Excavator maximum excavating force testing system and method and excavator
By integrating multi-dimensional sensors and a main controller onto the excavator, precise adjustment and automated testing of the excavator's posture are achieved, solving the problem of inaccurate posture adjustment in existing testing methods, improving testing accuracy and efficiency, and making it suitable for various scenarios.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- XUZHOU XCMG MINING MACHINERY CO LTD
- Filing Date
- 2026-03-11
- Publication Date
- 2026-04-28
AI Technical Summary
In existing methods for testing the maximum digging force of excavators, operators cannot precisely adjust the excavator's posture, resulting in large errors in the test data and failing to objectively reflect the equipment's true maximum digging force.
The system employs a tension gauge attitude sensor, a working device attitude sensor, a cylinder displacement sensor, and a vehicle body attitude sensor, combined with a main controller for real-time data acquisition and attitude calibration. Attitude adjustment is achieved through a PID feedback regulation mechanism. The main controller takes over the control of the excavator and outputs control signals to the actuators.
Significantly improves test accuracy and data authenticity, simplifies operation procedures, reduces test errors, improves test efficiency and adaptability, is applicable to different excavator models, reduces costs and provides full-process data support.
Smart Images
Figure CN121933175A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a system, method, and excavator for testing the maximum digging force of an excavator, and belongs to the field of excavator testing technology. Background Technology
[0002] In the field of excavator performance testing, maximum digging force is a core indicator for measuring the equipment's operational capability, and its testing accuracy directly impacts product performance evaluation and market access. The mainstream testing method for maximum digging force of excavators currently involves constructing a testing system using the excavator bucket, a force gauge, and a ground anchor. The force gauge is connected at both ends to the bucket teeth and the ground anchor, forming a force transmission path. The excavator's drive mechanism then applies force, and the force gauge acquires the digging force data. A crucial prerequisite for this testing process is that the excavator must be adjusted to the standard posture corresponding to the maximum digging force (i.e., the mechanical posture with optimal digging force transmission efficiency and conforming to industry testing standards) to ensure the authenticity of the test data.
[0003] However, existing testing methods have significant technical flaws: operators need to manually adjust the excavator's body position, slewing angle, and the relative posture of the boom, stick, and bucket based on experience to approximate the maximum digging force posture. However, in actual operation, operators cannot accurately perceive the real-time posture angles of the excavator's various structural components (such as the angle between the boom and the body, the hinge angle between the stick and the bucket, and the matching angle between the dynamometer axis and the bucket's force direction). They can only judge the adjustment effect through visual observation and operational experience, which makes it difficult for the excavator to accurately reach the target posture required for maximum digging force. This results in a large deviation in the test data, which cannot objectively reflect the equipment's true maximum digging force.
[0004] Analysis reveals that the core root cause of the above problems lies in the fact that the existing testing system lacks a real-time and accurate acquisition and linkage feedback mechanism for excavator posture information and tension gauge posture information. Operators cannot obtain quantitative posture data as a basis for adjustment and can only rely on subjective experience to make blind adjustments. This not only fails to guarantee the accuracy of posture adjustment but also makes it difficult to avoid human error in the adjustment process, ultimately resulting in poor reliability and repeatability of test results. Summary of the Invention
[0005] To address the problems existing in the prior art, the present invention provides a maximum digging force testing system, method, and excavator for excavators, achieving the purpose of precise attitude adjustment.
