WO2014167728A1 - 油圧シリンダのストローク動作診断支援装置及び油圧シリンダのストローク動作診断支援方法 - Google Patents
油圧シリンダのストローク動作診断支援装置及び油圧シリンダのストローク動作診断支援方法 Download PDFInfo
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- WO2014167728A1 WO2014167728A1 PCT/JP2013/061114 JP2013061114W WO2014167728A1 WO 2014167728 A1 WO2014167728 A1 WO 2014167728A1 JP 2013061114 W JP2013061114 W JP 2013061114W WO 2014167728 A1 WO2014167728 A1 WO 2014167728A1
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- Prior art keywords
- stroke
- hydraulic cylinder
- reset
- sensor
- cylinder
- Prior art date
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Classifications
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F9/00—Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
- E02F9/20—Drives; Control devices
- E02F9/22—Hydraulic or pneumatic drives
- E02F9/2264—Arrangements or adaptations of elements for hydraulic drives
- E02F9/2271—Actuators and supports therefor and protection therefor
-
- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F9/00—Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
- E02F9/20—Drives; Control devices
- E02F9/22—Hydraulic or pneumatic drives
- E02F9/2278—Hydraulic circuits
- E02F9/2296—Systems with a variable displacement pump
-
- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F9/00—Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
- E02F9/26—Indicating devices
- E02F9/264—Sensors and their calibration for indicating the position of the work tool
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B15/00—Fluid-actuated devices for displacing a member from one position to another; Gearing associated therewith
- F15B15/20—Other details, e.g. assembly with regulating devices
- F15B15/28—Means for indicating the position, e.g. end of stroke
- F15B15/2807—Position switches, i.e. means for sensing of discrete positions only, e.g. limit switches
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B15/00—Fluid-actuated devices for displacing a member from one position to another; Gearing associated therewith
- F15B15/20—Other details, e.g. assembly with regulating devices
- F15B15/28—Means for indicating the position, e.g. end of stroke
- F15B15/2815—Position sensing, i.e. means for continuous measurement of position, e.g. LVDT
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B19/00—Testing; Calibrating; Fault detection or monitoring; Simulation or modelling of fluid-pressure systems or apparatus not otherwise provided for
- F15B19/002—Calibrating
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B7/00—Measuring arrangements characterised by the use of electric or magnetic techniques
- G01B7/003—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring position, not involving coordinate determination
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D3/00—Indicating or recording apparatus with provision for the special purposes referred to in the subgroups
- G01D3/08—Indicating or recording apparatus with provision for the special purposes referred to in the subgroups with provision for safeguarding the apparatus, e.g. against abnormal operation, against breakdown
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
- G01D5/12—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means
- G01D5/14—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing the magnitude of a current or voltage
- G01D5/142—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing the magnitude of a current or voltage using Hall-effect devices
- G01D5/145—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing the magnitude of a current or voltage using Hall-effect devices influenced by the relative movement between the Hall device and magnetic fields
Definitions
- the present invention relates to a stroke motion diagnosis support device for a hydraulic cylinder and a stroke motion diagnosis support method for a hydraulic cylinder.
- a hydraulic excavator which is one of the work machines, has a traveling body, an upper revolving body that can swivel on the traveling body, and a work machine on the upper revolving body.
- the work machine includes a boom that is pivotally supported at one end on the base, an arm that is pivotally supported at the other end of the boom, and an attachment that is pivotally supported at the other end of the arm.
- the boom, arm, and attachment are driven by a hydraulic cylinder. In order to detect the position / posture of the work implement, the stroke of the hydraulic cylinder is measured.
- Patent Document 1 discloses a hydraulic excavator including a position sensor that detects a piston stroke position of a hydraulic cylinder that drives a working machine by rotation of a rotating roller on a cylinder rod. Since a minute slip occurs between the rotating roller and the cylinder rod, an error occurs between the stroke position obtained from the detection result of the position sensor and the actual stroke position. Therefore, in order to calibrate the stroke position obtained from the detection result of the position sensor at the reference position, a magnetic force sensor as a reset sensor is provided at the reference position on the outer surface of the cylinder tube of the hydraulic cylinder. The stroke position detected by the position sensor every time the piston passes the reference position during work is calibrated to enable accurate position measurement.
- the hydraulic cylinder described above has a stroke sensor (position sensor) and a reset sensor for calibrating the measurement error of the stroke sensor, so that the stroke length of the hydraulic cylinder is obtained with high accuracy.
- the stroke operation diagnosis of the hydraulic cylinder cannot be easily performed.
- the serviceman diagnoses the operating state of the stroke sensor or reset sensor. It was necessary to carry and measure.
- the service person can perform an electrical inspection such as detection of disconnection occurring in the stroke sensor, the reset sensor, etc. For example, detection of abnormalities that occur mechanically such as slippage of the stroke sensor etc. It was difficult.
- Patent Document 2 describes that a change in cylinder stroke position corresponding to a detent release position of a detent function for holding a work machine operation lever at a predetermined operation stroke position is displayed on a monitor screen.
- the present invention has been made in view of the above, and provides a hydraulic cylinder stroke operation diagnosis support apparatus and a hydraulic cylinder stroke operation diagnosis support method that can easily perform the hydraulic cylinder stroke operation diagnosis support. With the goal.
- a hydraulic cylinder stroke motion diagnosis support apparatus includes a movable part that is supported so as to be sequentially rotatable with respect to a vehicle body, and the vehicle body.
- a hydraulic cylinder disposed between or between the movable parts and rotatably supporting the movable part, a stroke sensor disposed on the hydraulic cylinder and measuring a stroke length of the hydraulic cylinder, and the stroke sensor
- a reset sensor for measuring a reset reference point for resetting the measurement value of the stroke length
- a stroke end detection processing unit for detecting a stroke end position of the hydraulic cylinder, and detecting the reset reference point and / or the stroke end position.
- the monitor displays a correction value calculated by the calibration processing unit.
- the monitor displays a plurality of correction values that are continuous in time series.
- the reset sensor is a rotary encoder that measures a rotation angle of the movable part, and the reset reference point is other than the stroke end. This is an intermediate reset position.
- the reset sensor is disposed on an outer periphery of a cylinder tube of the hydraulic cylinder, and is disposed on a piston at a rod tip of the hydraulic cylinder.
- the magnetic force sensor detects a magnet, and the reset reference point is an intermediate reset position other than the stroke end.
- the stroke operation diagnosis support method for a hydraulic cylinder includes a reset by a reset sensor to calibrate the stroke length when measuring the stroke length of the hydraulic cylinder by a stroke sensor disposed in the hydraulic cylinder.
- a screen for detecting a reference point and / or a stroke end position of the hydraulic cylinder, a measurement value of the stroke length by the stroke sensor, and a calibration state of the stroke length based on the detection result of the detection step And a display step for displaying.
- the stroke operation diagnosis support of the hydraulic cylinder can be performed easily and easily. it can.
- FIG. 1 is a perspective view showing an overall configuration of a hydraulic excavator that is an example of a work machine to which a hydraulic cylinder according to an embodiment of the present invention is applied.
- FIG. 2 is a block diagram showing an overall circuit configuration of a hydraulic excavator including the hydraulic cylinder stroke motion diagnosis support apparatus shown in FIG.
- FIG. 3 is a schematic diagram showing an arrangement configuration of the stroke sensor with respect to the hydraulic cylinder.
- FIG. 4 is a schematic diagram showing a schematic configuration and operation of the stroke sensor.
- FIG. 5 is a schematic diagram showing a schematic configuration of a rotary encoder that is a reset sensor.
- FIG. 6 is a schematic diagram showing the lifted state of the boom of the excavator.
- FIG. 1 is a perspective view showing an overall configuration of a hydraulic excavator that is an example of a work machine to which a hydraulic cylinder according to an embodiment of the present invention is applied.
- FIG. 2 is a block diagram showing an overall circuit configuration of a hydraulic exc
- FIG. 7 is a schematic diagram illustrating the stroke length of the hydraulic cylinder and the stroke length calibration process.
- FIG. 8 is a schematic diagram showing a schematic configuration and operation of a magnetic sensor that is a reset sensor.
- FIG. 9 is a flowchart showing a calibration prohibition process control procedure at the time of power activation.
