pumps (AREA)
  • Fluid-Pressure Circuits (AREA)

Abstract

一种泵车疏导控制系统,包括:出料高度采集单元(101),采集泵车的当前出料高度信息;泵送状态采集单元(102),采集泵车的当前泵送状态信息;处理器(104),预设有与出料高度相对应的泵送状态阈值,根据泵车的当前出料高度信息确定当前的泵送状态阈值,并将当前泵送状态信息与当前的泵送状态阈值进行比较,在当前泵送状态信息大于等于当前的泵送状态阈值时,确定堵管故障,向控制元件(106)发送动作信号;控制元件(106),根据动作信号执行相应操作,以排除堵管故障。还公开了一种泵车疏导控制方法和泵车。该泵车疏导控制系统、控制方法和泵车能够准确判断堵管故障并进行有效预警,并采取有效措施解决堵管故障。

Description

泵车疏导控制系统、 泵车疏导控制方法和泵车 本申请要求于 2012 年 9 月 28 日提交中国专利局、 申请号为 201210370430.3、 发明名称为"泵车疏导控制系统、 泵车疏导控制方法和泵 车"的中国专利申请的优先权, 其全部内容通过引用结合在本申请中。 技术领域
本发明涉及工程机械领域, 具体而言, 涉及一种泵车疏导控制系统、 具有该泵车疏导控制系统的泵车和一种泵车疏导控制方法。 背景技术
目前, 随着混凝土泵送设备功能的不断完善, 给客户带来了很大的经 济效益。 但是在混凝土泵送过程中, 由于混凝土规格型号的不同, 会出现 混凝土泵送困难, 甚至堵管的现象, 对客户和施工单位造成极大的困扰。 对于经验丰富的操作手而言, 可通过反泵 /正泵切换解决此类故障, 但是对 于堵管现象的判断却没有预见性, 耽误了一定的施工时间。
目前基本上采用人工经验方式解决此类故障, 主要存在以下缺点:
1 )采用自动高低压切换的方式, 在一定程度上增加了堵管的可能性, 增大施工难度, 并且在外部输送管不具备高压泵送的情况下极易导致爆管 等安全事故;
2 )采用先排量减小再高低压切换增大油缸推力的方式, 无法从根源上 解决此类情况发生, 基本与自动高低压切换方案类似;
3 )单纯依靠泵送压力进行判断, 无法准确定位堵管发生的几率, 易导 致误操作;
4 )对混凝土泵送状态没有前期预见性, 对设备运行状况信息无法量化 获得; 5 )没有进行相应的预警提示。
因此, 需要具备预见性的智能泵车疏导控制系统, 能够切切实实解决 堵管故障, 最大程度上节约施工成本。 发明内容
考虑到上述背景技术, 本发明的一个目的是提供一种泵车疏导控制系 统, 能够准确判断堵管故障并进行有效疏通。
根据本发明的一个方面, 提供了一种泵车疏导控制系统, 包括: 出料 高度采集单元、 泵送状态采集单元、 处理器和控制元件, 其中, 所述出料 高度采集单元采集泵车的当前出料高度信息, 并将采集的当前出料高度信 息传送至所述处理器; 所述泵送状态采集单元采集所述泵车的当前泵送状 态信息, 并将采集的当前泵送状态信息传送至所述处理器; 所述处理器, 预设有与出料高度相对应的泵送状态阀值, 根据所述泵车的所述当前出料 高度信息确定当前的泵送状态阀值, 并将所述当前泵送状态信息与所述当 前的泵送状态阈值进行比较, 在所述当前泵送状态信息大于等于所述当前 的泵送状态阈值时, 确定堵管故障, 向所述控制元件发送动作信号; 所述 控制元件, 连接至所述处理器, 根据所述动作信号执行相应操作, 以排除 所述堵管故障。
在系统数据库中预置了各种出料高度所对应的理想泵送状态阈值, 因 此首先需采集当前出料高度和当前泵送状态, 根据该当前出料高度查找出 对应的泵送状态阈值, 将该当前泵送状态与对应的泵送状态阈值进行比较, 以确定是否出现堵管故障, 并向控制元件发送动作信号, 准确及时地排除 该堵管故障。