[0006] To achieve the above objectives, the present invention employs a maximum digging force testing system for excavators, comprising: The tension gauge has two ends for connecting the bucket teeth of the excavator to the ground anchor, and the tension gauge is equipped with a tension gauge attitude sensor for collecting the attitude information of the tension gauge. The detection components include a working device attitude sensor, a cylinder displacement sensor, and a vehicle body attitude sensor. The working device attitude sensor is installed on the excavator boom, stick, bucket, and connecting rod to collect attitude information of the corresponding structural components. The cylinder displacement sensor is installed on the boom cylinder, stick cylinder, and bucket cylinder to collect the extension and retraction displacement of the corresponding cylinders. The vehicle body attitude sensor is installed on the excavator body to collect the vehicle body attitude information. The main controller is connected to the tension gauge attitude sensor, the working device attitude sensor, the cylinder displacement sensor, the vehicle body attitude sensor, and the excavator's actuator. The main controller is configured to: read the data collected by each sensor, combine it with pre-stored target attitude parameters for the excavator's maximum digging force and the excavator's structural component dimensions, calculate the deviation between the excavator's real-time attitude and the target attitude, and output control signals to the actuator to automatically adjust the excavator's attitude. The main controller can temporarily take over the excavator's control and employ a PID feedback adjustment mechanism to dynamically correct attitude deviations based on real-time feedback data from each sensor, thereby achieving attitude calibration. The actuator includes the excavator's travel motor, swing motor, boom cylinder, stick cylinder, bucket cylinder, and main valve that controls the movement of the above components. The actuator is used to receive control signals from the main controller and drive the excavator to complete the adjustment of the excavator's body posture and the posture adjustment of the working device.
[0007] As an improvement, the main controller includes a data reading module, a data storage module, and a data processing module; The main controller is connected to the data input module, which is communicatively connected to the tension gauge attitude sensor and the detection components. It is used to synchronously acquire tension gauge attitude data, working device attitude data, cylinder displacement data and vehicle body attitude data in real time and transmit them to the main controller. The data processing module is used to combine the excavator structural component size parameters, cylinder displacement data and working device posture data to calculate the real-time relative posture of the excavator working device, compare the posture information of the tension gauge posture sensor and the vehicle posture sensor to obtain the vehicle posture deviation, and generate the main valve control signal and motor control signal based on the total deviation between the target posture and the real-time posture. The data storage module is used to store target attitude parameters, raw data collected by each sensor, attitude calculation process data, and final test result data; The main controller is also equipped with a control output module, which is used to transmit the main valve control signal and the motor control signal to the actuator.
[0008] As an improvement, the PID feedback adjustment mechanism is as follows: the main controller dynamically adjusts the control signal based on the attitude data fed back by each sensor in real time, comparing the error between the real-time attitude of the excavator and the target attitude, until the deviation between the real-time attitude and the target attitude meets the calibration requirements, thus completing the adjustment of the excavator's attitude.
[0009] As an improvement, the main controller temporarily takes over the control of the excavator by outputting control commands. After the attitude adjustment is completed, the main controller releases the control and the control of the excavator is returned to the original controller of the excavator.
[0010] As an improvement, the main controller outputs motor control signals to drive the travel motor and slewing motor based on the attitude information detected by the tension gauge attitude sensor, thereby adjusting the excavator's body attitude to match the tension gauge attitude.
[0011] As an improvement, the main controller outputs a main valve control signal according to the target posture, driving the boom cylinder, stick cylinder, and bucket cylinder to adjust the posture of the working device. Each sensor provides real-time feedback of posture data until the posture of the working device reaches the target posture.
[0012] As an improvement, the main controller continuously monitors the attitude information of the dynamometer throughout the entire process of excavator attitude adjustment. If the attitude of the dynamometer changes, the main controller will synchronously adjust the attitude of the excavator body and working device.
[0013] A second aspect of the present invention also provides a method for testing the maximum digging force of an excavator, using the aforementioned excavator maximum digging force testing system, comprising the following steps: S1. Connect one end of the tension gauge to the ground anchor and the other end to the bucket teeth of the excavator to set up the test environment, start the test system and complete the initialization; S2. The main controller acquires the sensor data collected by the tension gauge attitude sensor and each detection component, and calculates the real-time attitude of the excavator by combining it with the pre-stored excavator structural component size parameters. S3. The main controller compares the deviation between the excavator's real-time posture and the target posture of maximum digging force, generates corresponding main valve control signals and motor control signals, and transmits them to the actuator. S4. The actuator responds to the control signal, drives the travel motor and swing motor to adjust the vehicle body posture, and drives the boom cylinder, stick cylinder and bucket cylinder to adjust the working device posture. During the adjustment process, a PID feedback adjustment mechanism is used to dynamically correct the posture deviation. S5. The main controller continuously monitors the attitude information of the tension gauge. If the attitude of the tension gauge changes, return to step S2 to readjust the excavator attitude. If the attitude of the tension gauge does not change, continue to verify whether the excavator attitude has reached the target attitude. S6. If the excavator reaches the target posture for maximum digging force, the main controller releases control of the excavator. The tester operates the bucket cylinder or stick cylinder until overflow, and collects and obtains the maximum digging force data of the excavator through the tension gauge to complete the test. If the target posture is not reached, return to step S2 to continue adjustment.