- FIG. 10 is a diagram showing an example of the stroke motion diagnosis support screen of the first embodiment displayed on the display unit of the standard monitor.
- FIG. 11 is a flowchart showing the display processing procedure of the display unit of the standard monitor.
- FIG. 12 is an explanatory diagram for explaining the operation of the working machine when performing the calibration process on the boom cylinder.
- FIG. 12 is an explanatory diagram for explaining the operation of the working machine when performing the calibration process on the boom cylinder.
- FIG. 13 is a flowchart showing the display processing procedure of the stroke initial calibration work support screen of the second embodiment displayed on the display unit of the HMI monitor.
- FIG. 14A is a diagram illustrating an example of the stroke initial calibration work support screen of the second embodiment displayed on the display unit of the HMI monitor.
- FIG. 14B is a diagram illustrating an example of a stroke initial calibration work support screen of the second embodiment displayed on the display unit of the HMI monitor.
- FIG. 14C is a diagram illustrating an example of the stroke initial calibration work support screen of the second embodiment displayed on the display unit of the HMI monitor.
- FIG. 14-4 is a diagram illustrating an example of a stroke initial calibration work support screen according to the second embodiment displayed on the display unit of the HMI monitor.
- FIG. 14A is a diagram illustrating an example of the stroke initial calibration work support screen of the second embodiment displayed on the display unit of the HMI monitor.
- FIG. 14B is a diagram illustrating an example of a stroke initial calibration work support screen of the second embodiment displayed on
- FIG. 14-5 is a diagram showing an example of the stroke initial calibration work support screen of the second embodiment displayed on the display unit of the HMI monitor.
- FIG. 14-6 is a diagram illustrating an example of the stroke initial calibration work support screen according to the second embodiment displayed on the display unit of the HMI monitor.
- FIG. 14-7 is a diagram showing an example of the stroke initial calibration work support screen of the second embodiment displayed on the display unit of the HMI monitor.
- FIG. 14-8 is a diagram showing an example of the stroke initial calibration work support screen of the second embodiment displayed on the display unit of the HMI monitor.
- FIG. 14-9 is a diagram showing an example of the stroke initial calibration work support screen of the second embodiment displayed on the display unit of the HMI monitor.
- FIG. 14-10 is a diagram showing an example of the stroke initial calibration work support screen of the second embodiment displayed on the display unit of the HMI monitor.
- the hydraulic excavator 1 includes a lower traveling body 2, an upper swing body 3, and a work implement 4.
- the lower traveling body 2 is configured to be capable of self-running when a pair of left and right crawler belts 2a rotate.
- the upper turning body 3 is installed on the lower traveling body 2 so as to be turnable.
- the work machine 4 is pivotally supported on the front side of the upper swing body 3 so as to be raised and lowered.
- the work machine 4 includes a boom 4a, an arm 4b, and a bucket 4c as an example of an attachment, and a hydraulic cylinder (bucket cylinder 4d, arm cylinder 4e, boom cylinder 4f).
- the vehicle body 1a is mainly composed of a lower traveling body 2 and an upper turning body 3.
- the upper swing body 3 has a cab 5 on the front left side (front side of the vehicle) and an engine room 6 for accommodating the engine and a counterweight 7 on the rear side (rear side of the vehicle).
- a driver's seat 8 for an operator to sit on is disposed in the cab 5.
- a plurality of antennas 9 are installed on both the left and right sides of the upper surface on the rear side of the upper swing body 3.
- the front, rear, left, and right sides of the vehicle are based on an operator seated in the driver's seat 8 disposed in the cab 5.
- the boom 4a, the arm 4b, and the bucket 4c are sequentially supported with respect to the vehicle main body 1a so that the boom 4a, the arm 4b, and the bucket 4c can be rotated. .
- the rotary encoder 20 is attached to the boom 4a.
- the rotary encoder 20 is also attached to the vehicle body as will be described later.
- the rotation of the arm 4b with respect to the boom 4a is transmitted to the rotary encoder 20 attached to the boom 4a via a lever that is pivotally supported on the arm 4b.
- the rotary encoder 20 outputs a pulse signal corresponding to the rotation angle of the arm 4b.
- the rotation of the boom 4a with respect to the vehicle main body 1a is transmitted to the rotary encoder 20 attached to the vehicle main body 1a via a pivotal lever on the boom 4a.
- the rotary encoder 20 outputs a pulse signal corresponding to the rotation angle of the boom 4a.
- FIG. 2 is a block diagram showing an overall circuit configuration of a hydraulic excavator including the hydraulic cylinder stroke motion diagnosis support apparatus shown in FIG.
- description will be given focusing on the boom cylinder among the hydraulic cylinders.
- operation diagnosis is similarly performed for the arm cylinder 4e and the bucket cylinder 4d other than the boom cylinder 4f.
- an electric signal is input to the main controller 32 from the electric operation lever device 101.
- the boom cylinder 4f is driven by supplying a control electric signal from the main controller 32 to the control valve 102 of the boom cylinder 4f.
- the work machine 4 is provided with a boom 4a, an arm 4b, and a bucket 4c.
- a boom cylinder 4f, an arm cylinder 4e, and a bucket cylinder 4d corresponding to the boom 4a the boom 4a.
- Each of the arm 4b and the bucket 4c is operated.
- the boom cylinder 4f is driven using, for example, a variable displacement hydraulic pump 103 as a drive source.
- the hydraulic pump 103 is driven by the engine 3a.
- the swash plate 103 a of the hydraulic pump 103 is driven by the servo mechanism 104.
- the servo mechanism 104 operates according to a control signal (electric signal) output from the main controller 32, and the swash plate 103a of the hydraulic pump 103 is changed to a position corresponding to the control signal.
- the engine drive mechanism 105 of the engine 3a operates in accordance with a control signal (electric signal) output from the main controller 32, and the engine 3a rotates at a rotational speed corresponding to the control signal.
- the discharge port of the hydraulic pump 103 communicates with the control valve 102 via the discharge oil passage 106.
- the control valve 102 communicates with the cap side oil chamber 40B and the rod side oil chamber 40H of the boom cylinder 4f via oil passages 107 and 108.
- the hydraulic oil discharged from the hydraulic pump 103 is supplied to the control valve 102 via the discharge oil passage 106.
- the hydraulic oil that has passed through the control valve 102 is supplied to the cap side oil chamber 40B or the rod side oil chamber 40H of the boom cylinder 4f via the oil passage 107 or the oil passage 108.
- the stroke sensor 10 is attached to the boom cylinder 4f.
- the stroke sensor 10 measures the stroke of the piston.
- a rotary encoder 20 that functions as a reset sensor is attached to a portion that pivotally supports one end of the boom 4a of the vehicle body 1a.
- the rotary encoder 20 detects the rotation angle of the boom 4a and outputs a pulse signal according to the rotation angle.
- the stroke sensor 10 and the rotary encoder 20 are each connected to a measurement controller 30.
- the battery 109 is a power source that activates the main controller 32.
- a measurement controller 30, a standard monitor 31, and an HMI (Human Machine Interface) monitor 33 as a guidance monitor for computerized construction are electrically connected to the battery 109.
- the main controller 32 is electrically connected to the battery 109 via the engine key switch 110.
- the battery 109 When the engine key switch 110 is turned on, the battery 109 is electrically connected to a starting motor (not shown) of the engine 3a to start the engine 3a, and the battery 109 is electrically connected to the main controller 32. And the main controller 32 is activated. When the engine key switch 110 is turned off, the electrical connection between the main controller 32 and the battery 109 is cut off, the engine 3a is stopped, and the main controller 32 stops starting.
- the main controller 32, the measurement controller 30, the standard monitor 31, the HMI monitor 33, and the position information detection device 19 are connected to each other via a network N in the vehicle.
- a switch state signal indicating the switch state (ON, OFF) of the engine key switch 110 is input from the main controller 32 to the measurement controller 30, the standard monitor 31, and the HMI monitor 33 via the network N.
- the switch state signal input to the measurement controller 30, the standard monitor 31, and the HMI monitor 33 is on, the measurement controller 30, the standard monitor 31, and the HMI monitor 33 are activated, and the switch state signal is When turned off, the measurement controller 30, the standard monitor 31, and the HMI monitor 33 are activated and stopped.
