A control system and control method for improving the efficiency of a loading shovel

Abstract

The application discloses a control system and control method for improving the operation efficiency of a loader, comprising a working device electric control handle, a boom angle sensor, a bucket angle sensor, a boom angle calibration switch, a bucket angle calibration switch and a hydraulic system controller, wherein the hydraulic system controller is connected with the working device electric control handle, the boom angle sensor, the bucket angle sensor, the boom angle calibration switch, the bucket angle calibration switch and a working device electromagnetic proportional control valve respectively. The application has low cost, avoids the need for manual continuous operation of the loader working device handle to make the boom in a floating position state, and frees the right hand of the driver. The application solves the problem of the need for the driver to manually operate the handle for a long time to gradually control the boom and the bucket to move to a scooping state, reduces the operation time, improves the operation efficiency, operation convenience and operation efficiency, and improves the comfort of the driver and the service life of the whole machine.

Description

Technical Field

[0001] This invention relates to a control system and control method for improving the operating efficiency of loaders, belonging to the field of loader technology. Background Technology

[0002] Currently, the market demands for loader operation efficiency, comfort, and intelligence are constantly increasing. Controlling loader operation efficiency and comfort is a key part of loader intelligence. Therefore, researching and developing a control system that can effectively improve the comfort and efficiency of loader operation is of great significance and can effectively optimize the operator's driving experience. Summary of the Invention

[0003] In view of the problems existing in the prior art, the present invention provides a control system and control method for improving the operating efficiency of loaders, which can effectively improve the operating efficiency and driving comfort of loaders.

[0004] To achieve the above objectives, the present invention employs a control system for improving the operating efficiency of a loader, comprising:

[0005] The working device electric control handle is used to send control commands to control the lifting, lowering, bucket retraction, and bucket tipping of the loader's working device. The control commands include four-way signals of the handle and an opening signal of 0-100%.

[0006] The sensors include a boom angle sensor and a bucket angle sensor. The boom angle sensor is used to obtain the relative angle between the boom of the loader working device and the front frame of the loader. The bucket angle sensor is used to obtain the relative angle between the rocker arm of the loader working device and the boom of the loader working device.

[0007] Angle calibration switches include a boom angle calibration switch and a bucket angle calibration switch. The boom angle calibration switch is used to send a trigger signal to calibrate and store the current angle value of the boom angle sensor, and the bucket angle calibration switch is used to send a trigger signal to calibrate and store the current angle value of the bucket angle sensor.

[0008] The hydraulic system controller is connected to the working device's electric control handle, sensors, angle calibration switch, and working device's electromagnetic proportional control valve. The controller receives position and opening signals from the working device's electric control handle and outputs control current to control the working device's electromagnetic proportional control valve, thereby driving the working device's boom lifting, boom lowering, bucket retraction, and bucket tipping. The controller receives angle signals from the sensors and trigger signals from the angle calibration switch, storing and memorizing boom and bucket angle values. Combining the calibrated and stored boom and bucket angle values, the system's internally stored working device geometric parameters, and the real-time angles from the boom and bucket angle sensors, the controller calculates the real-time length, minimum length, maximum length, and speed of the boom cylinder, as well as the real-time length, minimum length, maximum length, and speed of the bucket cylinder.

[0009] As an improvement, the hydraulic system controller is connected to the working device electric control handle, boom angle sensor, bucket angle sensor, boom angle calibration switch, bucket angle calibration switch, and working device electromagnetic proportional control valve via CAN bus or hardwired.

[0010] As an improvement, the working device electric control handle is installed on the right handrail in the loader cab; the boom angle calibration switch and bucket angle calibration switch are respectively installed on the right column in the loader cab; the boom angle sensor is installed at the connection between the working device boom and the front frame, and the bucket angle sensor is installed at the connection between the working device boom and the working device rocker arm; the hydraulic system controller is installed inside the rear cover in the loader cab, and the working device electromagnetic proportional control valve is installed at the connection between the front frame and the vehicle hydraulic system pipeline.

[0011] As an improvement, the electromagnetic proportional control valve of the working device adopts an integrated electro-hydraulic system multi-way valve, which is installed in the front frame of the loader and is used to receive the boom lifting current, boom lowering current, bucket retraction current and bucket tipping current output by the hydraulic system controller to control the loader's working device.

[0012] In addition, the present invention also provides a control method for improving the operating efficiency of a loader, which includes the following steps:

[0013] 1) The hydraulic system controller obtains the position and opening signals of the electric control handle of the working device through the built-in control system, and outputs the drive current to control the electromagnetic proportional control valve of the working device, thereby driving the boom to lift, lower, retract, and tip the bucket.

[0014] 2) The control system receives angle signals from the boom angle sensor and bucket angle sensor, and receives trigger signals from the boom angle calibration switch and bucket angle calibration switch to store and memorize the boom angle value and bucket angle value;

[0015] 3) The control system combines the calibrated and stored boom angle value, bucket angle value, working device geometric parameters, real-time angle of the boom angle sensor, and real-time angle of the bucket angle sensor to calculate the real-time length of the boom cylinder, the minimum length of the boom cylinder, the maximum length of the boom cylinder, the length of the boom cylinder at the target position, the movement speed of the boom cylinder, and the real-time length of the bucket cylinder, the minimum length of the bucket cylinder, the maximum length of the bucket cylinder, the length of the bucket cylinder at the target position, and the movement speed of the bucket cylinder.

[0016] Before the vehicle leaves the factory, the electric control handle of the working device must be manually operated to control the boom and bucket to move to the lifting limit position, lowering limit position, bucket retraction limit position, and bucket tipping limit position respectively. The four position angle values ​​of the working device are stored and memorized through the boom angle calibration switch and the bucket angle calibration switch. The control system calculates the maximum length of the boom cylinder, the minimum length of the boom cylinder, the maximum length of the bucket cylinder, and the minimum length of the bucket cylinder by combining the geometric parameters of the working device.