[0014] As an improvement, in step S6, the overflow state of the bucket cylinder or the stick cylinder is used as the basis for determining the maximum digging force output by the excavator.
[0015] In a third aspect, the present invention also provides an excavator equipped with the aforementioned excavator maximum digging force testing system; the boom, stick, bucket, connecting rod, and body of the excavator are all adapted to install sensors of the detection components, and each cylinder, main valve, travel motor, and swing motor are all adapted to receive control signals from the main controller to realize attitude adjustment of the body and working device.
[0016] Compared with the prior art, the beneficial effects of the present invention are: (1) This invention effectively solves many drawbacks of manual posture adjustment in the traditional maximum digging force test of excavators. By combining multi-dimensional sensing and precise calculation, the test accuracy and data authenticity are greatly improved. The test system relies on the tension gauge posture sensor, working device posture sensor, body posture sensor and cylinder displacement sensor to complete the full-dimensional data acquisition. Combined with the excavator structural component size parameters, spatial geometric calculation is performed to accurately obtain the real-time relative posture of the working device and the posture deviation of the body. At the same time, the PID feedback adjustment mechanism is used to dynamically correct the posture deviation, ensuring that the excavator is stably in the target posture corresponding to the maximum digging force. This avoids the posture deviation problem caused by manual adjustment from the root, making the digging force data collected by the tension gauge more consistent with the actual working conditions of the equipment and significantly reducing the test error.
[0017] (2) This invention automates the testing process through a main controller, greatly simplifying the operation process, improving testing efficiency, and lowering the technical threshold for operators. The main controller can autonomously complete the entire process of data reading, deviation calculation, control signal generation, and attitude adjustment without manual intervention in the attitude calibration process. Moreover, during the entire attitude adjustment process, the main controller will continuously monitor the attitude changes of the tension gauge and adjust accordingly, effectively avoiding repeated testing problems caused by disturbances in the testing environment, significantly shortening the testing cycle of a single device, and the efficiency improvement effect is particularly obvious in batch testing scenarios.
[0018] (3) This invention achieves flexible and safe switching of excavator control, taking into account both the accuracy of automated control and the convenience of manual operation. At the same time, the test system has strong adaptability and wide application scenarios. The main controller only temporarily takes over the excavator control during the attitude calibration stage. After the adjustment is completed, it automatically releases and returns to the controller. This ensures the accurate execution of attitude adjustment without affecting the subsequent routine cylinder overflow operation by the test personnel. The clear control switching logic avoids the conflict between automation and manual operation and reduces the risk of equipment misoperation. At the same time, the sensor of the test system adopts a modular installation design, which can be directly adapted to excavators of different models and tonnages without the need for major modifications to the equipment. The main controller can also quickly complete the test adaptation of new models by pre-storing parameters of different models. It is suitable for various scenarios such as production testing, after-sales maintenance, and performance verification.
[0019] (4) The test system of the present invention has a simple and reliable structure, low operating cost, and achieves full-process data traceability, providing detailed support for equipment management and performance optimization. All components of the system adopt mature communication protocols and connection methods, which are convenient to install and disassemble, and have low maintenance costs. No additional complex special equipment is required. The attitude adjustment can be completed directly using the original actuator of the excavator, which greatly reduces the equipment investment and deployment costs. At the same time, the data storage module of the main controller can completely record the target attitude parameters, sensor raw data, attitude calculation process data and final test results, and support data export and backtracking analysis. This not only facilitates the test personnel to check test anomalies, but also provides complete data support for the quality control and performance optimization of the excavator, effectively improving the standardization level of the test process. Attached Figure Description
[0020] Figure 1 This is a flowchart of the method of the present invention; Figure 2 This is a schematic diagram of the structure of the present invention. Detailed Implementation
[0021] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the embodiments and specific features in the embodiments are detailed descriptions of the technical solution of the present application, rather than limitations thereof. In the absence of conflict, the embodiments and technical features in the embodiments can be combined with each other.