- the operation lever devices 101R and 101L include, for example, operation levers 101Ra and 101La provided in the cab 5, and detection units 101Rb and 101Lb that detect operation signals indicating operation directions and operation amounts of the operation levers 101Ra and 101La, respectively. Have.
- the operation signals detected by the detection units 101Rb and 101Lb are input to the main controller 32.
- the control valve 102 is connected to the main controller 32 via an electric signal line.
- the operating lever devices 101R and 101L are a pair of left and right levers.
- the operation lever device 101R operates the boom 4a and the bucket 4c, and the operation lever device 101L operates to turn the arm 4b and the upper swing body 3. Note that the swing actuator of the upper swing body 3 is not shown.
- an operation signal of the operation lever 101Ra is input to the main controller 32, and a control signal for operating the control valve 102 by the main controller 32 is generated.
- This control signal is supplied from the main controller 32 to the control valve 102 via the electric signal line, and the valve position of the control valve 102 is changed.
- This hydraulic cylinder stroke operation diagnosis support apparatus includes a hydraulic cylinder (bucket cylinder 4d, arm cylinder 4e, boom cylinder 4f), a measurement controller 30, a standard monitor 31, an HMI monitor 33, and a main controller 32. .
- a stroke sensor 10 that detects the stroke amount of the hydraulic cylinder as a rotation amount is attached to each of the arm cylinder 4e and the boom cylinder 4f. Moreover, the stroke sensor 10 and the magnetic force sensor 20a are attached to the bucket cylinder 4d.
- a rotary encoder 20 that outputs a pulse signal according to the amount of rotation (angle) of the arm 4b and the boom 4a is attached to a portion that supports the rotation shaft of the arm 4b and the boom 4a.
- This pulse signal is a rectangular wave.
- the stroke sensor 10, the rotary encoder 20, and the magnetic force sensor 20a are electrically connected to the measurement controller 30.
- the measurement controller 30 includes a calibration processing unit 30b.
- the calibration processing unit 30b calibrates the stroke lengths measured by the stroke sensors 10 of the bucket cylinder 4d, arm cylinder 4e, and boom cylinder 4f based on the detection signals of the stroke sensor 10, the rotary encoder 20, and the magnetic force sensor 20a. That is, the stroke lengths measured by the stroke sensors 10 of the bucket cylinder 4d and the arm cylinder 4e are calibrated based on the measurement results of the corresponding rotary encoders 20, respectively. Further, the stroke length measured by the stroke sensor 10 of the bucket cylinder 4d is calibrated based on the measurement result of the magnetic sensor 20a functioning as a reset sensor.
- the measurement controller 30 calculates the position / posture of the bucket 4c based on the measured stroke length of each hydraulic cylinder.
- the measurement controller 30 has a stroke end detection processing unit 30a.
- the stroke end detection processing unit 30a detects whether or not the piston has reached the stroke end, that is, the maximum stroke position or the minimum stroke position.
- the operation levers 101Ra and 101La are in an operating state
- the stroke position measured by the stroke sensor 10 is within, for example, 3 mm from the preset stroke end position
- the moving speed of the piston is It is determined that the piston has reached the stroke end when the three conditions of the minute movement amount, for example, ⁇ 3 mm / sec or less are satisfied.
- the moving speed of the piston is obtained by time differentiation of the stroke position detected by the stroke sensor 10.
- Whether or not the stroke end has been reached may be based on the condition that the discharge pressure of the hydraulic pump 103 is acquired and the relief state exceeds a predetermined pressure.
- the calibration processing unit 30b resets the stroke length even when the piston reaches the stroke end in addition to the stroke length reset by the rotary encoder 20 and the magnetic force sensor 20a which are the reset sensors described above. .
- the measurement controller 30 has a malfunction detection processing unit 30c.
- the malfunction detection processing unit 30c When the measured stroke length exceeds a predetermined value larger than the stroke range defined by the minimum stroke end position and the maximum stroke end position, the malfunction detection processing unit 30c outputs an error indicating that the stroke is abnormal.
- the standard monitor 31 includes a calculation unit 31a, a display unit 31b, an operation unit 31c, a notification unit 31d, and a calibration invalid setting unit 31e.
- the calculation unit 31a communicates with the main controller 32 and the measurement controller 30 to acquire various types of information, displays the acquired various types of information on the display screen of the display unit 31b, and various instructions input from the operation unit 31c. Information is output to the display unit 31b and other controllers.
- the notification unit 31d is configured by a buzzer or the like, and outputs a sound or the like when an alarm such as an error is required.
- the calibration invalidity setting unit 31e sets the validity / invalidity of reset processing by a reset sensor, which will be described later.
- the display unit 31b may be a touch panel that also serves as the operation unit 31c.
- the HMI monitor 33 includes a calculation unit 33a, a display unit 33b, an operation unit 33c, a notification unit 33d, and a highlight display processing unit 33e.
- the calculation unit 33a communicates with the main controller 32 and the measurement controller 30 to acquire various types of information, displays the acquired various types of information on the display screen of the display unit 33b, and displays various instructions input from the operation unit 33c. Information is output to the display unit 33b and other controllers.
- the notification unit 33d is configured by a buzzer or the like, and outputs a sound or the like when a warning such as an error is required.
- the display unit 33b is configured by a touch panel that also serves as the operation unit 33c, but may be configured separately.
- the HMI monitor 33 supports an initial calibration work by changing a stroke initial work support screen described later.
- the position information detection device 19 calculates the position and orientation of the excavator 1 based on the position information acquired via the antenna 9, and transmits the result to the main controller 32 and the HMI monitor 33 for information processing. Construction processing is possible.
- the boom cylinder 4f includes a cylinder tube 4X and a cylinder rod 4Y that can move relative to the cylinder tube 4X in the cylinder tube 4X.
- a piston 4V is slidably provided on the cylinder tube 4X.
- a cylinder rod 4Y is attached to the piston 4V.
- the cylinder rod 4Y is slidably provided on the cylinder head 4W.
- a chamber defined by the cylinder head 4W, the piston 4V, and the cylinder inner wall is a rod-side oil chamber 40H.
- An oil chamber opposite to the rod-side oil chamber 40H via the piston 4V is a cap-side oil chamber 40B.
- the cylinder head 4W is provided with a seal member that seals the gap with the cylinder rod 4Y and prevents dust and the like from entering the rod-side oil chamber 40H.
- the cylinder rod 4Y is degenerated when hydraulic oil is supplied to the rod-side oil chamber 40H and discharged from the cap-side oil chamber 40B. Further, the cylinder rod 4Y extends when the hydraulic oil is discharged from the rod side oil chamber 40H and the hydraulic oil is supplied to the cap side oil chamber 40B. That is, the cylinder rod 4Y moves linearly in the left-right direction in the figure.
- a case 14 that covers the stroke sensor 10 and accommodates the stroke sensor 10 inside is provided outside the rod-side oil chamber 40H and in close contact with the cylinder head 4W.
- the case 14 is fastened to the cylinder head 4W by a bolt or the like and fixed to the cylinder head 4W.
- the stroke sensor 10 includes a rotating roller 11, a rotation center shaft 12, and a rotation sensor unit 13.
- the surface of the rotating roller 11 is in contact with the surface of the cylinder rod 4Y and is rotatably provided according to the direct movement of the cylinder rod 4Y. That is, the linear motion of the cylinder rod 4Y is converted into rotational motion by the rotating roller 11.
- the rotation center shaft 12 is disposed so as to be orthogonal to the linear movement direction of the cylinder rod 4Y.
- the rotation sensor unit 13 is configured to detect the rotation amount (rotation angle) of the rotation roller 11 as an electrical signal.
- a signal indicating the rotation amount (rotation angle) of the rotation roller 11 detected by the rotation sensor unit 13 is sent to the measurement controller 30 via the electric signal line, and the cylinder rod of the boom cylinder 4f is measured by the measurement controller 30. It is converted to a 4Y position (stroke position).
- the rotation sensor unit 13 has a magnet 13a and a Hall IC 13b.
- a magnet 13 a that is a detection medium is attached to the rotating roller 11 so as to rotate integrally with the rotating roller 11.
- the magnet 13 a rotates in accordance with the rotation of the rotating roller 11 around the rotation center axis 12.