根据本发明的另一方面, 还提供了一种泵车, 该泵车设置有上述任一 技术方案中所描述的泵车疏导控制系统。
根据本发明的又一方面, 还提供了一种泵车疏导控制方法, 包括以下 步骤: 采集泵车的当前出料高度信息和当前泵送状态信息; 预设有与出料 高度相对应的泵送状态阀值, 根据所述泵车的所述当前出料高度信息确定 当前的泵送状态阀值, 并将所述当前泵送状态信息与所述当前的泵送状态 阈值进行比较, 在所述当前泵送状态信息大于等于所述当前的泵送状态阈 值时, 确定堵管故障, 向控制元件发送动作信号; 所述控制元件根据所述 动作信号执行相应操作, 以排除所述堵管故障。
根据本发明的技术方案, 能够获得信息量化的泵送状态, 使得客户或 操作手及时了解泵送运行状况; 能够根据控制策略可精确判断堵管发生故 障; 能够利用声音、 文字、 动画等功能进行故障分级预警提示; 能够通过 自动 /手动两种模式选择故障解决控制方案, 及时有效地解决堵管故障, 灵 活性和可靠性得到极大提高。 附图说明
图 1是根据本发明的一个实施例的泵车疏导控制系统的示意图; 图 2是根据本发明的实施例的泵车疏导控制系统的控制过程示意图; 图 3是根据本发明的实施例的泵车疏导控制系统的示意图;
图 4是根据本发明的实施例的出料高度采集的示意图;
图 5是根据本发明的实施例的泵车疏导控制方法的流程图;
图 6是根据本发明的实施例的泵车疏导控制逻辑策略的流程图。 具体实施方式 下面结合附图和实施例对本发明做进一步说明。 需要说明的是, 在不 沖突的情况下, 本申请的实施例及实施例中的特征可以相互组合。
首先结合图 1至图 4详细说明根据本发明实施例的泵车疏导控制系统。 如图 1所示, 该泵车疏导控制系统包括出料高度采集单元 101、 泵送状 态采集单元 102、处理器 104和控制元件 106,其中, 出料高度采集单元 101 采集泵车的当前出料高度信息, 并将采集的当前出料高度信息传送至处理 器 104; 泵送状态采集单元 102采集泵车的当前泵送状态信息, 并将采集的 当前泵送状态信息传送至处理器 104;处理器 104预设有与出料高度相对应 的泵送状态阀值, 根据泵车的当前出料高度信息确定当前的泵送状态阀值, 并将当前泵送状态信息与当前的泵送状态阈值进行比较, 在当前泵送状态 信息大于等于当前的泵送状态阈值时, 确定堵管故障, 向控制元件 106发 送动作信号; 控制元件 106, 连接至处理器 104, 根据动作信号执行相应操 作, 以排除堵管故障。 其中, 如图 2所示, 泵送状态采集单元 102采集的 当前泵送状态信息可以为泵车的输送缸的换向周期、 主油缸的压力、 泵送 主系统的压力, 或者上述两种或两种以上信息, 通过这些主要参数便可以 确定当前的泵送状态。 因此, 当当前泵送状态信息为泵车的输送缸的换向 周期时, 泵送状态采集单元 102 包括配置为采集输送缸的换向周期的换向 采集仪; 当当前泵送状态信息为主油缸的压力时, 泵送状态采集单元 102 包括配置为采集主油缸的压力的第一压力传感器; 当当前泵送状态信息为 泵送主系统的压力时, 泵送状态采集单元 102 包括配置为采集泵送主系统 的压力的第二压力传感器。
在系统数据库中预置了各种出料高度所对应的泵送状态阈值, 因此首 先需采集当前出料高度和当前泵送状态, 根据该当前出料高度查找出对应 的泵送状态阈值, 将该当前泵送状态与对应的泵送状态阈值进行比较, 以 确定是否出现堵管故障, 并向控制元件 106发送动作信号, 准确及时地排 除该堵管故障。 例如, 预设了当前出料高度对应的主系统压力阈值, 当采 集到的主系统压力大于等于与当前出料高度对应的主系统压力阈值时, 说 明发生了堵管故障。