[0017] As an improvement, the steps for continuous floating position control during boom descent are as follows:

[0018] 1) Manually operate the electric control handle of the working device to lower the boom of the working device to the lowest position;

[0019] 2) Press the boom angle calibration switch to store the currently acquired angle value from the boom angle sensor;

[0020] 3) The control system combines the stored boom angle value and the acquired real-time boom angle value with the geometric parameters of the loader's working device to calculate the minimum length and real-time length of the boom cylinder.

[0021] 4) Operate the electric control handle of the working device to control the boom lifting, boom lowering, bucket retraction, and bucket tipping for normal operation;

[0022] 5) When manually operating the work device's electric control handle to lower the boom, the control system will determine in real time whether the current boom cylinder length is ≤ (minimum boom cylinder length + 50mm). If not, continue operating the handle to control the boom lowering. If so, manually operating the work device's electric control handle past the hard point structure in the boom lowering direction and holding it at the hard point structure for more than 2 seconds, the control system will determine that it has entered the boom lowering continuous floating position function. At this time, after the work device's electric control handle returns to the neutral position, the hydraulic system controller will continue to output the maximum boom lowering current to control the boom lowering work device solenoid valve to enter the floating state and remain in the floating state. When the work device's electric control handle is operated at any position with a handle opening of ≥5%, the control system will immediately exit the boom lowering continuous floating position function, and the work device's electric control handle can be operated to control the work device for normal lifting, lowering, and retraction operations.

[0023] As an improvement, the steps for ground leveling control are as follows:

[0024] 1) Control the loader's working device to move to the material-shoveling state using the electric control handle of the working device;

[0025] 2) Press the boom angle calibration switch and the bucket angle calibration switch to store the currently acquired angle values ​​from the boom angle sensor and the bucket angle sensor;

[0026] 3) The control system calculates the stored boom angle value, bucket angle value, and real-time boom angle value and real-time bucket angle value, combined with the geometric parameters of the loader's working device, to obtain the stored and memorized boom cylinder length and bucket cylinder length, real-time boom cylinder length, and real-time bucket cylinder length in the shoveling state.

[0027] 4) Operate the electric control handle of the working device to control the boom lifting, boom lowering, bucket retraction, and bucket tipping for normal operation;

[0028] 5) When the operator operates the electric control handle of the working device to trigger the ground leveling function enable signal, after the control system receives the trigger signal, it determines whether the current length of the boom cylinder is greater than (maximum length of boom cylinder + minimum length of boom cylinder) / 2; if yes, proceed to step 6); if no, proceed to step 8.

[0029] 6) If so, the hydraulic system controller outputs a proportional control current to control the boom of the working device to move towards the boom cylinder length in the aforementioned stored and memorized shoveling state. The bucket cylinder extends / retracts in real time according to the difference between the real-time length of the bucket cylinder and the length of the bucket cylinder in the aforementioned stored and memorized shoveling state, moving towards the calibrated target position; continue to step 7).

[0030] 7) Determine whether the absolute value of the difference between the real-time length of the boom cylinder and the real-time length of the bucket cylinder and the real-time length of the boom cylinder and the bucket cylinder in the shoveling state as previously calibrated and stored is ≤5mm; if yes, the ground leveling function is completed; if no, proceed to step 6).

[0031] 8) If not, determine whether the absolute value of the difference between the real-time length of the bucket cylinder and the calibrated, stored, and memorized length of the bucket cylinder under the shoveling state is <100mm; if not, proceed to step 9); if yes, proceed to step 6.

[0032] 9) If not, the bucket will adjust the extension / retraction of the bucket cylinder in real time according to the difference between the real-time length of the bucket cylinder and the length of the bucket cylinder under the aforementioned stored and memorized material-shoveling state, so that the bucket cylinder moves toward the calibrated target position.

[0033] As an improvement, after the electric control handle of the working device triggers the ground leveling function, if the electric control handle of the working device is manually operated to open to an opening of ≥5% at any position, the ground leveling function will be canceled. The operator can then manually operate the electric control handle of the working device to control the raising, lowering, retraction, and turning of the working device for normal operation or to trigger the ground leveling function again.

[0034] As an improvement, the steps for ground leveling and floating position control are as follows:

[0035] 1) Control the loader's working device to move to the material-shoveling state using the electric control handle of the working device;

[0036] 2) Press the boom angle calibration switch and the bucket angle calibration switch to memorize and store the currently acquired angle values ​​from the boom angle sensor and the bucket angle sensor;

[0037] 3) The control system calculates the stored boom angle value, bucket angle value, and real-time boom angle value and real-time bucket angle value, combined with the geometric parameters of the loader's working device, to obtain the stored and memorized boom cylinder length and bucket cylinder length, real-time boom cylinder length, and real-time bucket cylinder length in the shoveling state.

[0038] 4) Operate the electric control handle of the working device to control the boom lifting, boom lowering, bucket retraction, and bucket tipping for normal operation;

[0039] 5) When the electric control handle of the operating device triggers the ground leveling and floating position function enable signal, after the control system receives the trigger signal, it determines whether the current length of the boom cylinder is greater than (maximum length of boom cylinder + minimum length of boom cylinder) / 2; if yes, proceed to step 6); if no, proceed to step 9.

[0040] 6) If so, the hydraulic system controller outputs a proportional control current to control the boom of the working device to move towards the position of minimum boom cylinder length + 50mm. The bucket adjusts the extension / retraction of the bucket cylinder in real time according to the difference between the real-time length of the bucket cylinder and the bucket cylinder length in the aforementioned stored and memorized shoveling state, moving towards the calibrated target position, and proceeds to step 7).

[0041] 7) Determine if the current boom cylinder length is less than (minimum boom cylinder length + 50mm). If not, the hydraulic system controller continues to output proportional current to control the boom to continue falling. If yes, the hydraulic system controller outputs a stable small current to control the boom to fall slowly and steadily, and then proceeds to step 8).

[0042] 8) Determine whether the boom cylinder length has changed within 500ms. If so, the hydraulic system controller continues to output a stable current to control the boom to fall steadily and slowly. If not, determine that the bottom of the bucket is in contact with the ground. The hydraulic system controller continues to output the maximum boom lowering current to control the boom lowering working device solenoid valve to enter the floating state and remain in the floating state, thus completing the ground leveling and floating function.