[0022] 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. Example 1
[0023] like Figure 2As shown, a maximum digging force testing system for excavators includes a tension gauge, a detection component, a main controller, and an actuator. Through layout and collaborative design, the components achieve precision, automation, and high adaptability in the testing process. The two ends of the tensile tester are detachably connected to the excavator bucket teeth and the ground anchor, which ensures the stability of the tensile force transmission during testing and facilitates installation, disassembly, and equipment transportation. The tensile tester is equipped with an integrated tensile tester attitude sensor, which is used to collect attitude information such as the axial direction, horizontality, and angle of the tensile tester in real time. Through the integrated design with the tensile tester, the attitude data acquisition and tensile force transmission are synchronized, providing a benchmark for subsequent vehicle body attitude matching and avoiding the problem of test data distortion caused by tensile tester attitude deviation from the source. The detection components include working device attitude sensors, cylinder displacement sensors, and vehicle body attitude sensors, employing a multi-dimensional distributed layout to achieve comprehensive coverage of excavator attitude data acquisition. Four working device attitude sensors are fixedly installed at the middle sections of the boom, stick, bucket trunnion, and connecting rod, respectively, acquiring spatial attitude information (including pitch and roll angles) of each structural component one-to-one, avoiding blind spots in single sensor detection and ensuring comprehensive working device attitude monitoring. Three cylinder displacement sensors are embedded at the tail of the boom, stick, and bucket cylinders, respectively, acquiring the extension and retraction displacement of the corresponding cylinders in real time. This data complements the attitude sensor data, significantly improving the accuracy of working device attitude calculation through dual-dimensional data acquisition of attitude and displacement. The vehicle body attitude sensor is installed on the horizontal reference plane of the excavator body (e.g., at the bottom of the cab). This installation position minimizes interference from operational vibrations on data acquisition, ensuring the stability of vehicle body level, rotation angle, and axial reference attitude information acquisition, providing a reliable reference for vehicle body attitude calibration. The main controller establishes wired or wireless communication connections with the tension gauge attitude sensor, the working device attitude sensor, the cylinder displacement sensor, the vehicle body attitude sensor, and the excavator's actuators. As the core control unit of the system, its centralized control structure integrates multi-source data and enables automated decision-making: the main controller is configured to read the data collected by each sensor in real time, combine it with the pre-stored target attitude parameters of the excavator's maximum digging force (based on the optimal test attitude calibrated by the machine design) and the dimensional parameters of the excavator's structural components (including the boom, stick, connecting rod lengths, and hinge point spacing), and accurately calculate the excavator's real-time attitude using a built-in spatial geometry algorithm. The main controller outputs control signals to the actuators to automatically adjust the excavator's posture based on the deviation from the target posture, replacing traditional manual judgment and significantly improving the accuracy and efficiency of posture adjustment. Simultaneously, the main controller can interact with the excavator's original controller, temporarily taking over control of the excavator by outputting control commands. This control is automatically released after posture adjustment is complete. This flexible switching structure ensures accurate execution of automated adjustments without affecting subsequent manual operations. Furthermore, the main controller has a built-in PID feedback adjustment mechanism that can dynamically correct posture deviations based on real-time feedback data from various sensors, achieving closed-loop posture calibration and effectively avoiding error accumulation caused by static adjustments. The actuator directly reuses the excavator's original hydraulic actuator system, including the travel motor, swing motor, boom cylinder, stick cylinder, bucket cylinder, and the main valve that controls the movement of the above components. There is no need to add additional dedicated actuators, which greatly reduces the system deployment cost and modification difficulty. The actuator receives control signals from the main controller and drives the corresponding components to complete the vehicle body posture adjustment (travel and swing movements) and the working device posture adjustment (cylinder extension and retraction movements). This ensures that the posture adjustment is consistent with the excavator's original operating logic, improves system adaptability and operational stability, and avoids compatibility issues caused by adding new components.