如图 4所示, 该出料高度采集单元 101具体可以包括配置为检测泵车 各节臂架的转动角度的角度传感器, 出料高度采集单元 101根据泵车各节 臂架的转动角度以及泵车各节臂架的长度获取泵车的当前出料高度信息。 在当前泵送状态信息为泵车的输送缸的换向周期、 主油缸的压力和泵 送主系统的压力时, 处理器 104在判断出泵送主系统的压力持续预定第一 时间段大于等于泵送主系统的压力阈值时, 继续判断主油缸的压力是否持 续预定第二时间段大于等于主油缸的压力阈值, 若没有大于等于主油缸的 压力阈值, 则进行一级预警, 否则, 继续判断输送缸的换向周期是否大于 等于输送缸的换向周期阈值, 若大于等于换向周期阈值, 则进行二级预警。 如此, 可以根据故障的严重程度分级向操作人员进行报警, 通过声音、 文 字、 图像等方式提醒操作人员, 在二级预警时, 可通过扬声器播放预警声 音进行提醒。
泵车疏导控制系统还可以包括显示装置 108,显示装置 108连接至处理 器 104,显示泵送状态采集单元 102采集的信息以及显示一级预警对应的预 警信息、 二级预警对应的预警信息, 并播放二级预警对应的预警信息。 操 作人员可以通过显示装置 108直观、 清楚地了解泵送设备当前的状态信息, 并及时注意到是否发生堵管故障。
由于不同的泵送物料信息, 发生堵管的几率会不一样, 不同的泵送物 料信息对应的泵送状态阈值也会不一样, 因此, 数据库还存储有泵送物料 信息、 工作排量和出料高度所对应的泵送主系统的压力阈值、 主油缸的压 力阈值、 输送缸的换向周期阈值, 显示装置 108 配置为输入当前的泵送物 料信息并将输入的泵送物料信息传送至处理器 104,处理器 104根据当前的 泵送物料信息、 泵送设备的当前工作排量和当前出料高度从数据库中调出 相应的泵送状态阈值, 将采集到的当前泵送状态 (例如主系统压力、 主油 缸压力)与查找出的泵送状态阈值进行比较, 在大于等于泵送状态阈值时, 确定堵管故障。
结合图 1和图 2,优选地, 图 1中所示的控制元件 106可以包括第一控 制装置 1062, 第一控制装置 1062包括反泵油路上的电磁阀、主油泵的比例 电磁阀和发动机速度控制单元, 主油泵的比例电磁阀和发动机速度控制单 元分别接收来自处理器 104 的第一控制信号并根据第一控制信号进行排量 变化操作; 处理器 104在第一控制装置 1062执行排量变化操作后, 若堵管 故障仍未消除, 则向第一控制装置 1062中的反泵油路上的电磁阀、 主油泵 的比例电磁阀和发动机速度控制单元分别发送第二控制信号, 第一控制装 置 1062根据第二控制信号进行反泵操作。 排量变化操作和反泵操作均是排 除堵管故障的一种优选方式。 排量变化操作是指在油路没有变化的情况下, 增大主油泵的排量或减小主油泵的排量。
优选地, 图 1中所示的控制元件 106还可以包括第二控制装置 1064, 在第一控制装置 1062执行反泵操作后, 若堵管故障仍未消除, 则处理器向 第二控制装置 1064发送第三控制信号, 第二控制装置 1064包括高压油路 上的电磁阀、 主油泵的比例电磁阀和发动机速度控制单元, 分别接收来自 处理器的第三控制信号并根据三控制信号进行高压泵送操作。 高压泵送操 作也是排除堵管故障的一种方式, 但为了保证系统安全, 只有在反泵操作 没有成功时, 才采用该种方式。
由于高压泵送操作在外部输送管不具备高压泵送的情况下极易导致爆 管等安全事故, 因此, 只有在用户的同意之下才可以进行高压泵送操作。 因此, 处理器 104在接收到来自用户的确认信号后向第二控制装置发送第 三控制信号。