[0043] 9) If not, determine whether the absolute value of the difference between the real-time length of the bucket cylinder and the real-time length of the bucket cylinder in the calibrated and stored material-shoveling state is <100mm. If not, the bucket adjusts the extension / retraction of the bucket cylinder in real time according to the difference between the real-time length of the bucket cylinder and the aforementioned stored material-shoveling state length, moving towards the calibrated target position. When the absolute value of the difference between the real-time length of the bucket cylinder and the real-time length of the bucket cylinder in the calibrated and stored material-shoveling state is <100mm, proceed to step 6).

[0044] 10) After the working device's electric control handle triggers the ground leveling and floating position function, if the working device's electric control handle is manually operated to open at any position by ≥5%, the ground leveling and floating position function will be canceled. The working device can then be manually operated to control the raising, lowering, retracting, and turning of the working device for normal operation, or the ground leveling and floating position function can be triggered again.

[0045] As an improvement, the steps for tipping bucket limit position buffering and bucket knocking control are as follows:

[0046] 1) Operate the handle of the working device to control the movement of the bucket of the working device to the unloading state;

[0047] 2) Press the bucket angle calibration switch to memorize and store the angle value currently acquired by the bucket angle sensor;

[0048] 3) The control system calculates the minimum length of the bucket cylinder, the real-time length of the bucket cylinder, and the movement speed of the bucket cylinder under the stored and memorized unloading state, based on the stored bucket angle value and the real-time bucket angle value, combined with the geometric parameters of the loader's working device.

[0049] 4) The control system calculates the PID current in real time = the set minimum tipping current + (the real-time length of the bucket cylinder - the minimum length of the bucket cylinder) * kp + the moving speed of the bucket cylinder * kv;

[0050] Where, kp is the position feedback coefficient, and its value range is 0 - 1; kv is the speed feedback coefficient, and its value range is 0 - 1;

[0051] 5) Manually operate the electric control handle of the working device to control the bucket of the working device to tip.

[0052] 6) Judge in real time whether the tipping current output by the electric control handle of the manually operated working device is < the PID current; if not, enter step 7), if so, enter step 8);

[0053] 7) If not, judge that the bucket is in the tipping state buffer area, and the hydraulic system controller outputs the current formed by operating the working device handle to control the bucket cylinder to retract the bucket for tipping, and the collision between the bucket and the boom limit block can be realized for knocking the bucket;

[0054] 8) If so, the hydraulic system controller outputs the proportional current for controlling the bucket cylinder of the working device to retract; continue to step 9);

[0055] 9) During the tipping process, the control system judges in real time whether the tipping current output by the electric control handle of the manually operated working device is < the PID current; if not, the hydraulic system controller outputs the proportional current for controlling the bucket cylinder of the working device to retract, if so, continue to step 10);

[0056] 10) If so, it is determined that the tipping state enters the buffer area. Based on the current and the length of the bucket cylinder at the moment of entering the buffer area, as the operating handle controls the working device to tip, the current decreases and outputs in the form of a single parabola, and the tipping current output is 0 when reaching the position 5 mm away from the minimum tipping cylinder length; continue to step 11);

[0057] 11) After the unloading is completed and the working device handle returns to the middle position or after the bucket is retracted, when the working device bucket is tipped again, the control system will make the above judgments and processing again.

[0058] Compared with the prior art, the control system for improving the operation efficiency of the loader of the present invention has the beneficial effects that:

[0059] 1. The electrical components such as the electric control handle of the working device, boom angle sensor, bucket angle sensor, boom angle calibration switch, bucket angle calibration switch, hydraulic system controller, and working device electro-hydraulic proportional control valve adopted have low costs.

[0060] 2. It realizes the continuous floating position function of boom descent, controls the loader boom to enter the floating state and maintain the floating state for floating operation, avoids the previous need to manually operate the loader working device handle to keep the boom in the floating state, and frees the driver's right hand.

[0061] 3. The system enables the ground leveling function to be triggered by the electric control handle of the loader's working device. Regardless of the posture of the loader's boom and bucket, the control system can quickly control the boom and bucket to move to the calibrated material-shoveling state. This solves the problem that previously required the driver to manually operate the handle for a long time to gradually control the boom and bucket to move to the material-shoveling state. This method reduces operation time and improves work efficiency.

[0062] 4. The system enables the loader's working device to trigger a ground-leveling and floating position function via the electric control handle. Regardless of the loader's boom and bucket's posture, the control system can quickly adjust the bucket movement to the material-shoveling state and the boom movement to the lowest position. When the boom reaches the lowest position and the bottom of the bucket contacts the ground, the control system can automatically recognize this state and control the loader's boom to enter and remain in a floating state for floating operations. This solves the problems of the previous method where the driver manually operated the handle to gradually control the bucket movement to the material-shoveling state, the boom movement to the lowest position, and then manually continued to operate the loader's working device handle to bring the boom to the floating position. These methods required many steps, took a long time, and resulted in a large impact when the bottom of the bucket collided with the ground when the boom reached the lowest position. This method not only improves the convenience of operation and work efficiency but also enhances the driver's comfort.

[0063] 5. The system incorporates a tipping limit position buffer and bucket collision function. When the operator uses the loader's electric control handle to control the working device for unloading, the bucket's movement speed changes with the length of the bucket cylinder, ultimately outputting a single parabolic current that stops at a position 5mm away from the minimum length of the bucket cylinder. This prevents the bucket limit block from colliding with the boom during unloading, improving operational comfort and the overall service life of the machine. Furthermore, when there is adhering material in the bucket, the operator can use the working device's electric control handle to tip the bucket again within the buffer zone. The control system automatically uses a jump buffer function to control the bucket limit block from colliding with the boom, thereby removing the adhering material through vibration. This method significantly improves operational comfort and efficiency, while also solving the previous problem of the bucket limit block colliding with the boom every time unloading occurred, thus extending the overall service life of the machine. Attached Figure Description

[0064] Figure 1 This is a system framework diagram of the present invention;

[0065] Figure 2 This is a flowchart of the boom descent continuous floating position control of the present invention;

[0066] Figure 3 This is a flowchart of the ground leveling control process of the present invention;

[0067] Figure 4 This is a flowchart of the floating position control process for ground leveling according to the present invention;

[0068] Figure 5 This is a flowchart of the tipping bucket limit position buffer and bucket bumping control of the present invention. Detailed Implementation

[0069] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below. However, it should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of the invention.

