Excavator power distribution device and method and excavator

Abstract

The embodiment of the invention provides an excavator power distribution device and method and an excavator. The device comprises a load sensing module, a ground state sensing module, a power distribution module and a main control module, the load sensing module is used for collecting load data of the excavator; the ground state sensing module is used for detecting the relative speed of the excavator and calculating the ground friction coefficient; the power distribution module is used for driving the walking motors of the left and right tracks and adjusting the flow entering the walking motors of the left and right tracks; the main control module is electrically connected to the load sensing module, the ground state sensing module and the power distribution module and used for generating a power distribution instruction according to the load data and the ground friction coefficient and sending the power distribution instruction to the power distribution module to adjust the power distribution proportion of the left track and the right track. By means of the device, accurate distribution of power of the excavator can be achieved.

Description

Technical Field

[0001] This application relates to the field of vehicle power distribution control, and more particularly to an excavator power distribution device, method, and excavator. Background Technology

[0002] Excavators, as core equipment in earthmoving engineering, mining, and infrastructure construction, directly impact project progress and cost through their operational efficiency and safety. Under complex working conditions, excavators often face challenges such as unilateral heavy loads, significant differences in ground friction coefficients (muddy vs. hard surfaces), and slope stability. Furthermore, conflicts between heavy-load operations and travel commands (such as forcibly adjusting the equipment position during excavation) can cause a sudden surge in hydraulic system pressure, shortening the lifespan of critical components. Therefore, there is an urgent need for a device capable of real-time sensing of bucket load and ground conditions, and dynamically allocating track power based on multi-dimensional data to improve operational efficiency, reduce energy consumption, and ensure equipment safety.

[0003] In the existing technology, the commonly used power distribution method is the equal power distribution mode. Specifically, during the excavator's travel or combined operation, regardless of the actual stress state, load difference, and ground conditions of the left and right tracks or each actuator, the system distributes the power output by the engine or hydraulic pump equally in a fixed proportion. For example, the left and right tracks are each allocated 50% of the power, and the working device and the traveling mechanism are allocated in a fixed proportion.

[0004] However, existing solutions can lead to insufficient power, low fuel efficiency, and even equipment damage or safety accidents when one side is under heavy load. Summary of the Invention

[0005] This application provides an excavator power distribution device, method, and excavator to solve the problem in the prior art that the power distribution cannot be dynamically adjusted according to real-time load differences, which often leads to power waste on the non-load side and insufficient power on the load side, resulting in increased energy consumption, travel deviation, and decreased digging efficiency.

[0006] In a first aspect, embodiments of this application provide an excavator power distribution device, comprising:

[0007] The load sensing module is used to collect load data of the excavator, including cylinder pressure and bucket tilt angle.

[0008] The ground condition sensing module is used to detect the relative speed of the excavator and calculate the ground friction coefficient;

[0009] A power distribution module is used to drive the travel motors of the left and right tracks and to regulate the flow rate into the travel motors of the left and right tracks.

[0010] The main control module is electrically connected to the load sensing module, the ground condition sensing module, and the power distribution module. It is used to generate a power distribution command based on the load data and the ground friction coefficient, and send the power distribution command to the power distribution module to adjust the power distribution ratio of the left and right tracks.

[0011] In one possible implementation, the ground condition sensing module includes: a speed sensor and a rotation speed sensor;

[0012] The speed sensors are installed at the front end of the left and right tracks and are used to detect the actual moving speed of the excavator.

[0013] The speed sensor is installed on the drive wheel axle of the left and right tracks and is used to detect the theoretical speed of the excavator's drive wheels.

[0014] The ground condition sensing module is specifically used to calculate the theoretical speed of the excavator based on the theoretical rotational speed and track pitch, and to calculate the ground friction coefficient based on the ratio between the actual moving speed and the theoretical speed; and to send the ground friction coefficient to the main control module to obtain the power distribution ratio.

[0015] In one possible implementation, the main control module is specifically used for:

[0016] The load value and load distribution of the excavator are calculated based on the cylinder pressure and the tilt angle.

[0017] The total power requirement of the excavator is determined based on the load value and the load power mapping table.

[0018] Based on the total power demand and load distribution, determine the power of the left and right tracks respectively;

[0019] Based on the left and right track power and the ground friction coefficient, a power distribution command is generated.

[0020] In one possible implementation, the main control module is also used for:

[0021] Determine whether the bucket load exceeds the load threshold based on the load data;

[0022] When the load on the bucket exceeds the load threshold and no travel command is received, the power distribution module is controlled to adjust the hydraulic power ratio of the excavator body to a first value and the hydraulic power ratio of the left and right tracks to a second value, wherein the first value is greater than the second value.

[0023] When the bucket load exceeds the load threshold and a travel command is received, the power distribution module is controlled to adjust the hydraulic power ratio of the excavator body to be the same as the hydraulic power ratio of the left and right tracks.

[0024] In one possible implementation, the device further includes a human-machine interface module electrically connected to the main control module;

[0025] The human-machine interaction module is used to display at least one of the following: load value, load distribution, ground friction coefficient, and power distribution ratio, and to display a fault code when a sensor malfunctions.

[0026] Secondly, embodiments of this application provide an excavator power distribution method, applied to the excavator power distribution device described in the first aspect above, comprising:

[0027] The main control module acquires load data collected by the load sensing module and ground friction coefficient sent by the ground condition sensing module. The load data includes cylinder pressure and bucket tilt angle.

[0028] The main control module generates power distribution commands based on the load data and the ground friction coefficient.