优选地, 处理器 104根据用户的设置数据判断当前是否处于自动模式, 若处于自动模式, 则优先向第一控制装置发送第一控制信号, 若处于手动 模式, 则根据提示进行人工操作。
控制元件 106与处理器 104之间的具体交互过程参见图 2,第一控制装 置 1062包括反泵油路上控制油缸动作的相应电磁阀、 排量控制阀以及发动 机速度控制输出装置, 在确定堵管故障时, 处理器 104首先向第一控制装 置 1062中的排量控制阀 (即主油泵的比例电磁阀 )发送排量控制信号, 控 制其进行排量变化操作。 若在进行排量变化操作后堵管故障没有消除, 则 继续实现油缸反泵操作, 即主油缸和摆缸换向交替顺序动作实现反泵操作, 并根据反馈状态由处理器 104判断下次动作信号; 第二控制装置 1064包括 高压油路上控制油缸动作的相应电磁阀、 控制主油泵的排量控制阀以及发 动机速度控制输出装置, 在接收到处理器 104 的动作信号后, 实现高压泵 送操作。 在第二控制装置 1064启用后, 首先进行高压确认功能, 确认完毕 后, 进行一次高压泵送操作, 即主油缸和摆缸换向交替顺序动作实现高压 泵送操作, 并根据反馈状态由处理器 104判断下次动作信号。
在本实施例中, 处理器 104可采用工程机械三一专用运动控制器, 如 图 3所示, 主系统压力传感器 P1安装在泵送系统上、压力传感器 P2 和 P3 安装在主油缸上, 采集主油缸压力, 以及换向采集仪 S1和 S2安装在输送 缸上, 采集换向周期。
另一方面, 本发明实施例还提供了一种泵车, 该泵车包括如上述任一 技术方案中所描述的泵车疏导控制系统。
下面参考图 5和图 6来详细说明根据本发明的泵车疏导控制方法。 如图 5所示, 在步骤 402, 采集系统的泵送状态信息和出料高度信息, 其中, 泵送状态信息包括泵送系统压力、 主油缸压力、 换向周期。
在步骤 404, 对采集的信息进行计算处理, 调用数据库。 主系统压力的 影响因素与出料高度、 混凝土规格型号和排量等相关。 因此, 在设计泵送 压力阈值过程中, 综合考虑当前工作排量、 当前出料高度(由臂架姿态、 臂架长度和末端位置确定)等因素, 设定不同工况下对应的压力阈值或其 他状态阈值。 将采集的各信息量与根据系统当前状态从数据库中查找出的 相应阈值进行比较, 根据比较结果确定堵管故障。 在步骤 406, 在满足堵管条件时, 进入步骤 408 , 若不满足堵管条件, 则回到步骤 402。
在步骤 408, 判断是否满足一级预警条件, 若满足, 则进入步骤 410, 若不满足, 则进入步骤 409, 进行一级预警提示用户。 例如采用图像、 动画 来进行提示。
在步骤 410, 进行二级预警提示用户, 例如通过声音来进行提示。
在步骤 412, 判断是否进入自动模式, 若是, 则进入步骤 414, 若否, 则进入步骤 416。
在步骤 414, 自适应控制以抑制堵管, 消除故障, 使系统处于安全泵送 状态。 在步骤 416, 手动控制以抑制堵管, 消除故障, 使系统处于安全泵送 状态。 因此, 自适应控制抑制堵管功能包括两部分功能, 一是通过用户设 置可选为自动控制模式或手动控制模式; 二是在自动控制模式下, 增加用 户确认的第二控制功能即高压切换泵送功能。 具体地, 当用户设置为手动 模式时, 可相应根据预警提示进行相应操作或者人工经验解决故障; 当用 户设置为自动模式排除故障时, 处理器优先选用第一控制装置进行控制输 出, 在第一控制装置运行时, 会根据状态反馈, 适时调节控制时间、 排量、 发动机转速等; 若用户同时启动第二控制装置, 则在控制输出时, 优先选 用第一控制装置, 若在维持时间 t后(调用数据库阈值, 在不同工况下取值 不同), 故障仍无法消除, 则启动第二控制装置, 并且增加用户确认功能, 以免发生安全问题。