[0070] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of this invention is for the purpose of describing particular embodiments only and is not intended to limit the invention.

[0071] like Figure 1 As shown, a control system for improving the operating efficiency of a loader includes:

[0072] The working device electric control handle is used to send control commands for lifting, lowering, bucket retraction, and bucket tipping of the loader's working device. The commands consist of four directional signals from the handle and an opening signal from 0 to 100%, and are transmitted to the HCU via CAN communication.

[0073] The geometric parameters of the loader's working device, namely the length and installation angle information of each component of the working device during the loader's design;

[0074] The boom angle sensor is used to obtain the relative angle between the boom of the loader's working device and the front frame of the loader;

[0075] Bucket angle sensor is used to obtain the relative angle between the rocker arm and the boom of the loader working device;

[0076] The boom angle calibration switch has a trigger signal used to calibrate the current angle value stored by the boom angle sensor.

[0077] Bucket angle calibration switch: A trigger signal is used to calibrate and store the current angle value of the bucket angle sensor.

[0078] The hydraulic system controller (HCU) receives position and opening signals from the electric control handle of the working device, outputs drive current to control the electromagnetic proportional control valve of the working device, thereby driving the boom to lift, lower, retract, and tip the bucket. The HCU also receives angle signals from the boom angle sensor and bucket angle sensor, receives trigger signals from the boom angle calibration switch and bucket angle calibration switch, and stores the boom angle and bucket angle values. Furthermore, the HCU combines the calibrated and stored boom angle and bucket angle values ​​with the geometric parameters of the working device, the real-time angles from the boom angle sensor and bucket angle sensor, to calculate the real-time length, minimum length, maximum length, and speed of the boom cylinder, as well as the real-time length, minimum length, maximum length, and speed of the bucket cylinder.

[0079] The electromagnetic proportional control valve for the working device is a multi-way valve in an integrated electro-hydraulic system. It is installed in the front frame of the loader and is used to receive the boom lifting current, boom lowering current, bucket retraction current, and bucket tipping current output by the HCU.

[0080] As an improvement to the embodiment, the hydraulic system controller (HCU) is connected to the working device electric control handle, boom angle sensor, bucket angle sensor, boom angle calibration switch, bucket angle calibration switch, and working device electromagnetic proportional control valve via CAN bus or hardwired.

[0081] As an improvement to the embodiment, the working device electric control handle is installed on the right handrail in the loader cab; the boom angle calibration switch is installed on the right column in the loader cab; the bucket angle calibration switch is installed on the right column in the loader cab; the boom angle sensor is installed at the connection between the working device boom and the front frame; the bucket angle sensor is installed at the connection between the working device boom and the working device rocker arm; the hydraulic system controller (HCU) is installed inside the rear cover plate in the loader cab; and the working device electromagnetic proportional control valve is installed inside the front frame and connected to the vehicle's hydraulic system pipeline.

[0082] In addition, the present invention also provides a control method for improving the operating efficiency of a loader, which includes the following steps:

[0083] 1) The hydraulic system controller obtains the position and opening signals of the electric control handle of the working device through the built-in control system, and outputs the drive current to control the electromagnetic proportional control valve of the working device, thereby driving the boom to lift, lower, retract, and tip the bucket.

[0084] 2) The control system receives angle signals from the boom angle sensor and bucket angle sensor, and receives trigger signals from the boom angle calibration switch and bucket angle calibration switch to store and memorize the boom angle value and bucket angle value;

[0085] 3) The control system combines the calibrated and stored boom angle value, bucket angle value, working device geometric parameters, real-time angle of the boom angle sensor, and real-time angle of the bucket angle sensor to calculate the real-time length of the boom cylinder, the minimum length of the boom cylinder, the maximum length of the boom cylinder, the length of the boom cylinder at the target position, the movement speed of the boom cylinder, and the real-time length of the bucket cylinder, the minimum length of the bucket cylinder, the maximum length of the bucket cylinder, the length of the bucket cylinder at the target position, and the movement speed of the bucket cylinder.

[0086] Before the vehicle leaves the factory, the electric control handle of the working device must be manually operated to control the boom and bucket to move to the lifting limit position, lowering limit position, bucket retraction limit position, and bucket tipping limit position respectively. The four position angle values ​​of the working device are stored and memorized through the boom angle calibration switch and the bucket angle calibration switch. The control system calculates the maximum length of the boom cylinder, the minimum length of the boom cylinder, the maximum length of the bucket cylinder, and the minimum length of the bucket cylinder by combining the geometric parameters of the working device.

[0087] As an improvement to the embodiment, such as Figure 2 As shown, the loader operator manually operates the working device electric control handle to control the working device boom to lower to the lowest position, i.e., the minimum boom cylinder length position. Then, the operator presses the boom angle calibration switch. After receiving the boom angle calibration switch signal, the control system stores the angle value of the boom angle sensor currently acquired. The control system then calculates the minimum boom cylinder length and the real-time boom cylinder length by combining the stored boom angle value and the acquired real-time boom angle sensor angle value with the geometric parameters of the loader working device. At this time, the operator can operate the working device electric control handle to control the working device boom lifting, boom lowering, bucket retraction, and bucket tipping for normal operation.

[0088] When the boom is lowered by manually operating the electric control handle of the working device, the control system determines in real time whether the current boom cylinder length is ≤ (minimum boom cylinder length + 50mm). If not, the handle continues to be operated to control the boom to lower. If so, the electric control handle is manually operated past the hard point structure in the boom lowering direction and held at the hard point structure for more than 2 seconds. Then the control system determines that the boom lowering continuous floating position function has been entered. At this time, after the electric control handle of the working device returns to the neutral position, the hydraulic system controller (HCU) continues to output the maximum boom lowering current to control the boom lowering working device solenoid valve to enter the floating state and remain in the floating state. When the manual operation of the electric control handle is at any position with a handle opening of ≥5%, the control system immediately exits the boom lowering continuous floating position function, and the electric control handle of the working device can be operated to control the working device to carry out normal lifting, lowering, and retraction operations.