[0029] The main control module sends the power distribution command to the power distribution module to adjust the power distribution ratio of the left and right tracks.

[0030] In one possible implementation, the method further includes:

[0031] The ground condition sensing module collects the excavator's actual moving speed and the theoretical rotational speed of the drive wheels;

[0032] The ground condition sensing module calculates the theoretical speed of the excavator based on the theoretical rotational speed and track pitch, and calculates the ground friction coefficient based on the ratio between the actual moving speed and the theoretical speed.

[0033] In one possible implementation, the main control module generates a power distribution command based on the load data and the ground friction coefficient, including:

[0034] The main control module calculates the load value and load distribution of the excavator based on the cylinder pressure and the tilt angle;

[0035] The main control module determines the total power requirement of the excavator based on the load value and the load power mapping table;

[0036] The main control module determines the power of the left and right tracks based on the total power demand and load distribution, and generates the power distribution command based on the power of the left and right tracks and the ground friction coefficient.

[0037] In one possible implementation, the method further includes:

[0038] The main control module determines whether the bucket load exceeds the load threshold based on the load data.

[0039] When the bucket load exceeds the load threshold and no travel command is received, the main control module controls the power distribution module to adjust the hydraulic power ratio of the excavator body to a first value and the hydraulic power ratio of the left and right tracks to a second value, wherein the first value is greater than the second value.

[0040] When the bucket load exceeds the load threshold and a travel command is received, the power distribution module is controlled to adjust the hydraulic power ratio of the excavator body to be the same as the hydraulic power ratio of the left and right tracks.

[0041] Thirdly, embodiments of this application provide an excavator, which includes a body, left and right tracks, and a bucket. The excavator can perform the second aspect and / or various possible excavator power distribution methods described above through the first aspect and / or various possible excavator power distribution devices described above.

[0042] This application provides an excavator power distribution device, method, and excavator. The device integrates a load sensing module, a ground condition sensing module, a power distribution module, and a main control module to achieve precise power distribution for the excavator. First, the load sensing module collects the excavator's load data to reflect the actual force under current operating conditions. Then, the ground condition sensing module detects the excavator's relative speed and calculates the ground friction coefficient to reflect the adhesion of the left and right tracks and the ground conditions. Next, the power distribution module adjusts the hydraulic oil flow into the left and right travel motors to achieve controllable adjustment of the power output to the left and right tracks. Finally, the main control module, based on the load data and the ground friction coefficient, comprehensively judges the required driving force and available adhesion of the left and right tracks, generates an optimal power distribution command, and sends it to the power distribution module, causing power to be distributed towards the side with a larger load or better adhesion conditions. Through the coordinated work of the above modules, real-time adaptive power distribution based on load and ground conditions is achieved, improving the traction performance and stability of the entire machine in different ground environments. Simultaneously, power waste is reduced, yaw is improved, and the overall passability and operating efficiency of the excavator are enhanced. Attached Figure Description

[0043] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0044] Figure 1 A schematic diagram of the excavator power distribution device provided in the embodiments of this application. Figure 1 ;

[0045] Figure 2 A schematic diagram of the excavator power distribution device provided in the embodiments of this application. Figure 2 ;

[0046] Figure 3 A schematic diagram of the excavator power distribution device provided in the embodiments of this application. Figure 3 ;

[0047] Figure 4 A schematic diagram of the excavator power distribution device provided in the embodiments of this application. Figure 4 ;

[0048] Figure 5 This is a flowchart illustrating the excavator power distribution method provided in an embodiment of this application.

[0049] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0050] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0051] Excavators, as core equipment in earthmoving engineering, mining, and infrastructure construction, directly impact project progress and cost through their operational efficiency and safety. Under complex working conditions, excavators often face challenges such as unilateral heavy loads, significant differences in ground friction coefficients (muddy vs. hard surfaces), and slope stability. Furthermore, conflicts between heavy-load operations and travel commands (such as forcibly adjusting the equipment position during excavation) can cause a sudden surge in hydraulic system pressure, shortening the lifespan of critical components. Therefore, there is an urgent need for a device capable of real-time sensing of bucket load and ground conditions, and dynamically allocating track power based on multi-dimensional data to improve operational efficiency, reduce energy consumption, and ensure equipment safety.

[0052] In the existing technology, the commonly used power distribution method is the equal power distribution mode. Specifically, during the excavator's travel or combined operation, regardless of the actual stress state, load difference, and ground conditions of the left and right tracks or each actuator, the system distributes the power output by the engine or hydraulic pump equally in a fixed proportion. For example, the left and right tracks are each allocated 50% of the power, and the working device and the traveling mechanism are allocated in a fixed proportion.

[0053] However, while existing solutions have simple modes and stable control logic, they cannot be dynamically adjusted according to real-time load differences, often resulting in wasted power on the non-load side and insufficient power on the load side, thus causing problems such as increased energy consumption, travel deviation and reduced digging efficiency.

[0054] Based on this, this application proposes a power distribution device for excavators. Addressing the problem that existing equal power distribution modes cannot dynamically adjust based on real-time load differences, leading to power waste, yaw, and reduced operating efficiency, the inventors, based on the control principle that power should match actual force requirements and adhesion capabilities, conceived that if the bucket load and its distribution could be obtained in real time through a load sensing module, and the relative speed of the left and right tracks could be obtained through a ground condition sensing module to calculate the ground friction coefficient, the force requirements and available adhesion on each side could be accurately reflected. Then, based on the above information, the optimal power distribution ratio between the left and right tracks is dynamically generated, and the input flow of the left and right travel motors is adjusted in a closed loop to tilt the power distribution towards the side with a larger load or better adhesion conditions. This method not only effectively avoids the problems of idle power on the non-loaded side and insufficient power on the load side, but also reduces travel deviation, improves traction stability, and significantly improves the overall machine passability and excavation efficiency under complex ground conditions.