下面结合图 6说明根据本发明的一个实施例的疏导控制逻辑策略。 在步骤 502, 采集系统的泵送状态信息和当前出料高度、 当前排量, 其 中, 泵送状态信息包括主系统压力、 主油缸压力、 换向周期等, 臂架姿态 确定了出料高度。
在步骤 504,根据当前出料高度以及当前排量等信息从数据库中挑出相 应的泵送状态阈值。
在步骤 506,判断采集的主系统压力是否持续超出设定主系统压力阈值 P_M, 若是, 则进入步骤 508 , 若没有, 则回到步骤 502。
在步骤 508,判断采集的主油缸压力是否持续超出设定主油缸压力阈值 P_C, 若是, 则进入步骤 510, 若没有, 则进行预警并进行相应排堵操作, 然后回到步骤 502。
在步骤 510, 判断采集的换向周期是否持续超于设定换向周期阈值 T, 若是, 则控制输出, 排出故障后进入步骤 512, 系统处于安全泵送状态。 若 否, 则回到步骤 502。
应该理解, 可以不安装压力传感器或者角度传感器, 只通过换向周期 进行堵管故障判断与控制。
以上结合附图详细说明了根据本发明的技术方案, 可获得信息量化的 泵送状态, 使得操作手及时了解泵送运行状况; 根据控制策略可精确判断 是否发生堵管故障; 利用声音、 文字、 动画等功能进行故障分级预警提示; 通过自动 /手动两种模式选择故障解决控制方案,及时有效地解决堵管故障, 灵活性和可靠性得到极大提高。
以上所述仅为本发明的优选实施例而已, 并不用于限制本发明, 对于 本领域的技术人员来说, 本发明可以有各种更改和变化。 凡在本发明的精 神和原则之内, 所作的任何修改、 等同替换、 改进等, 均应包含在本发明 的保护范围之内。
工业实用性
本发明提供的一种泵车疏导控制系统、 泵车疏导控制方法和泵车, 能 够获得信息量化的泵送状态, 使得客户或操作手及时了解泵送运行状况; 能够根据控制策略可精确判断堵管发生故障; 能够利用声音、 文字、 动画 等功能进行故障分级预警提示; 能够通过自动 /手动两种模式选择故障解决 控制方案, 及时有效地解决堵管故障。 因此, 本发明具有工业实用性

Claims

权利要求书
1. 一种泵车疏导控制系统, 其特征在于, 包括: 出料高度采集单元 ( 101 )、 泵送状态采集单元( 102 )、 处理器( 104 )和控制元件( 106 ) , 其 中,
所述出料高度采集单元(101 )采集泵车的当前出料高度信息, 并将采 集的当前出料高度信息传送至所述处理器(104 );
所述泵送状态采集单元(102 )采集所述泵车的当前泵送状态信息, 并 将采集的当前泵送状态信息传送至所述处理器( 104 );
所述处理器(104 ), 预设有与出料高度相对应的泵送状态阀值, 根据 所述泵车的所述当前出料高度信息确定当前的泵送状态阀值, 并将所述当 前泵送状态信息与所述当前的泵送状态阈值进行比较, 在所述当前泵送状 态信息大于等于所述当前的泵送状态阈值时, 确定堵管故障, 向所述控制 元件 (106 )发送动作信号;
所述控制元件 (106 ), 连接至所述处理器( 104 ), 根据所述动作信号 执行相应操作, 以排除所述堵管故障。
2. 根据权利要求 1 所述的泵车疏导控制系统, 其特征在于, 所述泵 送状态采集单元(102 )采集的所述当前泵送状态信息为所述泵车的输送缸 的换向周期、 主油缸的压力、 泵送主系统的压力, 或者上述两种或两种以 上信息。