[0089] As an improvement to the embodiment, such as Figure 3 As shown, the loader operator manually operates the working device electric control handle to control the loader working device to move to the shoveling state. Then, the operator presses the boom angle calibration switch and the bucket angle calibration switch. After receiving the boom angle calibration switch signal and the bucket angle calibration switch signal, the control system stores the currently acquired boom angle sensor angle value and bucket angle sensor angle value. Based on the stored boom angle value, bucket angle value, and the acquired real-time boom angle sensor angle value and real-time bucket angle sensor angle value, and combined with the geometric parameters of the loader working device, the control system calculates the stored and stored boom cylinder length and bucket cylinder length in the shoveling state, as well as the real-time length of the boom cylinder and the real-time length of the bucket cylinder. At this time, the operator can operate the working device electric control handle to control the working device boom lifting, boom lowering, bucket retraction, and bucket tipping for normal operation.

[0090] When the operator operates the electric control handle of the working device to trigger the ground leveling function enable signal, the control system receives the trigger signal and determines whether the current length of the boom cylinder is greater than (maximum length of boom cylinder + minimum length of boom cylinder) / 2.

[0091] (1) If so, the HCU outputs a proportional control current to control the boom of the working device to move toward the boom cylinder length in the aforementioned stored and memorized shoveling state. The bucket adjusts the extension / retraction of the bucket cylinder in real time to move toward the calibrated target position according to the difference between the real-time length of the bucket cylinder and the real-time length of the bucket cylinder in the aforementioned stored and memorized shoveling state. When the absolute value of the difference between the real-time length of the boom cylinder, the real-time length of the bucket cylinder and the real-time length of the boom cylinder in the aforementioned stored and memorized shoveling state and the real-time length of the bucket cylinder in the aforementioned stored and memorized shoveling state is ≤5mm, the ground leveling function is completed.

[0092] (2) If not, determine whether the absolute value of the difference between the real-time length of the bucket cylinder and the calibrated, stored, and memorized length of the bucket cylinder under the shoveling state is <100mm:

[0093] ① If not, the bucket will adjust the extension / retraction of the bucket cylinder in real time according to the difference between the real-time length of the bucket cylinder and the length of the bucket cylinder in the aforementioned stored and memorized shoveling state, so that the bucket cylinder can move toward the calibrated target position.

[0094] ② When the absolute value of the difference between the real-time length of the bucket cylinder and the calibrated, stored, and memorized length of the bucket cylinder in the shoveling state is <100mm, the HCU outputs a proportional control current to control the boom of the working device to move towards the aforementioned stored, stored, and memorized boom cylinder length. The bucket adjusts the extension / retraction of the bucket cylinder in real time according to the difference between the real-time length of the bucket cylinder and the aforementioned stored, stored, and memorized length of the bucket cylinder in the shoveling state, moving towards the calibrated target position. Continuing, when the absolute value of the difference between the real-time length of the boom cylinder, the real-time length of the bucket cylinder and the aforementioned stored, stored, and memorized lengths of the boom cylinder and the bucket cylinder in the shoveling state is ≤5mm, the ground leveling function is completed.

[0095] After the ground leveling function is triggered by operating the electric control handle of the working device, if the electric control handle of the working device is manually operated to open to an opening of ≥5% at any position, the ground leveling function will be canceled. The operator can then manually operate the electric control handle of the working device to control the raising, lowering, retraction, and turning of the working device for normal operation or to trigger the ground leveling function again.

[0096] As an improvement to the embodiment, such as Figure 4 As shown, the loader operator manually operates the working device electric control handle to control the loader working device to move to the shoveling state. Then, the operator presses the boom angle calibration switch and the bucket angle calibration switch. After receiving the boom angle calibration switch signal and the bucket angle calibration switch signal, the control system stores the currently acquired boom angle sensor angle value and bucket angle sensor angle value. Based on the stored boom angle value, bucket angle value, and the acquired real-time boom angle sensor angle value and real-time bucket angle sensor angle value, the control system calculates the stored and stored boom cylinder length (i.e., minimum boom cylinder length) and bucket cylinder length, boom cylinder real-time length, and bucket cylinder real-time length in the shoveling state, in conjunction with the geometric parameters of the loader working device. At this time, the operator can operate the working device electric control handle to control the working device boom lifting, boom lowering, bucket retraction, and bucket tipping for normal operation.

[0097] When the operator operates the electric control handle of the working device to trigger the ground leveling and floating position function enable signal, the control system receives the trigger signal and determines whether the current length of the boom cylinder is greater than (maximum length of boom cylinder + minimum length of boom cylinder) / 2.

[0098] (1) If so, the HCU outputs proportional control current to control the boom of the working device to move towards the position of minimum boom cylinder length + 50mm. The bucket adjusts the extension / retraction of the bucket cylinder in real time according to the difference between the real-time length of the bucket cylinder and the length of the bucket cylinder under the aforementioned stored and memorized shoveling state, so as to move towards the calibrated target position.

[0099] Determine if the current boom cylinder length is less than (minimum boom cylinder length + 50mm): ① If not, the HCU continues to output proportional current to control the boom to continue falling; ② If yes, the HCU outputs a stable small current to control the boom to fall slowly and steadily (to avoid a large collision between the bucket and the ground).

[0100] Continue to determine whether the boom cylinder length changes within 500ms: ① If yes, the HCU continues to output a stable small current to control the boom to fall steadily and slowly; ② If no, determine that the bottom of the bucket is in contact with the ground, the hydraulic system controller (HCU) continues to output the maximum boom lowering current, controls the boom lowering working device solenoid valve to enter the floating state and remain in the floating state, and completes the ground leveling and floating function.

[0101] (2) If not, determine whether the absolute value of the difference between the real-time length of the bucket cylinder and the real-time length of the bucket cylinder under the calibrated and stored material-loading state is <100mm:

[0102] ① If not, the bucket will adjust the extension / retraction of the bucket cylinder in real time according to the difference between the real-time length of the bucket cylinder and the length of the bucket cylinder in the aforementioned stored and memorized shoveling state, so that the bucket cylinder can move toward the calibrated target position.