[0055] The technical solution of this application and how the technical solution of this application solves the above-mentioned technical problems are described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments. The embodiments of this application will now be described with reference to the accompanying drawings.

[0056] Figure 1 A schematic diagram of the excavator power distribution device provided in the embodiments of this application. Figure 1 ; Figure 2 A schematic diagram of the excavator power distribution device provided in the embodiments of this application. Figure 2 ; Figure 3 A schematic diagram of the excavator power distribution device provided in the embodiments of this application. Figure 3 ; Figure 4 A schematic diagram of the excavator power distribution device provided in the embodiments of this application. Figure 4 See Figures 1 to 4The excavator power distribution device includes: a load sensing module 10, a ground condition sensing module 20, a power distribution module 30, a main control module 40, and a human-machine interaction module 50; wherein, the load sensing module 10 may further include a pressure sensor 101 and an angle sensor 102; the ground condition sensing module 20 may further include a speed sensor 201 and a rotation speed sensor 202; the power distribution module 30 may further include a power source unit 301, a flow regulation unit 302, a power switching unit 303, and a pressure protection unit 304.

[0057] It should be understood that this application collects load information such as cylinder pressure, tilt angle and material weight, and further combines the actual speed and theoretical speed to calculate the ground friction coefficient, so that the power distribution algorithm can simultaneously consider load changes and ground condition changes, achieving a more flexible and intelligent power distribution strategy than traditional hydraulic control systems.

[0058] In a specific embodiment of this application, the load sensing module 10 realizes multi-dimensional sensing of the bucket load status through the pressure sensor 101 and the angle sensor 102; the ground status sensing module 20 realizes comprehensive detection of the excavator's actual moving speed and theoretical moving speed through the speed sensor 201 and the rotation speed sensor 202; the power distribution module 30 realizes dynamic adjustment of the left and right track power and the proportion of the overall machine power through the power source unit 301, the flow regulation unit 302, the power switching unit 303 and the pressure protection unit 304; the main control module 40 is responsible for performing data acquisition, calculation, decision-making and control output; and the human-machine interaction module 50 communicates with the main control module 40 for status display, parameter setting and fault alarm.

[0059] In an optional embodiment, the load sensing module 10 communicates with the ground status sensing module 20, the power distribution module 30, the main control module 40, and the human-machine interaction module 50 via a CAN FD bus. The transmission rate of the CAN FD bus can be 5Mbps, and the transmission delay is no more than 10ms, thereby ensuring that load data, ground status data, and control commands can be exchanged with millisecond-level delays, achieving the requirement of a power distribution response time ≤0.1s.

[0060] Understandably, through the coordinated work of the above modules, the system can continuously output optimal walking power under working conditions such as load changes, uneven force on the left and right tracks, and fluctuations in the ground friction coefficient, thereby reducing walking deviation, improving digging efficiency, and reducing power waste and hydraulic system pressure peaks.

[0061] The load sensing module 10 is used to collect load data of the excavator. Specifically, the pressure sensor 101 is installed in the boom cylinder and stick cylinder to detect cylinder pressure; the angle sensor 102 is installed at the hinge between the bucket and the stick to detect the bucket tilt angle.

[0062] In this embodiment, the load sensing module 10 achieves accurate acquisition of the excavator bucket load value and load distribution through the coordinated configuration of multiple sensors. In one embodiment, the pressure sensor 101 is a high-precision pressure sensor with a measurement range of 0-40MPa and an accuracy of not less than ±0.5%FS. Threaded interfaces (e.g., M16×1.5) are reserved at the oil ports of the rodless and rod chambers of the boom cylinder, and the pressure sensor 101 is installed through a threaded connection. A fluororubber sealing ring is set between the oil port and the sensor to prevent hydraulic oil leakage. Pressure sensors 101 are also set at the oil ports of the rodless and rod chambers of the stick cylinder to realize pressure detection of each cylinder of the boom and stick. Furthermore, the main control module 40 can calculate the load torque of the bucket based on the rodless and rod chamber pressures of the boom and stick cylinders and the corresponding lever arm length. The calculation formula is, for example:

[0063] M = F1 × L1 - F2 × L2

[0064] Where F1 is the rodless chamber pressure, F2 is the rod chamber pressure, L1 and L2 are the lever arm lengths, and M is the load torque. By analyzing the changes in M ​​under different working conditions, torque information related to the bucket load value can be obtained, providing a basis for subsequent load value calculations.

[0065] In one embodiment, the angle sensor 102 is a dual-axis tilt sensor, and the measurement range can be... The accuracy is no less than A sensor mounting bracket with a thickness of approximately 8mm is welded next to the hinge pin between the bucket and the stick, and the angle sensor 102 is fixed to the bracket with bolts (e.g., M8×20). The detection axis of the angle sensor 102 is kept parallel to the hinge pin between the bucket and the stick, thereby ensuring that the detected tilt angle is consistent with the actual bucket tilt posture. Furthermore, the main control module 40 can adjust the bucket tilt angle output by the angle sensor 102. This is used to determine the load distribution direction. For example, when the bucket tilts to the left at an angle greater than 10°, it is determined to be a left-side load; when it tilts to the right at an angle greater than 10°, it is determined to be a right-side load. The load was determined to be on the right side, and the tilt angle was... Within the range, it can be determined to be a basically symmetrical (two-sided) load.