- the magnet 13 a is configured such that the N pole and the S pole are alternately switched according to the rotation angle of the rotating roller 11.
- the magnet 13a is configured such that the magnetic force (magnetic flux density) detected by the Hall IC 13b periodically varies with one rotation of the rotating roller 11 as one cycle.
- the Hall IC 13b is a magnetic sensor that detects the magnetic force (magnetic flux density) generated by the magnet 13a as an electrical signal.
- the Hall IC 13b is provided at a position separated from the magnet 13a by a predetermined distance along the axial direction of the rotation center shaft 12.
- the electrical signal detected by the Hall IC 13b is sent to the measurement controller 30, and the electrical signal of the Hall IC 13b is converted into the rotation amount of the rotating roller 11, that is, the displacement amount of the cylinder rod 4Y of the boom cylinder 4f. Converted to (stroke length). Specifically, the amount of linear movement of the cylinder rod 4Y when the rotation roller 11 makes one rotation is calculated as 2 ⁇ d using the rotation radius d of the rotation roller 11.
- the rotation angle of the rotating roller 11 and the electrical signal (voltage) detected by the Hall IC 13b will be described.
- the magnetic force (magnetic flux density) transmitted through the Hall IC 13b changes periodically according to the rotation angle, and an electric signal (voltage) that is a sensor output. Changes periodically.
- the rotation angle of the rotating roller 11 can be measured from the magnitude of the voltage output from the Hall IC 13b.
- the number of rotations of the rotating roller 11 can be measured by counting the number of times one cycle of the electrical signal (voltage) output from the Hall IC 13b is repeated. Then, based on the rotation angle of the rotation roller 11 and the rotation speed of the rotation roller 11, the displacement amount (stroke length) of the cylinder rod 4Y of the boom cylinder 4f is measured.
- the rotary encoder 20 includes a disk part 25, a light emitting part 26, and a light receiving part 27.
- the light emitting part 26 and the light receiving part 27 are arranged so as to sandwich the disk part 25.
- the light emitting unit 26 includes a light emitting element that emits light to the light receiving unit 27.
- the light receiving unit 27 includes four light receiving elements 27 a that can receive light emitted from the light emitting unit 26.
- the four light receiving elements 27a have the same width W, and are arranged in an arc continuously in series.
- the light receiving element 27a converts the received light quantity into an electrical signal.
- a plurality of first transmission parts 25 a that transmit light emitted from the light emitting part 26 to the light receiving part 27 are arranged in the disk part 25.
- the first transmission part 25a is a substantially rectangular slit extending in the radial direction having a circumferential width of 2W, and is arranged in the vicinity of the outer periphery of the disk part 25 in an annular shape parallel to the outer periphery at an interval of 2W.
- a single transmission part 25b is arranged on the inner periphery of the ring formed by the first transmission part 25a.
- the transmission part 25b is a substantially rectangular slit extending in the radial direction.
- the disk part 25 rotates in synchronization with the rotation of the boom 4a relative to the vehicle body 1a.
- the four light receiving elements 27a each output an electrical signal according to the amount of light transmitted through the first and second transmission parts 25a and 25b by the rotation of the disk part 25.
- the light receiving unit 27 corresponds to the amount of light transmitted through the first and second transmission units 25a and 25b, and is separated from the first and third light receiving elements 27a connected in series, and the second and fourth light receiving units.
- the electric signal output from the element 27a is converted into a pulse signal.
- the light receiving unit 27 outputs the converted pulse signal to the measurement controller 30.
- the reason why the electrical signals from the two light receiving elements 27a are used to generate one pulse signal is to improve the robustness of the sensor against external light or the like.
- the light receiving portion 27 when the light receiving element 27a outputs an electric signal based on the light transmitted through the transmitting portion 25b, the light receiving portion 27 outputs a corresponding pulse signal. That is, the light receiving unit 27 outputs three pulse signals generated according to the rotation angle of the disk unit 25. Since the rotation angle of the disk portion 25 is the same as the rotation angle of the boom 4a, the pulse signal is output according to the rotation angle of the boom cylinder 4f.
- the rotary encoder 20 is an incremental type, and passes through the transmission part 25b by one rotation of the disk part 25 and the A-phase pulse signal, the B-phase pulse signal different from the A phase by 90 °. And a Z-phase pulse signal (reference pulse signal) that is generated once.
- the measurement controller 30 counts the rise and fall changes of the A-phase and B-phase pulse signals. The count number is proportional to the amount of rotation of the boom cylinder 4f.
- the measurement controller 30 determines the rotation direction of the boom 4a from the phase difference between the A phase and the B phase. Further, the reference position of the rotation of the boom 4a is measured by the Z-phase pulse signal, and the count number is cleared.
- the approximate center of the pivotable angle range of the boom 4a is set as the reference position.
- the measurement controller 30 monitors the count value of the rotary encoder 20, stores an arbitrary number of strokes for each preset count value, and sets the average value as a reset reference point (intermediate reset position) as a set reference position. ).
- the Z-phase pulse signal is output when the light transmitted through the transmission part 25 a corresponding to the Z-phase is blocked by the disk part 25. That is, the Z-phase pulse signal is detected when the pulse signal falls.
- the rotary encoder 20 outputs a Z-phase pulse signal at an approximately central angle in the pivotable angle range of the boom 4a. That is, the rotary encoder 20 outputs a Z-phase pulse signal at substantially the center of the stroke area of the boom cylinder 4f.
- the intermediate reset position of the rotary encoder 20 is as described above, but any position other than the stroke end of the hydraulic cylinder may be used as the intermediate reset position.
- a minute slip occurs between the rotating roller 11 of the stroke sensor 10 and the cylinder rod 4Y.
- a large slip occurs.
- This slip causes an error (cumulative error due to slip) between the stroke measurement position of the cylinder rod 4Y obtained from the detection result of the stroke sensor 10 and the actual position of the cylinder rod 4Y. Therefore, in order to calibrate the stroke measurement value obtained from the detection result of the stroke sensor 10, a rotary encoder 20 as a reset sensor is provided.
- the rotary roller 11 and the rotary encoder 20 are connected to a measurement controller 30, and the measurement controller 30 calibrates the stroke length measured by the stroke sensor 10 based on the pulse signal output from the rotary encoder 20.
- the boom 4a rises.
- the stroke length of the boom cylinder 4f at this time is measured by the stroke sensor 10.
- the rotary encoder 20 as the boom 4a is raised, the boom 4a rotates with respect to the vehicle body 1a, so that the disk portion 25 rotates.
- the light receiving unit 27 receives light emitted from the light emitting unit 26 that has passed through the transmitting units 25 a and 25 b of the disk unit 25.
- a pulse signal corresponding to the rotation angle of the disk portion 25 is output from the light receiving portion 27.
- the light receiving unit 27 outputs A-phase, B-phase, and Z-phase pulse signals, respectively.
- the Z-phase pulse signal is associated with a reference angle that is a predetermined rotation angle of the boom 4a, and is output when the boom 4a comes to the position of the reference angle.
- the measurement controller 30 stores a reference stroke length L2 at the time of initial calibration.
- the initial calibration is to obtain and store the reference stroke length L2 when the hydraulic excavator 1 is shipped from the factory or when the rotary encoder 20 or the magnetic sensor 20a, which is a reset sensor, is replaced.
- the measurement controller 30 first detects a boom corresponding to a count value of a predetermined integer number of times (here, every multiple of -2) of the rotary encoder 20 after detection of the falling edge of the Z-phase pulse.
- the stroke lengths L2-1 to L2-3 of the cylinder 4f are stored, and the average value is stored as the reference stroke length L2.
- L0 indicates a change in stroke length at the time of initial calibration
- LA indicates a change in stroke length other than the initial calibration
- LP indicates a change in count value of the rotary encoder 20. .
- the measurement controller 30 corresponds to a predetermined integer number (here, every multiple of 2) of the rotary encoder 20 when detecting a Z-phase pulse signal during the normal operation of the boom cylinder 4f.
- the extension of the stroke length L1-1 to L1-3 of the boom cylinder 4f to be detected is detected.
- the measurement controller 30 stores the stroke lengths L1-1 to L1-3 measured a predetermined number of times, and stores the average value as the measurement stroke length L1.