[0103] ② When the absolute value of the difference between the real-time length of the bucket cylinder and the real-time length of the bucket cylinder stored in the calibrated material-loading state is <100mm, the HCU outputs a proportional control current to control the boom of the working device to move towards the position of minimum boom cylinder length +50mm. The bucket adjusts the extension / retraction of the bucket cylinder in real time according to the difference between the real-time length of the bucket cylinder and the aforementioned stored length of the bucket cylinder in the material-loading state, moving towards the calibrated target position. It is determined whether the current boom cylinder length is <(minimum boom cylinder length +50mm). If not, the HCU continues to output... The proportional current controls the boom to continue falling. If so, the HCU outputs a stable small current to control the boom to fall slowly and steadily (to avoid a large collision between the bucket and the ground). It checks whether the boom cylinder length has changed within 500ms. If so, the HCU continues to output a stable small current to control the boom to fall slowly and steadily. If not, it checks whether the bottom of the bucket is in contact with the ground. The hydraulic system controller (HCU) continuously outputs the maximum boom-lowering current to control the boom-lowering working device solenoid valve to enter the floating state and remain in the floating state, completing the ground leveling and floating function.

[0104] After the electric control handle of the working device triggers the ground leveling and floating position function, if the electric control handle of the working device is manually operated to open to an opening of ≥5% at any position, the ground leveling and floating position function will be canceled. The operator can then manually operate the electric control handle of the working device to control the raising, lowering, retraction and overturning of the working device for normal operation or trigger the ground leveling and floating position function again.

[0105] As an improvement to the embodiment, such as Figure 5 As shown, manually operate the working device handle to control the bucket of the working device to move to the unloading state, and then press the bucket angle calibration switch. After the control system receives the signal of the bucket angle calibration switch, it stores the angle value of the current bucket angle sensor. Based on the stored bucket angle value, the real-time angle value of the obtained bucket angle sensor, and combined with the geometric parameters of the loader working device, the control system calculates and obtains the minimum length of the bucket cylinder, the real-time length of the bucket cylinder, and the movement speed of the bucket cylinder in the stored and memorized unloading state. The control system calculates in real time that PID current = set minimum tipping current + (real-time length of bucket cylinder - minimum length of bucket cylinder) * kp + movement speed of bucket cylinder * kv; where kp is the value of the position feedback coefficient, with a range of 0 - 1; kv is the speed feedback coefficient, with a numerical range of 0 - 1;

[0106] Manually operate the electro-control handle of the working device to control the bucket of the working device to tip, and judge in real time whether the tipping current output by the manually operated electro-control handle of the working device is < PID current;

[0107] (1) If not, it is judged that the bucket is in the tipping state buffer zone, and the HCU outputs the current formed by operating the working device handle to control the bucket cylinder to retract and the bucket to tip, and the collision between the bucket and the boom limiting block can be realized to knock the bucket (remove the adhesives in the bucket);

[0108] (2) If so, the HCU outputs a proportional current to control the bucket cylinder of the working device to retract. During the tipping process, the control system judges in real time whether the tipping current output by the manually operated electro-control handle of the working device is < PID current: ① If not, the HCU continues to output a proportional current to control the bucket cylinder of the working device to retract, ② If so, it is determined that the tipping state enters the buffer zone. Based on the current and the length of the bucket cylinder at the moment of entering the buffer zone, as the operation handle controls the working device to tip, the current decreases and outputs in the form of a single parabola, and the tipping current is output as 0 when reaching the position 5 mm away from the minimum tipping cylinder length (to avoid the collision between the bucket and the boom limiting block and improve the operation comfort);

[0109] After the unloading is completed and the operation device handle returns to the middle position or after the bucket is retracted, when the working device bucket is tipped again, the control system will make the above judgments and treatments again.

[0110] The embodiments of the present invention have been described above in conjunction with the accompanying drawings. However, the present invention is not limited to the above specific embodiments. The above specific embodiments are merely illustrative and not restrictive. Under the inspiration of the present invention, those of ordinary skill in the art can also make many forms without departing from the purpose of the present invention and the scope protected by the claims. These all fall within the protection scope of the present invention.