[0066] Understandably, the signals from each sensor in the load sensing module 10 can be input to the main control module 40 via analog input or digital bus, and centrally managed via the CAN FD bus. By employing pressure, angle, and weight sensors for coordinated detection, this application can not only obtain the bucket load size but also identify load distribution characteristics, providing a precise basis for subsequent differentiated power allocation between the left and right tracks. This effectively avoids the problems of insufficient power on the load side and wasted power on the non-load side in existing technologies under unilateral heavy-load conditions.

[0067] The speed sensor 201 in the ground condition perception module 20 is installed at the front end of the left and right tracks to detect the actual moving speed of the excavator; the speed sensor 202 is installed on the drive wheel axle of the left and right tracks to detect the theoretical speed of the excavator's drive wheels; the ground condition perception module 20 calculates the theoretical speed of the excavator based on the theoretical speed and track pitch, and calculates the ground friction coefficient based on the ratio between the actual moving speed and the theoretical speed; the ground friction coefficient is sent to the main control module 40 to obtain the power distribution ratio.

[0068] In this embodiment, the ground condition sensing module 20, through the cooperation of the speed sensor 201 and the rotation speed sensor 202, enables the identification of the excavator's adhesion status under different ground conditions. In one embodiment, the speed sensor 201 is a laser Doppler speed sensor, with a measurement range of... The measurement accuracy is not less than ±0.01m / s. L-shaped brackets are welded to the front end of the left and right track frames approximately 300mm above the ground. The brackets can be made of Q235 steel plate. Mounting holes are made on the brackets, and the speed sensor 201 is fixed to the brackets with bolts, ensuring its emission direction is perpendicular to the ground and consistent with the track's forward direction. A protective plate approximately 5mm thick is installed on the outside of the brackets to prevent impact from hard objects such as stones during operation. The speed sensor 201 can detect the excavator's actual moving speed V1 in real time. The main control module 40 can acquire the data of V1 from the left and right tracks via the CANFD bus to determine whether the tracks are slipping on one side. In one embodiment, the speed sensor 202 is a magnetoelectric speed sensor with a measurement range of, for example, 0~3000rpm and an accuracy not less than... Mounting holes are machined at the end caps of the left and right drive wheel shafts, and speed sensors 202 are inserted, with their probe faces aligned with the gear ring (e.g., with 20 teeth) on the drive wheel shaft. The gap between the speed sensor 202 and the gear ring is maintained within 1-2 mm to obtain a stable pulse signal. The sensor cable can be routed inside the track frame and connected to the main control module 40. Based on the drive wheel speed n detected by the speed sensor 202, combined with the preset track pitch P (e.g., 200 mm), the main control module 40 can calculate the theoretical linear speed V2 of the track. The calculation formula is as follows:

[0069] V2 = n × P × 60 / 1000

[0070] The ground condition sensing module 20 can calculate the ground friction coefficient based on the ratio of V1 to V2. Specifically, it can take the following form:

[0071]

[0072] Where k is a correction coefficient, with a value ranging from 0.95 to 1.05, used to compensate for sensing errors and operating condition disturbances. When When the actual track speed is significantly lower than the theoretical speed, it indicates a low-friction surface (e.g., muddy or slippery ground). Typically, a value less than 0.3 indicates a need for adhesion compensation in the power output. When... When the value is greater than 0.6, it can be determined as a hard, high-friction surface. If the power output is too large at this time, it may cause excessive compaction of the surface and increase energy consumption. It is necessary to appropriately reduce the power output.

[0073] In a further embodiment, the main control module 40 can also be based on Calculate the dynamic compensation coefficient, for example: when At that time, a dynamic compensation coefficient can be set. ;when At that time, a dynamic compensation coefficient can be set. The revised power or This enables the enhancement of dynamics on low-friction surfaces and the suppression of dynamics on high-friction hard surfaces.

[0074] For example, on muddy roads ( If power compensation is not provided, the tracks are prone to slippage; with the ground condition sensing module 20 in this embodiment, when the main control module 40 detects... And the calculation yielded When in use, the power compensation coefficient will be automatically increased, thereby enhancing the effective output power and improving the adhesion between the tracks and the ground, significantly improving the safety and passability of the excavator in complex working conditions such as slopes and slippery ground.

[0075] The power source unit 301 in the power distribution module 30 includes a first variable pump supplying oil to the left track travel motor and a second variable pump supplying oil to the right track travel motor; the flow regulation unit 302 includes a first electromagnetic proportional flow valve and a second electromagnetic proportional flow valve respectively disposed on the oil outlet lines of the first and second variable pumps, used to regulate the hydraulic oil flow supplied to the left and right track travel motors by controlling the opening of the first and second electromagnetic proportional flow valves respectively; the power switching unit 303 is an electro-hydraulic proportional power distribution valve group disposed between the hydraulic oil circuit of the excavator and the hydraulic oil circuit of the track travel motor, used to dynamically adjust the power ratio between the excavator body and the left and right tracks; the pressure protection unit 304 is an overflow valve disposed on the left and right track travel motors, used to release pressure when the oil circuit pressure exceeds the pressure threshold.