- the measurement controller 30 stores a reference stroke length L2 for a predetermined integer number of counts of the rotary encoder 20 which is calculated and stored by the initial calibration.
- the measurement controller 30 calculates a difference L3 between the measurement stroke length L1 detected during the normal operation other than the initial calibration and the reference stroke length L2 detected during the initial calibration.
- the measurement controller 30 calibrates the measurement value of the stroke sensor 10 using the difference L3 when stopping after detecting the Z-phase pulse signal and measuring it by the normal operation of the boom cylinder 4f.
- the measurement controller 30 detects that the boom 4a has reached the reference rotation angle by the fall of the Z phase of the rotary encoder 20, and then detects a rotation of a predetermined angle from the rotation angle.
- the stroke length of the boom cylinder 4f in the meantime is stored a predetermined number of times, and the average value (measured stroke length L1) is stored. Further, the measured measurement stroke length L1 is compared with a reference stroke length L2 serving as a reference stored in advance in the initial calibration to calculate a deviation (difference L3). And when the boom 4a stops, the calibration process which incorporates the deviation into a measured value is performed.
- the magnetic force sensor 20a is attached to the outside of the cylinder tube 4X.
- the magnetic force sensor 20a has two magnetic force sensors 61 and 62 that are spaced apart from each other by a predetermined distance along the linear movement direction of the piston 4V.
- the magnetic sensors 61 and 62 are provided at a known intermediate reset position (origin position).
- the piston 4V is provided with a magnet 63 that generates magnetic lines of force.
- the magnetic force sensors 61 and 62 transmit the magnetic force lines generated by the magnet 63, detect the magnetic force (magnetic flux density), and output an electric signal (voltage) corresponding to the magnetic force (magnetic flux density). Signals detected by the magnetic force sensors 61 and 62 are sent to the measurement controller 30.
- the measurement controller 30 performs calibration to reset the stroke position obtained from the detection result of the stroke sensor 10 to the intermediate reset position (origin position) based on the change in the detection result of the magnetic force sensors 61 and 62.
- This calibration content is the same as the calibration by the rotary encoder 20.
- the stroke length may change due to the weight of the work implement unless the work implement is brought into a stable posture in a device power loss state in which the stroke length is not detected (power is not supplied to the main controller 30). In this case, a deviation occurs between the actual stroke length of the hydraulic cylinder and the measured stroke length measured immediately after the device power supply is lost.
- the malfunction detection processing unit 30c warns that an error has occurred with a buzzer, etc. It will give an obstacle.
- the measurement controller 30 controls to prohibit the stroke length calibration process until it passes through the intermediate reset position of the reset sensor and resets. In other words, a deviation between the actual stroke length and the last measured stroke length is allowed until it passes through the intermediate reset position of the reset sensor, so that an error occurrence warning is not performed.
- the measurement controller 30 determines whether or not the power supply is activated (step S101).
- the initial stroke length (initial count value by the rotary encoder 20) is set to a value outside the measurement measurement range (step S102).
- the measurement controller 30 determines whether or not the intermediate reset position has been passed (step S103). If the intermediate reset position has not been passed (No at Step S103), the malfunction detection processing unit 30c does not output an error even though the stroke length is outside the measurement measurement range (Step S104), and Step S103. Repeat the determination process.
- step S105 it is further determined whether or not the measurement stroke length (count value) is outside the measurement measurement range (step S105). If the measurement stroke length is outside the measurement measurement range (step S105, Yes), for example, an error is output from the notification unit 31d (step S106), and the determination process of step S105 is repeated. On the other hand, when the measurement stroke length is not outside the measurement measurement range (step S105, No), this determination process is repeated.
- the measurement controller 30 described above stores a predetermined number of strokes based on the count values for the A-phase, B-phase, and Z-phase of the rotary encoder 20, and the reference stroke length L2 and the measurement stroke length are calculated based on the average value. L1 is calculated.
- the count value immediately after the power-on of the measurement controller 30 is unknown until it passes through the Z phase and is cleared to zero. Therefore, it is necessary to calibrate the stroke using the count value after passing through the Z phase of the rotary encoder 20 immediately after the measurement controller 30 is powered on.
- the measurement controller 30 stores in advance an initial count value when the rotary encoder 20 is activated. This initial count value is set to a large value of 9000, for example, when the count value of the measurement measurement range of the rotary encoder 20 is ⁇ 3000.
- FIG. 10 shows an example of a stroke motion diagnosis support screen displayed on the display unit 31b.
- a stroke operation diagnosis support screen shown in FIG. 10 when a service menu, an inspection menu, and a cylinder inspection are sequentially selected from the initial screen, a selection menu for a boom cylinder, an arm cylinder, and a bucket cylinder is displayed. It is a screen.
- the distance between cylinder pins calculated based on the measurement result of the stroke sensor 10 is displayed in real time.
- the distance between the cylinder pins means that the cylinder tube 4X shown in FIG. 7 is rotatably attached to the mounting pin PA on the minimum stroke end side that is attached to the vehicle body 1a and the boom cylinder 4f that is a movable part. This is the distance from the maximum stroke end side mounting pin PB provided at one end of the cylinder rod 4Y.
- the stroke length described above is the stroke length L shown in FIG. 7 and is the distance between the cylinder pin distance Lmin to the minimum stroke end position and the cylinder pin distance Lmax to the maximum stroke end position.
- correction values calibrated when the rotary encoder 20 is reset are displayed. For example, the difference L3 shown in FIG. 7 is displayed. The most recent correction value is displayed in the area E3, and the correction value immediately before the most recent correction value is displayed in the area E2. These correction values are updated every time the rotary encoder 20 is reset. In addition, you may provide not only two area
- function icons corresponding to the lower part of the screen corresponding to these six function keys F1 to F6 are displayed.
- an icon indicating a return function is displayed in an area E25 at the bottom of the screen corresponding to the function key F5.
- the operation unit 31c includes other special function keys and numeric keys.
- the operation unit 31c may be provided with a key independent of the standard monitor 31.
- the count value of the rotary encoder 20 is displayed in real time in an area E5 below the area E4. Further, a reference stroke length L2 detected at the time of initial calibration is displayed in an area E6 below the area E5.
- a bar-shaped region E8 that extends horizontally is provided below the region E7.
- the left end of the bar indicates the minimum stroke end position, and the right end of the bar indicates the maximum stroke end position.
- the stroke length corresponding to the value of the area E1 is changed to the bar length and displayed. That is, the area E8 displays the measured value of the stroke length by the stroke sensor 10 as a bar graph and graphically displays the continuous time change of the stroke.
- the reference stroke length L2 at the time of initial calibration is displayed at a position E5-1 on the bar graph, and a position E5-2 indicating a range of stroke deviation allowable from this position E5-1 is displayed on the bar graph. .
- the character “OK” is highlighted, for example, in red as in the area E7.
- the character “OK” is highlighted in red, for example, as in the area E7.
- the highlight display of the area E10 and the area E12 is turned off when the stroke end state is released.
- a sound is output from the notification unit 31d when reset.
- the standard monitor 31 acquires the current stroke length and the count value of the rotary encoder 20 from the measurement controller 30 and displays them in real time in the areas E1 and E5, respectively, and displays the bar graph in the area E8 in real time (step). S201). Thereafter, it is determined whether or not the measurement controller 30 has notified whether or not the intermediate reset process has been normally performed (step S202). If the intermediate reset has been performed normally (step S202, Yes), “OK” is displayed in the area E4 (step S203). Further, it is determined whether or not the previous correction value for the stroke length is stored (step S204).
- step S204 When the previous correction value is stored (step S204, Yes), the previous correction value is displayed in the area E2, the current correction value is displayed in the area E3 (step S205), and the process proceeds to step S207. On the other hand, if the previous correction value is not stored (No at Step S204), the current correction value is displayed in the region E3 (Step S206), and the process proceeds to Step S207.
- step S207 it is determined whether or not the stroke end reset has been normally performed. If the stroke end reset is normal (step S207, Yes), “OK” is displayed in the corresponding area E10, E12 (step S208), the process proceeds to step S201, and the stroke end reset is normal. If not (No at Step S207), the process proceeds to Step S201 as it is.