Claims

1. A control method for improving the operating efficiency of a loader, characterized in that, The control system adopted to improve the working efficiency of the loader includes: an electric control handle for the working device, which is used to send control commands to control the lifting, lowering, bucket retraction and tipping of the loader's working device. The control commands include four-way signals of the handle and an opening signal of 0-100%. The sensors include a boom angle sensor and a bucket angle sensor. The boom angle sensor is used to obtain the relative angle between the boom of the loader working device and the front frame of the loader. The bucket angle sensor is used to obtain the relative angle between the rocker arm of the loader working device and the boom of the loader working device. Angle calibration switches include a boom angle calibration switch and a bucket angle calibration switch. The boom angle calibration switch is used to send a trigger signal to calibrate and store the current angle value of the boom angle sensor, and the bucket angle calibration switch is used to send a trigger signal to calibrate and store the current angle value of the bucket angle sensor. The hydraulic system controller is connected to the working device's electric control handle, sensors, angle calibration switch, and working device's electromagnetic proportional control valve. The controller receives position and opening signals from the working device's electric control handle and outputs control current to control the working device's electromagnetic proportional control valve, thereby driving the working device's boom lifting, boom lowering, bucket retraction, and bucket tipping. The controller receives angle signals from the sensors and trigger signals from the angle calibration switch, storing and memorizing boom and bucket angle values. Combining the calibrated and stored boom and bucket angle values, the system's internally stored working device geometric parameters, and the real-time angles from the boom and bucket angle sensors, the controller calculates the real-time length, minimum length, maximum length, and speed of the boom cylinder, as well as the real-time length, minimum length, maximum length, and speed of the bucket cylinder. Includes the following steps: 1) The hydraulic system controller obtains the position and opening signals of the electric control handle of the working device through the built-in control system, and outputs the drive current to control the electromagnetic proportional control valve of the working device, thereby driving the boom to lift, lower, retract, and tip the bucket. 2) The control system receives angle signals from the boom angle sensor and bucket angle sensor, and receives trigger signals from the boom angle calibration switch and bucket angle calibration switch to store and memorize the boom angle value and bucket angle value; 3) The control system, in conjunction with the calibrated and stored boom angle value, bucket angle value, working device geometric parameters, real-time angle of the boom angle sensor, and real-time angle of the bucket angle sensor, calculates the real-time length of the boom cylinder, the minimum length of the boom cylinder, the maximum length of the boom cylinder, the length of the boom cylinder at the target position, the movement speed of the boom cylinder, and the real-time length of the bucket cylinder, the minimum length of the bucket cylinder, the maximum length of the bucket cylinder, the length of the bucket cylinder at the target position, and the movement speed of the bucket cylinder. Before the vehicle leaves the factory, the electric control handle of the working device must be manually operated to control the boom and bucket to move to the lifting limit position, lowering limit position, bucket retraction limit position, and bucket tipping limit position respectively. The four position angle values ​​of the working device are stored and memorized through the boom angle calibration switch and the bucket angle calibration switch. The control system calculates the maximum length of the boom cylinder, the minimum length of the boom cylinder, the maximum length of the bucket cylinder, and the minimum length of the bucket cylinder by combining the geometric parameters of the working device. The steps for controlling the continuous floating position of the boom during descent are as follows: 1) Manually operate the electric control handle of the working device to lower the boom of the working device to the lowest position; 2) Press the boom angle calibration switch to store the currently acquired angle value from the boom angle sensor; 3) The control system combines the stored boom angle value and the acquired real-time boom angle value with the geometric parameters of the loader's working device to calculate the minimum length and real-time length of the boom cylinder. 4) Operate the electric control handle of the working device to control the boom lifting, boom lowering, bucket retraction, and bucket tipping for normal operation; When the boom is lowered by manually operating the electric control handle of the working device, the control system determines in real time whether the current boom cylinder length is ≤ (minimum boom cylinder length + 50mm). If not, the handle continues to be operated to control the boom to lower. If so, and the manual operation of the electric control handle passes the hard point structure in the boom lowering direction and remains at the hard point structure for more than 2 seconds, the control system determines that it has entered the boom lowering continuous floating position function. At this time, after the electric control handle of the working device returns to the neutral position, the hydraulic system controller continues to output the maximum boom lowering current to control the boom lowering working device solenoid valve to enter the floating state and remain in the floating state. When the electric control handle of the working device is operated at any position with a handle opening of ≥5%, the control system immediately exits the boom lowering continuous floating position function, and the electric control handle of the working device can be operated to control the working device for normal lifting, lowering, and retraction operations.

2. The control method for improving the operating efficiency of a loader according to claim 1, characterized in that, The steps for controlling ground leveling are as follows: 1) Control the loader's working device to move to the material-shoveling state using the electric control handle of the working device; 2) Press the boom angle calibration switch and the bucket angle calibration switch to store the currently acquired angle values ​​from the boom angle sensor and the bucket angle sensor; 3) The control system calculates the stored boom angle value, bucket angle value, and real-time boom angle value and real-time bucket angle value, combined with the geometric parameters of the loader's working device, to obtain the stored and memorized boom cylinder length and bucket cylinder length, real-time boom cylinder length, and real-time bucket cylinder length in the shoveling state. 4) Operate the electric control handle of the working device to control the boom lifting, boom lowering, bucket retraction, and bucket tipping for normal operation; 5) When the operator operates the electric control handle of the working device to trigger the ground leveling function enable signal, after receiving the trigger signal, the control system determines whether the current length of the boom cylinder is greater than (maximum length of boom cylinder + minimum length of boom cylinder) / 2; if yes, proceed to step 6); if no, proceed to step 8). 6) If so, the hydraulic system controller outputs a proportional control current to control the boom of the working device to move towards the boom cylinder length in the aforementioned stored and memorized shoveling state. The bucket cylinder extends / retracts in real time according to the difference between the real-time length of the bucket cylinder and the previously stored and memorized length of the bucket cylinder in the shoveling state, moving towards the calibrated target position; continue to step 7). 7) Determine if the absolute value of the difference between the real-time length of the boom cylinder and the real-time length of the bucket cylinder and the previously calibrated and stored real-time lengths of the boom cylinder and the bucket cylinder in the shoveling state is ≤5mm; if yes, the ground leveling function is completed; if no, proceed to step 6). 8) If not, determine whether the absolute value of the difference between the real-time length of the bucket cylinder and the calibrated, stored, and memorized length of the bucket cylinder under the shoveling state is <100mm; if not, proceed to step 9); if yes, proceed to step 6). 9) If not, the bucket will adjust the extension / retraction of the bucket cylinder in real time according to the difference between the real-time length of the bucket cylinder and the length of the bucket cylinder under the aforementioned stored and memorized material-shoveling state, so that the bucket cylinder moves toward the calibrated target position.

3. The control method for improving the operating efficiency of a loader according to claim 2, characterized in that, After the ground leveling function is triggered by operating the electric control handle of the working device, if the electric control handle of the working device is manually operated to open to an opening of ≥5% at any position, the ground leveling function will be canceled. The operator can then manually operate the electric control handle of the working device to control the raising, lowering, retraction, and turning of the working device for normal operation or to trigger the ground leveling function again.