[0076] It should be noted that the displacement of the variable pump can be 125 mL / r, and the maximum working pressure is 35 MPa. The first variable pump is connected to the left track travel motor via a high-pressure oil circuit; the second variable pump is connected to the right track travel motor via a high-pressure oil circuit. Both variable pumps are connected to the engine output end via flanges, which can be made of high-strength aluminum alloy to balance strength and weight. The pump body is mounted on the engine side bracket, and a rubber shock-absorbing pad with a thickness of about 10 mm is installed between the bracket and the machine body to reduce the impact of engine vibration on the stability of the variable pump. The electromagnetic proportional flow valve has an adjustment range of 0-200 L / min and a response time of no more than 20 ms. The hydraulic oil flow rate entering the left and right travel motors is controlled by changing the valve core opening. The main control module 40 calculates the left and right track power Pleft, Pright, and the power after friction coefficient correction. This generates a corresponding control current signal, thereby controlling the opening of the first electromagnetic proportional flow valve and the second electromagnetic proportional flow valve, and realizing differentiated control of the driving force of the left and right tracks.

[0077] In one embodiment, the power switching unit 303 is an electro-hydraulic proportional power distribution valve assembly, installed between the excavator's main hydraulic manifold and the track travel hydraulic circuit, with a maximum flow rate of 300 L / min. The main control module 40 dynamically adjusts the power distribution ratio between the hydraulic circuit of the working device (boom, stick, bucket, etc.) and the track travel circuit based on the load value G and the presence of a travel command. For example: when G does not exceed the rated load threshold, the power ratio of the vehicle body and tracks is set to 50% and 50% respectively; when G exceeds 60% of the rated load and there is no travel command, the power ratio of the vehicle body is increased to 70%, and the track power ratio is reduced to 30%, ensuring priority for excavation operations; when G exceeds 60% of the rated load and there is a travel command, the power ratio can be adjusted back to 50% and 50% to avoid severe track power shortage leading to engine stalling. On the other hand, in single-sided heavy-duty excavation conditions, such as when the bucket is tilted to the left for excavation, the main control module 40 can increase the opening of the left electromagnetic proportional flow valve to more than 70% and reduce the opening of the right electromagnetic proportional flow valve to about 20%, thereby providing higher driving force to the left track, ensuring the walking stability and excavation efficiency of the heavy-duty side, while reducing unnecessary energy consumption on the non-load side.

[0078] Furthermore, the pressure threshold set for the relief valve in the pressure protection unit 304 can be 28 MPa. When the travel oil circuit pressure exceeds this threshold, the relief valve automatically opens to release pressure, returning some of the high-pressure oil to the oil tank or low-pressure circuit, thus preventing damage to hydraulic components such as the travel motor due to overpressure.

[0079] It is understandable that, through the cooperation of the aforementioned power source unit 301, flow regulation unit 302, power switching unit 303 and pressure protection unit 304, independent oil supply and independent flow regulation of the left and right tracks can be achieved, and safety pressure relief protection under overpressure conditions can prevent motor damage.

[0080] The main control module 40 is used to first calculate the excavator's load value and load distribution based on the cylinder pressure, tilt angle, and weight of the material in the bucket; then, based on the load value and load power mapping table, determine the excavator's total power demand; then, based on the total power demand and load distribution, determine the power of the left and right tracks respectively; and finally, based on the power of the left and right tracks and the ground friction coefficient, generate power distribution instructions.

[0081] It should be noted that the main control module 40 includes an embedded controller, whose processor can be a quad-core Cortex-A53 with a main frequency of 1.5GHz and 2GB of memory. The controller integrates a CAN FD interface, an analog input interface (e.g., 16 channels), and a digital output interface (e.g., 8 channels) to meet the needs of multi-channel sensor data acquisition and multi-actuator control.

[0082] In one embodiment, the main control module 40 has a preset load-power mapping table. For example, when G=5t, the total power demand P=15kW; when G=8t, the total power demand P=22kW; when G=rated load 10t, the total power demand can be further increased. The main control module 40 can determine the current total power demand P by looking up the value G in the mapping table or by interpolation. Furthermore, based on the bucket tilt angle α and the total power P, the main control module 40 can differentiate the power distribution between the left and right tracks according to a preset function. The left and right power Pleft and Pright can be calculated as follows:

[0083]

[0084]

[0085] in The unit can be a "determination coefficient" (which converts the angle into a dimensionless coefficient according to certain rules). When the bucket tilts to the left, P_left increases and P_right decreases, and vice versa. Subsequently, the main control module 40 uses the friction coefficient provided by the ground condition sensing module 20. Compensation and correction are applied to P left and P right to obtain... It generates corresponding current control commands and outputs them to the electromagnetic proportional flow valve to achieve actual flow regulation.

[0086] Understandably, the main control module 40 sends the generated power distribution commands to the various electromagnetic proportional flow valves and electro-hydraulic proportional power distribution valve groups in the power distribution module 30 via the CAN FD bus or analog output. Simultaneously, the main control module 40 continuously collects feedback signals such as oil circuit pressure and track speed. When it detects a deviation in travel speed or an abnormal pressure, it can perform closed-loop correction of the flow valve opening and power ratio, thereby improving the accuracy and stability of power distribution execution.

[0087] Furthermore, the main control module 40 is also used to determine whether the bucket load exceeds the load threshold based on the load data; when the bucket load exceeds the load threshold and no travel command is received, the control power switching unit adjusts the hydraulic power ratio of the excavator body to a first value and adjusts the hydraulic power ratio of the left and right tracks to a second value, with the first value being greater than the second value; while when the bucket load exceeds the load threshold and a travel command is received, the control power switching unit adjusts the hydraulic power ratio of the excavator body to be the same as the hydraulic power ratio of the left and right tracks.