[0024] As one embodiment, the main controller adopts a modular design, including a data reading module, a data storage module, a data processing module, and a control output module. Each module performs its own function and works together. This modular structure not only facilitates later maintenance, function upgrades, and fault diagnosis, but also improves the stability and reliability of system operation. The main controller establishes a communication connection with an independently set data input module. The data input module acts as a data relay unit and establishes a stable communication connection with the tension gauge attitude sensor and each sensor in the detection component. It is used to synchronously acquire various attitude data and displacement data in real time. After integration and noise reduction processing, the data is transmitted to the main controller. The centralized data transmission structure avoids signal interference caused by multiple sensors being directly connected to the main controller, thereby improving the stability and timeliness of data transmission. The data processing module is the core computing unit. By combining the pre-stored excavator structural component size parameters, cylinder displacement data, and posture data of each structural component, it calculates the real-time relative posture of the working device (including the angles between each structural component and the overall spatial position) through spatial geometric modeling. At the same time, it compares the posture information of the tension gauge posture sensor and the vehicle posture sensor to calculate the vehicle posture deviation. Finally, it generates targeted main valve control signals and motor control signals based on the total deviation. The multi-parameter fusion calculation structure design ensures the accuracy of the control signals and provides a scientific basis for posture adjustment. The data storage module is used to store target attitude parameters, raw data collected by each sensor, intermediate data in the attitude calculation process, and final test result data, so as to realize the retention of data throughout the test process. This facilitates the investigation and review of test anomalies and provides detailed data support for excavator performance optimization and quality control. The control output module is used to accurately transmit the control signals generated by the data processing module to the corresponding components of the actuator. Its signal amplification and stable transmission structure avoids signal attenuation and distortion, ensuring the accuracy and timeliness of the actuator's action response.
[0025] As one embodiment, the PID feedback adjustment mechanism adopts closed-loop control logic. Specifically, the main controller obtains the attitude adjustment data fed back by each sensor in real time through the data reading module, compares the error between the excavator's real-time attitude and the target attitude, dynamically adjusts the output strength and direction of the control signal, and continuously iterates and corrects until the deviation between the real-time attitude and the target attitude meets the preset calibration requirements (e.g., angle deviation ≤ 0.3°). This closed-loop adjustment structure can respond to attitude changes in real time, effectively avoid error accumulation, and significantly improve the accuracy and stability of attitude calibration.
[0026] As one embodiment, the main controller outputs a targeted motor control signal based on the attitude information detected by the tension gauge attitude sensor, driving the travel motor and the slewing motor to adjust the vehicle body attitude, so that the vehicle body attitude is accurately matched with the tension gauge attitude. This attitude matching structure ensures that the force direction of the tension gauge is consistent with the force direction of the excavator, avoiding test errors caused by force deviation and improving the authenticity of the maximum digging force data.
[0027] As one embodiment, the main controller outputs a main valve control signal according to the target posture, drives each cylinder to adjust the posture of the working device, and at the same time forms a dynamic adjustment closed loop by real-time feedback data from each sensor until the posture of the working device reaches the target posture. This cyclic adjustment structure ensures that the working device accurately reaches the optimal test posture, providing a reliable basis for the maximum digging force test.