3. 根据权利要求 2所述的泵车疏导控制系统, 其特征在于, 当所述 当前泵送状态信息为泵车的输送缸的换向周期时, 所述泵送状态采集单元
( 102 ) 包括配置为采集所述输送缸的换向周期的换向采集仪; 当所述当前 泵送状态信息为主油缸的压力时, 所述泵送状态采集单元(102 ) 包括配置 为采集所述主油缸的压力的第一压力传感器; 当所述当前泵送状态信息为 泵送主系统的压力时, 所述泵送状态采集单元( 102 ) 包括配置为采集所述 泵送主系统的压力的第二压力传感器。
4. 根据权利要求 2所述的泵车疏导控制系统, 其特征在于, 在所述 当前泵送状态信息为所述泵车的输送缸的换向周期、 主油缸的压力和泵送 主系统的压力时, 所述处理器(104 )在判断出所述泵送主系统的压力持续 预定第一时间段大于等于所述泵送主系统的压力阈值时, 继续判断所述主 油缸的压力是否持续预定第二时间段大于等于所述主油缸的压力阈值, 若 没有大于等于所述主油缸的压力阈值, 则进行一级预警, 否则, 继续判断 所述输送缸的换向周期是否大于等于所述输送缸的换向周期阈值, 若大于 等于所述换向周期阈值, 则进行二级预警。
5. 根据权利要求 1至 4中任一项所述的泵车疏导控制系统, 其特征 在于, 所述出料高度采集单元(101 ) 包括配置为检测泵车各节臂架的转动 角度的角度传感器, 所述出料高度采集单元(101 )根据泵车各节臂架的转 动角度以及所述泵车各节臂架的长度获取所述泵车的所述当前出料高度信 息。
6. 一种泵车, 其特征在于, 设置有权利要求 1至 5中任一项所述的 泵车疏导控制系统。
7. 一种泵车疏导控制方法, 其特征在于, 包括以下步骤:
采集泵车的当前出料高度信息和当前泵送状态信息;
预设有与出料高度相对应的泵送状态阀值, 根据所述泵车的所述当前 出料高度信息确定当前的泵送状态阀值, 并将所述当前泵送状态信息与所 述当前的泵送状态阈值进行比较, 在所述当前泵送状态信息大于等于所述 当前的泵送状态阈值时, 确定堵管故障, 向控制元件发送动作信号;
所述控制元件根据所述动作信号执行相应操作, 以排除所述堵管故障。
8. 根据权利要求 7所述的泵车疏导控制方法, 其特征在于, 采集的 所述当前泵送状态信息为所述泵车的输送缸的换向周期、 主油缸的压力和 / 或泵送主系统的压力;
通过换向采集仪采集所述输送缸的换向周期, 通过第一压力传感器采 集所述主油缸的压力, 和 /或通过第二压力传感器采集所述泵送主系统的压 力。
9. 根据权利要求 8所述的泵车疏导控制方法, 其特征在于, 在所述 泵送状态信息为所述泵车的输送缸的换向周期和主油缸的压力和泵送主系 统的压力的情况下, 在判断出所述泵送主系统的压力持续预定第一时间段 大于等于所述泵送主系统的压力阈值时, 继续判断所述主油缸的压力是否 持续预定第二时间段大于等于所述主油缸的压力阈值, 若没有大于等于所 述主油缸的压力阈值, 则进行一级预警, 否则, 继续判断所述输送缸的换 向周期是否大于等于所述输送缸的换向周期阈值, 若大于等于所述换向周 期阈值, 则进行二级预警。
10. 根据权利要求 7至 9中任一项所述的泵车疏导控制方法, 其特征 在于, 所述采集泵车的当前出料高度信息具体为: 检测泵车各节臂架的转 动角度, 根据泵车各节臂架的转动角度以及所述泵车各节臂架的长度获取 所述泵车的所述当前出料高度信息。
PCT/CN2012/085847 2012-09-28 2012-12-04 泵车疏导控制系统、泵车疏导控制方法和泵车 WO2014048026A1 (zh)

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