[0088] In one embodiment, the load threshold can be set to 60% of the excavator's rated load. For example, when the rated load is 10t, the load threshold can be set to 6t. When the current load G calculated by the main control module 40 is greater than 6t, the excavator is considered to be in a heavy-load condition.

[0089] It should be noted that when G > 6t and the main control module 40 does not receive a travel command, the excavator mainly performs in-situ digging operations. At this time, the main control module 40 controls the power switching unit 303 to increase the power ratio (first value) of the hydraulic circuit belonging to the working device to, for example, 70%, and decrease the power ratio (second value) of the track travel circuit to, for example, 30%, to ensure that the boom, stick, and bucket movements receive sufficient hydraulic power and a higher response speed. This strategy effectively avoids the phenomenon of "the bucket not being able to dig" caused by the even distribution of power during heavy-duty digging, thus improving digging efficiency.

[0090] When G > 6t and the main control module 40 receives the travel command, the excavator is in a heavy-load and traveling condition. If the power ratio of the working device remains too high, it will cause insufficient track power, resulting in pressure buildup in the travel motor and a sharp increase in hydraulic pressure. In this situation, the main control module 40 controls the power switching unit 303 to adjust the power ratio of the working device hydraulic circuit and the track travel hydraulic circuit to be the same, for example, both at 50%. This ensures that the bucket maintains a stable load and that the tracks have sufficient power for low-speed movement, thereby preventing the hydraulic system pressure from exceeding the rated value for a long time and reducing damage to the travel motor and engine.

[0091] For example, taking a 20t excavator as an example, when the left side of the bucket is heavily loaded with G=7t (exceeding the 6t threshold), and the current operation is only digging and does not require walking: the main control module 40 sets the power ratio of the side body to 70% and the power ratio of the tracks to 30%; the left track adjusts the power ratio according to the tilt angle. and After compensation, higher power can be output to stabilize the posture, while the right track maintains lower power to avoid power waste. When the bucket is full of material and needs to move to the left to adjust its position: the main control module 40 detects the travel command and adjusts the power ratio to 50% for the working device and 50% for the tracks; at the same time, it maintains that the power of the left track is greater than that of the right track, so that the equipment can move smoothly in the load-side direction, avoiding the risk of stalling and rollover. Through the above dynamic power ratio adjustment strategy, the present invention can achieve a balance between heavy-duty digging and heavy-duty traveling, reduce hydraulic shock, and reduce motor maintenance rate and engine wear.

[0092] Finally, the human-machine interface module 50 is used to display at least one of the following: load value, load distribution, ground friction coefficient, and power distribution ratio, as well as to display a fault code when a sensor malfunctions.

[0093] It should be understood that the human-machine interface module 50 enables the visualization, adjustment, and diagnostics of the power distribution system. Real-time display of key operating parameters (load, power ratio, friction coefficient, etc.) via the touchscreen allows operators to promptly grasp the system status even under complex operating conditions. Simultaneously, by providing a manual calibration entry point for the load-power mapping table, power distribution strategies can be quickly adapted to different operational scenarios (mining, infrastructure, farmland, etc.), thereby improving system versatility. Furthermore, by integrating fault alarm information, the fault diagnosis process can be moved forward, reducing downtime.

[0094] In this embodiment, the controller of the main control module 40 is installed in the electrical cabinet at the rear of the cab. The electrical cabinet is designed to be waterproof and dustproof (protection level IP65). The controller is connected to each sensor and actuator via a CAN FD bus. The bus uses shielded cables to reduce electromagnetic interference.

[0095] The 7-inch touchscreen display of the human-machine interface module is fixed to the right side of the cab control panel via a bracket. The bracket can rotate 360° for easy viewing by the operator. Its built-in interface receives data processed by the main control module 40 in real time and refreshes and displays key parameters such as bucket load value, left and right track power distribution ratio, and ground friction coefficient. The display supports manual calibration, allowing the operator to access the settings interface to modify and save the load power mapping relationship. The display and the main control module are connected via a USB-C interface, integrating data transmission and power supply. The display is also equipped with an audible and visual alarm system. When the main control module 40 detects an abnormality in the angle sensor 102, the interface immediately displays fault code "E001" and alerts the operator through a buzzer and a red warning light. Similarly, when the oil pressure exceeds 28MPa, the interface displays fault code "E002," and the main control module 40 automatically controls the electromagnetic proportional flow valve to close for 10 seconds for protection, reopening it after the pressure recovers.

[0096] Through the design and implementation of the aforementioned human-machine interaction module 50, the system can not only graphically display key operating conditions, significantly improving operational perceptibility, but also flexibly adjust the power strategy according to specific operating conditions, thereby improving operational efficiency and adaptability. Furthermore, fault alarms and automatic degradation operation modes greatly improve system reliability, reducing downtime by 60% and ensuring stable operation of the power distribution device even in the event of sensor failure or abnormal oil pressure.

[0097] It should also be noted that if a controlled shutdown is not performed after the hydraulic system has finished operation, the power distribution valve group may remain partially open, posing a risk of residual pressure causing oil circuit shock, motor idling, or long-term pressure fatigue of valve components. Simultaneously, the main control module 40 needs to complete the writing and cache clearing of operation data before shutdown to avoid data loss or incomplete recording. Furthermore, the display and alarm modules also need to complete status reset during shutdown to ensure the system is in a known and stable initial state upon the next startup. Therefore, by uniformly executing the shutdown procedure through the main control module 40, the safe depressurization of the oil circuit, reliable reset of control components, and timely saving of critical data can be ensured, thereby improving the system's operational reliability and overall machine lifespan.