- the stroke length reaches the maximum stroke end, and the distance between the cylinder pins is displayed in real time in the area E1. Further, when the maximum stroke end is reached, the stroke end is reset, and the correction value is displayed in the area E2. For example, when the correction value is not several millimeters, it is diagnosed that there is a possibility that the stroke sensor 10 is slipping. Further, since the bar display of the stroke length change is continuously graphically displayed in the region E8, the operation state of the stroke sensor 10 can be diagnosed depending on whether the bar display moves smoothly. Note that the reset by the rotary encoder 20 may not be invalidated and may remain valid.
- the graphical display of the region E8 can be diagnosed with a long stroke length. This eliminates the trouble of detaching the connector of the rotary encoder 20 and making a diagnosis, and an efficient diagnosis can be performed.
- ⁇ Reset operation check Reset operation by reset sensor>
- a lowering operation for lowering the boom 4a from the maximum stroke end is performed.
- the reset display by the rotary encoder 20 is normally performed by confirming that “OK” is highlighted and that the reset is issued. Diagnosed. If there is no highlighting of “OK” and no notification that the reset has been made, the reset process of the rotary encoder 20 is not operating, and it can be diagnosed that the rotary encoder 20 has failed.
- the stroke motion diagnosis can be performed easily and easily. It can be carried out.
- the sliding motion of the stroke sensor can be diagnosed in detail.
- the initial stroke value when the rotary encoder 20 is turned on is set to a value outside the measurement range of the stroke length measured by the stroke sensor 10, the initial stroke value is erroneously generated due to noise or the like until the first reset process. It is possible to prevent the reset process from being performed and to perform the initial reset process normally.
- the stroke motion diagnosis can be performed easily and easily by displaying the measured value of the stroke length and the calibration state on the stroke motion diagnosis support screen of the hydraulic cylinder.
- the stroke initial operation calibration work support screen for the hydraulic cylinder is displayed on the display unit 33b of the HMI monitor 33 so that the initial calibration work can be easily performed.
- the initial calibration work is to obtain and store the reference stroke length L2 at the time of factory shipment or when the reset sensor is replaced.
- calibration processing such as resetting of the stroke length is performed based on the reference stroke length L2 subjected to the initial calibration processing.
- the initial calibration work was performed based on a checklist by the service person himself.
- the stroke initial calibration work support screen is displayed by selecting the service menu from the initial screen and then selecting the initial calibration work menu to display the stroke initial calibration work support screen shown in FIG. 14-1 or FIG. 14-2. It is displayed on the part 33b (step S301).
- the status of the initial calibration target is displayed as “READY” when the initial calibration work of the hydraulic cylinder is not performed.
- the stroke initial calibration work support screen shown in FIG. 14-2 when the initial calibration work of the hydraulic cylinder is performed and the reference stroke length L2 is written in the measurement controller 30, the status of the initial calibration target is displayed. “OK” is displayed. Whether the screen of FIG. 14-1 or FIG. 14-2 is displayed is determined by the calculation unit 31a of the HMI monitor 33 based on the writing state of the reference stroke length L2 in the measurement controller 30.
- an outline of operations to be performed for each hydraulic cylinder and an instruction to lower the engine speed and then press the start button are displayed at the top of the screen. .
- the posture before the initial calibration work of the entire hydraulic excavator on which the hydraulic cylinder is mounted is graphically displayed on the left side of the screen, and the posture after the initial calibration work is graphically displayed on the right side of the screen.
- the status of the initial calibration work for each hydraulic cylinder is displayed in the area E30 at the bottom of the screen.
- “READY” is displayed for each hydraulic cylinder.
- “OK” is displayed for each hydraulic cylinder.
- the “Start” button displayed in the area E31 is pressed and held for 0.5 seconds or longer, for example, in accordance with the displayed instructions (step S302).
- the screen shifts to the stroke initial calibration work support screen shown in 14-3.
- the “Clear” button displayed in the area E32 is pressed and held for 0.5 seconds or longer, for example. Transition to the screen shown in 14-1.
- the calculation unit 33a instructs the measurement controller 30 to reset the data of the reference stroke L2 currently written. As a result, all the statuses of the area E30 become “READY”.
- the highlighting processing unit 33e graphically displays the entire posture of the excavator in the center of the screen, and the bucket that is the work machine to be calibrated can be distinguished from other work machines. Highlighting such as changing to a color or tone is made. Further, the highlighting processing unit 33e displays an arrow indicating the operation direction of the bucket (step S303). The service person operates the bucket lever in the “DUMP” direction until the status of the bucket changes to “DIG” based on the work content and the graphical display displayed at the top of the screen. At the bottom of this screen, it is shown that this work stage is step 1.
- step S304 when the arithmetic unit 33a detects that the bucket has reached the stroke end position in the “DUMP” direction and has entered the relief state (step S304, Yes), the operation unit 33a makes a transition to the screen illustrated in FIG.
- the color of the work machine to be calibrated is changed, but the color and tone of other work machines may be changed.
- the highlight processing unit 33e graphically displays the entire posture of the excavator in the center of the screen, and the bucket that is the work machine to be calibrated can be distinguished from other work machines. Highlighting such as changing to a color or tone is made. Further, the highlighting processing unit 33e displays an arrow indicating the operation direction of the bucket (step S305). The service person slowly moves the bucket lever in the “DIG” direction until the status of the bucket changes to “OK” based on the work content and the graphical display displayed at the top of the screen. At the bottom of this screen, it is shown that this work stage is step 2.
- the calculation unit 33a detects the reference stroke L2 during the operation of the bucket in the “DIG” direction (step S306, Yes), and further detects the bucket end status and enters the relief state. “OK” is displayed (step S307), and the reference stroke L2 is written in the measurement controller 30. Thereafter, since there is a work machine (arm) that is the next initial calibration target (step S309, Yes), the calculation unit 22a changes to the screen shown in FIG. 14-5.
- the highlight processing unit 33e graphically displays the entire posture of the excavator in the center of the screen, and the arm that is the work machine to be calibrated can be distinguished from other work machines. Highlighting such as changing to a color or tone is made. Further, the highlighting processing unit 33e displays an arrow indicating the operating direction of the arm (step S303). The service person operates the arm lever in the “DUMP” direction until the arm status changes to “DIG” based on the work content and the graphical display displayed at the top of the screen. The lower part of the screen shows that this work stage is step 3. Thereafter, when the arithmetic unit 33a detects that the arm is in the stroke end position in the “DUMP” direction and has entered the relief state (step S304, Yes), the operation unit 33a makes a transition to the screen illustrated in FIG. 14-6.
- the highlighting processing unit 33e graphically displays the overall posture of the excavator in the center of the screen, and the arm that is the work machine to be calibrated can be distinguished from other work machines. Highlighting such as changing to a color or tone is made. Further, an arrow indicating the operating direction of the arm is displayed by the highlighting processing unit 33e (step S305). The serviceman slowly moves the arm lever in the “DIG” direction until the status of the arm changes to “OK” based on the work content and the graphical display displayed at the top of the screen. At the bottom of this screen, it is shown that this work stage is step 4.
- the arithmetic unit 33a detects the reference stroke length L2 while the arm is moving in the “DIG” direction (step S306, Yes), and further detects the arm end status when the stroke end position is reached. Is displayed as “OK” (step S307), and the reference stroke length L2 is written in the measurement controller 30. Thereafter, since there is a work machine (boom) that is the next initial calibration target (step S309, Yes), the computing unit 33a makes a transition to the screen shown in FIG. 14-7.
- the highlighting processing unit 33e graphically displays the overall posture of the excavator in the center of the screen, and the boom as the work machine to be calibrated can be distinguished from other work machines. Highlighting such as changing to a color or tone is made. Further, an arrow indicating the operation direction of the boom is displayed by the highlighting processing unit 33e (step S303). The service person operates the boom lever in the “UP” direction until the boom status changes to “DOWN” based on the work content and the graphical display displayed at the top of the screen. At the bottom of this screen, it is shown that this work stage is step 5. Thereafter, when the computing unit 33a detects that the boom has reached the stroke end position in the “UP” direction and has entered a relief state (step S304, Yes), the operation unit 33a makes a transition to the screen illustrated in FIG. 14-8.