4. The control method for improving the operating efficiency of a loader according to claim 1, characterized in that, The steps for leveling the ground and controlling the floating position are as follows: 1) Control the loader's working device to move to the material-shoveling state using the electric control handle of the working device; 2) Press the boom angle calibration switch and the bucket angle calibration switch to memorize and store the currently acquired angle values ​​from the boom angle sensor and the bucket angle sensor; 3) The control system calculates the stored boom angle value, bucket angle value, and real-time boom angle value and real-time bucket angle value, combined with the geometric parameters of the loader's working device, to obtain the stored and memorized boom cylinder length and bucket cylinder length, real-time boom cylinder length, and real-time bucket cylinder length in the shoveling state. 4) Operate the electric control handle of the working device to control the boom lifting, boom lowering, bucket retraction, and bucket tipping for normal operation; 5) When the electric control handle of the operating device triggers the ground leveling and floating position function enable signal, after receiving the trigger signal, the control system determines whether the current length of the boom cylinder is greater than (maximum boom cylinder length + minimum boom cylinder length) / 2; if yes, proceed to step 6); if no, proceed to step 9). 6) If so, the hydraulic system controller outputs a proportional control current to control the boom of the working device to move towards the position of minimum boom cylinder length + 50mm. The bucket adjusts the extension / retraction of the bucket cylinder in real time according to the difference between the real-time length of the bucket cylinder and the bucket cylinder length in the previously stored and memorized loading state, moving towards the calibrated target position, and proceeds to step 7). 7) Determine whether the current length of the boom cylinder is < (the minimum length of the boom cylinder + 50 mm). If not, the hydraulic system controller continues to output a proportional current to control the boom to continue descending. If so, the hydraulic system controller outputs a stable small current to control the boom to descend stably and slowly, and continue to step 8); 8) Determine whether the length of the boom cylinder changes within 500 ms. If so, the hydraulic system controller continues to output a stable current to control the boom to descend stably and slowly. If not, determine whether the bottom of the bucket contacts the ground. The hydraulic system controller continuously outputs the maximum boom lowering current to control the boom lowering working device solenoid valve to enter the floating state and remain in the floating state, completing the function of leveling and entering the floating state when contacting the ground; 9) If not, determine whether the absolute value of the difference between the real-time length of the bucket cylinder and the real-time length of the bucket cylinder in the calibrated storage memory in the bucket loading state is < 100 mm. If not, the bucket adjusts the extension / retraction of the bucket cylinder in real time according to the difference between the real-time length of the bucket cylinder and the length of the bucket cylinder in the aforementioned stored memory in the bucket loading state, and moves towards the calibrated target position; when the absolute value of the difference between the real-time length of the bucket cylinder and the real-time length of the bucket cylinder in the calibrated bucket loading state stored in the memory is < 100 mm, enter step 6); 10) After operating the electro-control handle of the working device to trigger the function of leveling and entering the floating position when contacting the ground, if the opening degree of the electro-control handle of the working device is ≥ 5% at any position during manual operation, the function of leveling and entering the floating position when contacting the ground is cancelled, and the electro-control handle of the working device can be manually operated to control the lifting, lowering, retracting and turning of the working device for normal operation or trigger the function of leveling and entering the floating position when contacting the ground again.

5. The control method for improving the operating efficiency of a loader according to claim 1, characterized in that, The steps of tipping limit buffer and bucket knocking control are as follows: 1) Operate the working device handle to control the bucket of the working device to move to the unloading state; 2) Press the bucket angle calibration switch to memorize and store the angle value of the current bucket angle sensor obtained; 3) The control system calculates and obtains the minimum length of the bucket cylinder, the real-time length of the bucket cylinder and the movement speed of the bucket cylinder in the stored memory in the unloading state according to the stored bucket angle value, the obtained real-time bucket angle value, and combined with the geometric parameters of the loader working device; 4) The control system calculates the PID current in real time = the set minimum tipping current + (the real-time length of the bucket cylinder - the minimum length of the bucket cylinder) * kp + the movement speed of the bucket cylinder * kv; Among them, kp is the position feedback coefficient, and the value range is 0 - 1; kv is the speed feedback coefficient, and the value range is 0 - 1; 5) Manually operate the electro-control handle of the working device to control the bucket of the working device to tip; 6) Judge in real time whether the tipping current output by manually operating the electro-control handle of the working device is < the PID current; if not, enter step 7, if so, enter step 8); 7) If not, judge that the bucket is in the tipping state buffer zone, and the hydraulic system controller outputs the current formed by operating the working device handle to control the bucket cylinder to retract and the bucket to tip, and the collision between the bucket and the boom limit block can be realized to knock the bucket; 8) If so, the hydraulic system controller outputs a proportional current to control the bucket cylinder of the working device to retract; continue to step 9); 9) During the tipping process, the control system continuously determines whether the tipping current output by the electro-control handle of the working device in manual operation is <PID current; if not, the hydraulic system controller outputs a proportional current to control the bucket cylinder of the working device to retract by operating the electro-control handle of the working device, and if so, proceed to step 10); 10) If so, it is determined that the tipping state enters the buffer zone. Based on the current and the length of the bucket cylinder at the moment of entering the buffer zone, as the operation handle controls the working device to tip, the current decreases and is output in the form of a single parabola, and the tipping current is output as 0 when reaching the position 5 mm away from the minimum tipping cylinder length; proceed to step 11); 11) After the unloading is completed, when the operation handle of the working device returns to the neutral position or the bucket is retracted, and the working device bucket is tipped again, the control system will make the above judgments and processes again.

6. The control method for improving the operating efficiency of a loader according to claim 1, characterized in that, The hydraulic system controller is connected to the electro-control handle of the working device, boom angle sensor, bucket angle sensor, boom angle calibration switch, bucket angle calibration switch, and electro-hydraulic proportional control valve of the working device through the CAN bus or hard wiring.

7. The control method for improving the operating efficiency of a loader according to claim 1, characterized in that, The electro-control handle of the working device is installed at the right armrest position in the loader cab; the boom angle calibration switch and bucket angle calibration switch are respectively installed on the right column in the loader cab; the boom angle sensor is installed at the connection between the working device boom and the front frame, and the bucket angle sensor is installed at the connection between the working device boom and the working device rocker arm; the hydraulic system controller is installed inside the rear cover in the loader cab, and the electro-hydraulic proportional control valve of the working device is installed at the connection between the front frame and the vehicle hydraulic system pipeline.

8. The control method for improving the operating efficiency of a loader according to claim 1, characterized in that, The electro-hydraulic proportional control valve of the working device uses an integrated electro-controlled hydraulic system multi-way valve, which is installed inside the loader front frame and is used to receive the boom lifting current, boom lowering current, bucket retraction current, and bucket tipping current output by the hydraulic system controller to control the loader working device.

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