[0098] After the operator shuts down the engine, the main control module 40 immediately executes the shutdown logic. First, it sends a shutdown command to the power distribution valve group, cutting off the left and right track oil circuits and eliminating residual power output. Subsequently, the controller issues a reset command to the electromagnetic proportional flow valves, returning each valve to the closed state. After the oil circuits are completely isolated, the system automatically writes the load data, power distribution records, and key sensor statuses for the current work cycle to the local storage medium, setting a retention period of 72 hours for subsequent operational analysis or troubleshooting. After data saving is complete, the display shows "Shutdown Complete," and the system enters sleep mode, reducing power consumption to below 5W.

[0099] Understandably, the oil circuit isolation and valve reset during the shutdown process effectively prevent unexpected track movement after shutdown, improving operational safety in various work scenarios. Data retention significantly enhances maintenance efficiency, allowing after-sales engineers to quickly pinpoint the time of failure and operational characteristics, thereby reducing troubleshooting time. The low-power sleep mode design further extends battery life, improving the overall system economy and reliability.

[0100] This application provides a power distribution device for an excavator. This device integrates a load sensing module, a ground condition sensing module, a power distribution module, and a main control module to achieve precise power distribution for the excavator. First, the load sensing module collects the excavator's load data, reflecting the actual force under the current operating conditions. Then, the ground condition sensing module detects the excavator's relative speed and calculates the ground friction coefficient to reflect the adhesion of the left and right tracks and the ground conditions. Next, the power distribution module adjusts the hydraulic oil flow into the left and right travel motors, thereby achieving controllable adjustment of the power output to the left and right tracks. Finally, the main control module, based on the load data and the ground friction coefficient, comprehensively judges the required driving force and available adhesion of the left and right tracks, generates an optimal power distribution command, and sends it to the power distribution module, causing power to be distributed towards the side with a larger load or better adhesion conditions. Through the coordinated work of the above modules, real-time adaptive power distribution based on load and ground conditions is achieved, improving the traction performance and stability of the entire machine in different ground environments. Simultaneously, it reduces power waste, improves yaw rate, and enhances the overall passability and operating efficiency of the excavator.

[0101] Figure 5 A flowchart illustrating the excavator power distribution method provided in this application embodiment; as follows: Figure 5 As shown, the method includes:

[0102] S501, the main control module acquires the load data collected by the load sensing module and the ground friction coefficient sent by the ground condition sensing module.

[0103] The load data includes cylinder pressure and bucket tilt angle.

[0104] It should be noted that the calculation process of the ground friction coefficient is as follows: the ground condition sensing module first collects the actual moving speed of the excavator and the theoretical rotational speed of the drive wheels; then the ground condition sensing module calculates the theoretical speed of the excavator based on the theoretical rotational speed and the track pitch, and calculates the ground friction coefficient based on the ratio between the actual moving speed and the theoretical speed.

[0105] S502, the main control module generates power distribution commands based on load data and ground friction coefficient.

[0106] In one possible implementation, the main control module calculates the excavator's load value and load distribution based on the cylinder pressure and tilt angle; then, the main control module determines the excavator's total power demand based on the load value and load power mapping table; finally, the main control module determines the power of the left and right tracks respectively based on the total power demand and load distribution, and generates power distribution instructions based on the power of the left and right tracks and the ground friction coefficient.

[0107] S503, the main control module sends the power distribution command to the power distribution module to adjust the power distribution ratio of the left and right tracks.

[0108] In one possible implementation, the main control module first determines whether the bucket load exceeds the load threshold based on the load data; then, when the bucket load exceeds the load threshold and no travel command is received, the main control module controls the power distribution module to adjust the hydraulic power ratio of the excavator body to a first value and the hydraulic power ratio of the left and right tracks to a second value; finally, when the bucket load exceeds the load threshold and a travel command is received, the main control module controls the power distribution module to adjust the hydraulic power ratio of the excavator body to be the same as the hydraulic power ratio of the left and right tracks.

[0109] It is understandable that by acquiring and integrating bucket load data and ground friction coefficient in real time through the above steps, dynamically calculating the differentiated power distribution ratio of the left and right tracks based on the load distribution, and making real-time compensation and correction according to ground adhesion conditions, and intelligently coordinating the power distribution between the working device and the walking system under heavy load conditions, the excavator's power system achieves adaptive and precise matching with the working conditions. This significantly improves operating efficiency and fuel economy, effectively reduces the risk of track slippage and system overload, and enhances the operational safety and stability of the equipment under complex terrain and heavy load conditions. Specific implementation processes of the embodiments have been described in this application. Figures 1 to 4 The corresponding embodiments will be described in detail, but will not be repeated here.

[0110] This application provides an excavator, which includes a body, left and right tracks, and a bucket. When distributing power, the excavator can perform the excavator power distribution method through the aforementioned excavator power distribution device.

[0111] It should be noted that the devices in the embodiments provided in this application are all common devices on the market. They can be selected according to the needs when used. The circuit connection relationship of each device is a simple series and parallel connection circuit, which can be easily implemented by those skilled in the art. It belongs to the prior art and will not be described in detail here.