- the highlight processing unit 33e graphically displays the entire posture of the excavator in the center of the screen, and the boom as the work machine to be calibrated can be distinguished from other work machines. Highlighting such as changing to a color or tone is made. Further, an arrow indicating the operation direction of the boom is displayed by the highlighting processing unit 33e (step S305). The service person slowly moves the boom lever in the “DOWN” direction until the work implement touches the ground based on the work content and the graphical display displayed at the top of the screen. At the bottom of this screen, it is shown that this work stage is step 6.
- step S306 When the calculation unit 33a detects the reference stroke length L2 during the operation of the boom in the “DOWN” direction (step S306, Yes), the boom status is displayed as “OK” (step S307), and this reference stroke length L2 is displayed. Is written in the measurement controller 30. Thereafter, since there is no work machine that is the next initial calibration target (step S309, No), the computing unit 33a makes a transition to the screen shown in FIG. 14-9.
- the status of the hydraulic cylinders is all “OK”, and a description indicating that the initial calibration work is completed is displayed (step S310). Further, when the bucket, arm, and boom are reciprocated, the reset position is recognized, and the check button in the area E33 is pressed after this reciprocation, the initial calibration work is completed. And the calculating part 33a performs the process which returns to a menu screen.
- the procedure of the initial calibration work described above is performed in the order of the bucket, the arm, and the boom.
- the present invention is not limited to this.
- the initial calibration work for the arm ends.
- the initial calibration work for other calibration objects is performed, and when the initial calibration work for all the hydraulic cylinders is completed, the screen display shown in FIG. 14-9 is made.
- the screen transitions to the screen shown in FIG. 14-10. Then, the calculation unit 33a displays an error code in the area E34 (step S308). As a result, the error content corresponding to the error code and the corresponding content can be known. The error content and the corresponding content for this error code may be automatically displayed on the screen. If the calibration of the calibration target fails, the reference stroke length L2 is not updated and the currently stored reference stroke length L2 is retained.
- the calculation unit 33a issues an alarm for calling attention through the notification unit 33d.
- the computing unit 33a determines whether or not the initial calibration work is incomplete depending on whether or not the reference stroke length L2 is all written in the measurement controller 30.
- the position information detection device 19 detects the position of the excavator 1 based on the received position information. And the direction are calculated and output to the main controller 32 and the HMI monitor 33 as vehicle body position information.
- work position information regarding the horizontal and vertical positions of the cutting edge of the work machine 4 is acquired by the measurement controller 30 and output to the main controller 32 and the HMI monitor 33.
- the main controller 32 and the HMI monitor 33 can automatically control the cutting edge of the work implement 4 based on the vehicle position information and the work position information, and further based on the three-dimensional work information.
- a pop-up error screen is displayed on the display screen.
- the initial calibration process is canceled and the menu screen is displayed again.
- the initial calibration work using the stroke initial calibration work support screen is performed again.
- the calculation unit 33a of the HMI monitor 33 shifts the stroke initial calibration work support screen based on the detection of the operating state of the work implement and the input of the operation unit 33c, and further, a reference stroke which is a calibration result.
- the length L2 is written, and control for displaying an error screen is performed.
- the service person can complete the initial calibration work only by operating the work implement according to the stroke initial calibration work support screen and performing simple input from the operation unit 33c.
- the reset by the reset sensor or the reset at the stroke end is performed for the operation only in one stroke direction, not in both stroke directions.
- the reset position has directionality and reset processing must be processed for each direction, and the processing itself becomes complicated.
- the bucket cylinder 4d and the arm cylinder 4e perform the reset process only in the cylinder extending direction
- the boom cylinder 4f performs the reset process only in the cylinder shortening direction.
- the reason why the boom cylinder 4f is reset in the cylinder shortening direction is that the contraction side stroke end of the boom cylinder 4f is normally not usable because the work implement is positioned below the ground level.
- the initial calibration work support screen is displayed on the HMI monitor 33, but the initial configuration work support screen may be displayed on the standard monitor 31.
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Abstract
Description
[油圧ショベルの全体構成]
図1に示すように、油圧ショベル1は、下部走行体2と、上部旋回体3と、作業機4とを有している。下部走行体2は左右一対の履帯2aが回動することにより自走可能に構成されている。上部旋回体3は下部走行体2に旋回自在に設置されている。作業機4は、上部旋回体3の前方側に起伏自在に軸支されている。この作業機4は、ブーム4a、アーム4b、アタッチメントの一例としてバケット4c、油圧シリンダ(バケットシリンダ4d、アームシリンダ4e、ブームシリンダ4f)を有している。