[0112] The various embodiments or implementation methods described in this specification are presented in a progressive manner. Each embodiment focuses on the differences from other embodiments, and the same or similar parts between the embodiments can be referred to each other.

[0113] It should be noted that the embodiments referred to in the specification, such as "one embodiment," "embodiment," "exemplary embodiment," and "some embodiments," may include specific features, structures, or characteristics, but not every embodiment necessarily includes that specific feature, structure, or characteristic. Furthermore, such phrases do not necessarily refer to the same embodiment. Moreover, when a specific feature, structure, or characteristic is described in connection with an embodiment, implementing such a feature, structure, or characteristic in conjunction with other embodiments, whether explicitly described or not, is within the knowledge scope of those skilled in the art.

[0114] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0115] It should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

[0116] Finally, it should be noted that other embodiments of the invention will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This invention is intended to cover any variations, uses, or adaptations of the invention that follow the general principles of the invention and include common knowledge or customary techniques in the art not disclosed herein, and is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of the invention is limited only by the appended claims.

Claims

1. A power distribution device for an excavator, characterized in that, include: The load sensing module is used to collect load data of the excavator, including cylinder pressure and bucket tilt angle. The ground condition sensing module is used to detect the relative speed of the excavator and calculate the ground friction coefficient; A power distribution module is used to drive the travel motors of the left and right tracks, and to regulate the flow rate into the travel motors of the left and right tracks. The main control module is electrically connected to the load sensing module, the ground condition sensing module, and the power distribution module. It is used to generate a power distribution command based on the load data and the ground friction coefficient, and send the power distribution command to the power distribution module to adjust the power distribution ratio of the left and right tracks.

2. The apparatus according to claim 1, characterized in that, The ground condition sensing module includes: a speed sensor and a rotation speed sensor; The speed sensors are installed at the front end of the left and right tracks and are used to detect the actual moving speed of the excavator. The speed sensor is installed on the drive wheel axle of the left and right tracks and is used to detect the theoretical speed of the drive wheels of the excavator. The ground condition sensing module is specifically used to calculate the theoretical speed of the excavator based on the theoretical rotational speed and track pitch, and to calculate the ground friction coefficient based on the ratio between the actual moving speed and the theoretical speed; and to send the ground friction coefficient to the main control module to obtain the power distribution ratio.

3. The apparatus according to claim 2, characterized in that, The main control module is specifically used for: The load value and load distribution of the excavator are calculated based on the cylinder pressure and the tilt angle. The total power requirement of the excavator is determined based on the load value and the load power mapping table. Based on the total power demand and load distribution, determine the power of the left and right tracks respectively; Based on the left and right track power and the ground friction coefficient, a power distribution command is generated.

4. The apparatus according to claim 1, characterized in that, The main control module is also used for: Determine whether the bucket load exceeds the load threshold based on the load data; When the load on the bucket exceeds the load threshold and no travel command is received, the power distribution module is controlled to adjust the hydraulic power ratio of the excavator body to a first value and the hydraulic power ratio of the left and right tracks to a second value, wherein the first value is greater than the second value. When the bucket load exceeds the load threshold and a travel command is received, the power distribution module is controlled to adjust the hydraulic power ratio of the excavator body to be the same as the hydraulic power ratio of the left and right tracks.

5. The apparatus according to claim 1, characterized in that, The device also includes a human-machine interaction module electrically connected to the main control module; The human-machine interaction module is used to display at least one of the following: load value, load distribution, ground friction coefficient, and power distribution ratio, and to display a fault code when a sensor malfunctions.

6. A power distribution method for an excavator, characterized in that, The method, applied to the excavator power distribution device according to any one of claims 1 to 5, comprises: The main control module acquires load data collected by the load sensing module and ground friction coefficient sent by the ground condition sensing module. The load data includes cylinder pressure and bucket tilt angle. The main control module generates power distribution commands based on the load data and the ground friction coefficient. The main control module sends the power distribution command to the power distribution module to adjust the power distribution ratio of the left and right tracks.

7. The method according to claim 6, characterized in that, The method further includes: The ground condition sensing module collects the excavator's actual moving speed and the theoretical rotational speed of the drive wheels; The ground condition sensing module calculates the theoretical speed of the excavator based on the theoretical rotational speed and track pitch, and calculates the ground friction coefficient based on the ratio between the actual moving speed and the theoretical speed.

8. The method according to claim 6, characterized in that, The main control module generates power distribution commands based on the load data and the ground friction coefficient, including: The main control module calculates the load value and load distribution of the excavator based on the cylinder pressure and the tilt angle; The main control module determines the total power requirement of the excavator based on the load value and the load power mapping table; The main control module determines the power of the left and right tracks based on the total power demand and load distribution, and generates the power distribution command based on the power of the left and right tracks and the ground friction coefficient.

9. The method according to claim 6, characterized in that, The method further includes: The main control module determines whether the bucket load exceeds the load threshold based on the load data. When the bucket load exceeds the load threshold and no travel command is received, the main control module controls the power distribution module to adjust the hydraulic power ratio of the excavator body to a first value and the hydraulic power ratio of the left and right tracks to a second value, wherein the first value is greater than the second value. When the bucket load exceeds the load threshold and a travel command is received, the power distribution module is controlled to adjust the hydraulic power ratio of the excavator body to be the same as the hydraulic power ratio of the left and right tracks.

10. An excavator, characterized in that, The excavator includes a body, left and right tracks, and a bucket. The excavator can execute the excavator power distribution method as described in any one of claims 6-9 through the excavator power distribution device as described in any one of claims 1-5.

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