図1および図2を参照して、油圧ショベル1の油圧回路について説明する。図2は、図1に示した油圧シリンダのストローク動作診断支援装置を含む油圧ショベルの全体回路構成を示すブロック図である。以下、油圧シリンダのうちブームシリンダに着目して説明する。なお、説明は行わないがブームシリンダ4f以外のアームシリンダ4e、バケットシリンダ4dについても同様に動作診断を行う。図2において、電気式の操作レバー装置101から電気信号が、メインコントローラ32に入力される。そして、メインコントローラ32から制御電気信号が、ブームシリンダ4fの制御弁102に供給されることによって、ブームシリンダ4fが駆動される。
続いて、油圧シリンダのストローク動作診断支援装置について説明する。この油圧シリンダのストローク動作診断支援装置は、油圧シリンダ(バケットシリンダ4d、アームシリンダ4e、ブームシリンダ4f)と、計測用コントローラ30と、スタンダードモニタ31と、HMIモニタ33と、メインコントローラ32とを有する。
次に、図3および図4を参照して、ストロークセンサ10について説明する。ここでは、説明の便宜上、ブームシリンダ4fに取り付けられたストロークセンサ10について説明するが、アームシリンダ4eも同様のストロークセンサ10が取り付けられている。
図5に示すように、ロータリエンコーダ20は、円盤部25と、発光部26と、受光部27とを有している。発光部26と、受光部27とは、円盤部25を挟むように配置されている。発光部26は、受光部27に対して発光する発光素子を有している。受光部27は、発光部26からの発光を受光可能な4個の受光素子27aを有している。4個の受光素子27aは、それぞれ同じ幅Wを有して、直列に連続して弧状に配列されている。受光素子27aは、受光した光量を電気信号に変換する。円盤部25には、発光部26からの発光を受光部27に透過する複数の第1の透過部25aが配置されている。第1の透過部25aは円周方向の幅が2Wの径方向に延びる略矩形のスリットで、円盤部25の外周近傍にその外周と平行な環状に2Wの間隔で配置されている。第1の透過部25aにより形成される環の内周に単一の透過部25bが配置されている。透過部25bは、径方向に延びる略矩形のスリットである。
つぎに、計測用コントローラ30によるストローク長の計測および校正について説明する。なお、ここでは、ブーム4aが昇降する場合のストローク長の計測および校正を例に説明する。図6に示すように、ブームシリンダ4fの伸縮に伴って、ブーム4aが昇降する。ブームシリンダ4fは、ブーム4aが最も上昇した際に伸び側のストロークエンドに達し、ブーム4aが最も下降した際に縮み側のストロークエンドに達する。この際のブームシリンダ4fのストローク長は、ストロークセンサ10における回転ローラ11の回転量から測定される。
バケットシリンダ4dは、ブームシリンダ4fおよびアームシリンダ4eに比べて、水中や土砂と接する機会が多いため、ロータリエンコーダ20を装着することができない。このため、バケットシリンダ4dには、上述したように、リセットセンサとして磁力センサ20aがシリンダチューブ4Xの外周に取り付けられ、ストロークセンサ10の検出結果から得られるストローク位置を、中間リセット位置(原点位置)にリセットする校正を行っている。
ところで、ストローク長が検出されない装置電源喪失状態(メインコントローラ30に電源が供給されていない状態)で、作業機を安定した姿勢にしないと作業機の自重によってストローク長が変化する場合がある。この場合、油圧シリンダの実ストローク長と装置電源喪失直後に計測した計測ストローク長との間にずれが生ずる。ここで、装置電源起動時に、実ストローク長と最後の計測ストローク長とにずれがあると、誤動検出処理部30cはエラーが発生したとしてブザーなどで警告してしまい、作業機操作の進行に障害を与えてしまう。
上述した計測用コントローラ30には、ロータリエンコーダ20のA相、B相、Z相によるカウント値をもとに、ストロークを所定回数分、記憶し、その平均値により基準ストローク長L2や計測ストローク長L1を算出している。しかし、計測用コントローラ30の電源起動直後のカウント値は、Z相を通過して0クリアするまでは、正しいカウント値であるか判らない。したがって、計測用コントローラ30の電源起動直後は、ロータリエンコーダ20のZ相を通過した後のカウント値を使ってストロークの校正を行う必要がある。具体的には、計測用コントローラ30には、ロータリエンコーダ20の装置電源起動時の初期カウント値が予め記憶されている。この初期カウント値は、ロータリエンコーダ20の計測測定範囲のカウント値が±3000である場合、例えば、9000という大きな値に設定しておく。
校正無効設定部31eにより、リセットの無効設定である「OFF」が表示されている場合、校正処理部30bは、校正処理が無効であるとしてロータリエンコーダ20のリセットを実施しない。
スタンダードモニタ31の表示部31bには、ストロークセンサ10によるストローク長の計測値および校正処理部30bによるストローク長の校正状態が画面表示されるようになっている。図10は、表示部31bに表示されるストローク動作診断支援画面の一例を示している。図10に示したストローク動作診断支援画面は、初期画面からサービスメニュー、点検メニュー、シリンダ点検を順次選択すると、ブームシリンダ、アームシリンダ、バケットシリンダの選択メニューが表示され、ブームシリンダを選択したときの画面である。
まず、領域E4のデフォルトは、「ON」であるため、ファンクションキーF2を長押しして「OFF」にし、ロータリエンコーダ20によるリセットを無効状態にする。そして、ブーム4aをバケット4cの設置状態から上げる動作を行う。
また、領域E5に表示されるロータリエンコーダ20のカウント値が変化しているか否か、また、位置E5-1,E5-2が示す領域間でZ相が入力され、ロータリエンコーダ20のカウント値が正常に0クリアされたかを確認することによって、ロータリエンコーダ20が故障しているか否かを診断することができる。
また、領域E12には、最大ストロークエンドでのリセットがなされるため、「OK」のハイライト表示およびリセットされたことの発報によって、最大ストロークエンドでのリセットが正常に行われていると診断される。「OK」のハイライト表示およびリセットされたことの発報がない場合、ストロークエンドのリセット処理が動作していないと診断できる。
つぎに、ブーム4aを最大ストロークエンドから下げる下げ操作を行う。この場合、領域E7には、ロータリエンコーダ20によるリセット時に、「OK」のハイライト表示およびリセットされたことの発報を確認することによって、ロータリエンコーダ20によるリセット処理が正常に行われていると診断される。「OK」のハイライト表示およびリセットされたことの発報がない場合、ロータリエンコーダ20のリセット処理が動作しておらず、ロータリエンコーダ20が故障していると診断できる。
上述した実施の形態1では、油圧シリンダのストローク動作診断支援画面にストローク長の計測値及び校正状態を表示出力することによってストローク動作の診断を簡易かつ容易に行えるものであった。この実施の形態2では、HMIモニタ33の表示部33bに油圧シリンダのストローク初期動作校正作業支援画面を表示して、初期校正作業を容易に行うことができるようにしている。
1a 車両本体
2 下部走行体
2a 履帯
3 上部旋回体
3a エンジン
4 作業機
4a ブーム
4b アーム
4c バケット
4d バケットシリンダ
4e アームシリンダ
4f ブームシリンダ
4X シリンダチューブ
4W シリンダヘッド
4Y シリンダロッド
4V ピストン
5 キャブ
6 エンジンルーム
7 カウンタウェイト
8 運転席
9 アンテナ
10 ストロークセンサ
11 回転ローラ
12 回転中心軸
13 回転センサ部
13a 磁石
13b ホールIC
14 ケース
19 位置情報検出装置
20 ロータリエンコーダ
20a 磁力センサ
25 円盤部
25a,25b 透過部
26 発光部
27 受光部
27a 受光素子
30 計測用コントローラ
30a ストロークエンド検出処理部
30b 校正処理部
30c 誤動作検出処理部
31 スタンダードモニタ
31a,33a 演算部
31b,33b 表示部
31c,33c 操作部
31d,33d 報知部
31e 校正無効設定部
32 メインコントローラ
33 HMIモニタ
33e 強調表示処理部
40H ロッド側油室
40B キャップ側油室
61 磁力センサ
63 磁石
101,101R,101L 操作レバー装置
101Ra,101Rb 操作レバー
101Rb,101Lb 検出部
102 制御弁
103 油圧ポンプ
103a 斜板
104 サーボ機構
105 エンジン駆動機構
106 吐出油路
107,108 油路
109 バッテリ
110 エンジンキースイッチ
d 回転半径
E1~E8,E10,E12,E22,E30~E34 領域
F1,F2,F5 ファンクションキー
L ストローク長
L1 計測ストローク長
L2 基準ストローク長
L3 差分
N ネットワーク
PA,PB 取付ピン
Claims (6)
- 車両本体に対して順次、回動可能に支持される可動部と、
前記車両本体と可動部との間あるいは前記可動部間に配置され前記可動部を回動可能に支持する油圧シリンダと、
前記油圧シリンダに配置され前記油圧シリンダのストローク長を計測するストロークセンサと、
前記ストロークセンサによる前記ストローク長の計測値をリセットするリセット基準点を計測するリセットセンサと、
前記油圧シリンダのストロークエンド位置を検出するストロークエンド検出処理部と、
前記リセット基準点および/または前記ストロークエンド位置を検出した場合に、前記ストローク長の計測値を校正する校正処理部と、
前記ストロークセンサによるストローク長の計測値及び前記校正処理部による校正状態を少なくとも画面表示するモニタと、
を備えたことを特徴とする油圧シリンダのストローク動作診断支援装置。 - 前記モニタは、前記校正処理部によって演算された補正値を表示することを特徴とする請求項1に記載の油圧シリンダのストローク動作診断支援装置。
- 前記モニタは、時系列で連続する複数の前記補正値を表示することを特徴とする請求項2に記載の油圧シリンダのストローク動作診断支援装置。
- 前記リセットセンサは、前記可動部の回動角度を計測するロータリエンコーダであり、
前記リセット基準点は、ストロークエンド以外の中間リセット位置であることを特徴とする請求項1~3のいずれか一つに記載の油圧シリンダのストローク動作診断支援装置。 - 前記リセットセンサは、前記油圧シリンダのシリンダチューブの外周に設置され、前記油圧シリンダのロッド先端のピストンに配置された磁石を検出する磁力センサであり、
前記リセット基準点は、ストロークエンド以外の中間リセット位置であることを特徴とする請求項1~3のいずれか一つに記載の油圧シリンダのストローク動作診断支援装置。 - 油圧シリンダに配置されたストロークセンサによって前記油圧シリンダのストローク長を計測する際、前記ストローク長の校正を行うために、リセットセンサによるリセット基準点および/または前記油圧シリンダのストロークエンド位置を検出する検出ステップと、
前記ストロークセンサによるストローク長の計測値、及び前記検出ステップの検出結果をもとにした前記ストローク長の校正状態を少なくとも画面表示する表示ステップと、
を含むことを特徴とする油圧シリンダのストローク動作診断支援方法。
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CN107795545A (zh) * | 2017-10-20 | 2018-03-13 | 东莞市嘉刚机电科技发展有限公司 | 转角油压缸s杆转角精度检测机构 |
CN107795545B (zh) * | 2017-10-20 | 2023-12-05 | 东莞市嘉刚机电科技发展有限公司 | 转角油压缸s杆转角精度检测机构 |
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US9347763B2 (en) | 2016-05-24 |
CN104220839A (zh) | 2014-12-17 |
KR20150109482A (ko) | 2015-10-01 |
KR101768351B1 (ko) | 2017-08-14 |
CN104220839B (zh) | 2017-03-15 |
DE112013000155T5 (de) | 2015-02-19 |
US20150047427A1 (en) | 2015-02-19 |
JP5746772B2 (ja) | 2015-07-08 |
JPWO2014167728A1 (ja) | 2017-02-16 |
DE112013000155B4 (de) | 2020-06-25 |
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