[0028] As one embodiment, the main controller continuously monitors the attitude information of the dynamometer throughout the attitude adjustment process. If a change in the attitude of the dynamometer is detected, the excavator body and working device attitude are immediately adjusted synchronously. This real-time linkage adjustment structure can quickly respond to disturbances in the test environment, ensuring that the excavator is always in the best test state that adapts to the attitude of the dynamometer, thereby improving the anti-interference ability and data stability of the test process. Example 2
[0029] A second aspect of the present invention also provides a method for testing the maximum digging force of an excavator. This method is based on the excavator maximum digging force testing system described in Embodiment 1 above. Through a collaborative process of automated attitude calibration and precise data acquisition, the authenticity and reliability of the test results are ensured. Specifically, the method includes the following steps: S1. Set up the test environment: Connect one end of the tension gauge to the fixed ground anchor using a high-strength connector for detachable connection, and firmly connect the other end to the excavator bucket teeth through an adapter to ensure that the tension is transmitted without slippage; start the test system, complete the communication link initialization between the main controller and each sensor and actuator, and load the pre-stored target attitude parameters of the maximum digging force of the corresponding model and the size parameters of the excavator structural components to provide basic data for subsequent attitude calculation and adjustment; S2. Real-time Attitude Acquisition and Calculation: The main controller synchronously acquires the attitude data of the tension gauge from the tension gauge attitude sensor, the attitude data of each structural component from the working device attitude sensor in the detection assembly, the cylinder extension and retraction displacement data from the cylinder displacement sensor, and the vehicle body attitude data from the vehicle body attitude sensor through the data input module; combined with the pre-stored excavator structural component size parameters, the data is fused and calculated using the built-in spatial geometry algorithm to accurately obtain the real-time combined attitude of the excavator (including the vehicle body attitude and the relative attitude of the working device). S3. Deviation Comparison and Control Signal Generation: The main controller compares the calculated real-time combined posture of the excavator with the pre-stored maximum digging force target posture parameter by parameter, quantitatively analyzes the deviation of the vehicle body level, the deviation of the included angle of each structural component of the working device, and the deviation of the posture matching between the vehicle body and the tension gauge. Based on the magnitude and direction of the deviation, it generates targeted main valve control signals (corresponding to the extension and retraction of each cylinder) and motor control signals (corresponding to the travel / slewing motor actions), and transmits them to the actuator through the control output module. S4. Attitude Adjustment and Closed-Loop Correction: The actuator receives the control signal output by the main controller and drives the travel motor and swing motor to work together to adjust the vehicle posture, and drives the boom cylinder, stick cylinder and bucket cylinder to extend and retract to adjust the posture of the working device; during the adjustment process, the PID feedback regulation mechanism is activated, and the main controller receives the attitude adjustment data fed back by each sensor in real time, dynamically corrects the output strength and duration of the control signal, avoids attitude adjustment overshoot or error accumulation, and ensures a smooth and accurate adjustment process; S5. Attitude Stability Monitoring and Verification: The main controller continuously monitors the data collected by the tension gauge attitude sensor throughout the attitude adjustment process. If a deviation in the tension gauge attitude is detected (such as due to environmental disturbances or slight displacement of the ground anchor), it immediately returns to step S2 to re-collect data and calculate the real-time attitude, and initiates secondary attitude adjustment. If the tension gauge attitude remains stable, it further verifies whether the excavator's real-time combined attitude meets the preset deviation threshold of the target attitude for the maximum digging force (e.g., angle deviation ≤ 0.3°). S6. Maximum Digging Force Test and Data Acquisition: If the excavator reaches the target posture for maximum digging force, the main controller sends a control release command to the original controller of the excavator, returning control to the original controller; the tester operates the bucket cylinder or stick cylinder normally through the excavator operating handle until the cylinder reaches the overflow state. At this time, the tension gauge collects the maximum tension data output by the excavator in real time and transmits it to the main controller. The main controller records and stores the data, and the test is completed; if the excavator posture does not reach the target posture, return to step S2 to restart the posture adjustment process.
[0030] As one embodiment, in step S6, the overflow state of the bucket cylinder or stick cylinder is used as the sole basis for determining the maximum digging force output of the excavator. This determination method is consistent with the working condition of the maximum output force in the actual operation of the excavator, ensuring that the collected tension data can truly reflect the maximum digging force performance of the excavator. Example 3
[0031] A third aspect of the present invention also provides an excavator that integrates the excavator maximum digging force testing system described in Embodiment 1 above. By reserving an adapter installation structure and signal interaction interface, seamless compatibility between the testing system and the excavator's original system is achieved without requiring large-scale structural modifications to the excavator, thus balancing testing functionality and normal operating performance. The specific structural design is as follows: The excavator features pre-installed standardized mounting seats (with locating pin holes and bolt fixing positions) at the mid-section of the boom, mid-section of the stick, bucket trunnion, and mid-section of the connecting rod. These seats are designed for precise installation of the working device attitude sensors in the detection assembly, ensuring a rigid connection between the sensors and all structural components and preventing data acquisition from being interfered with by vibration. The excavator cab has a pre-installed horizontal mounting plane and signal wiring channel at its bottom for fixing the vehicle attitude sensors, while also preventing sensor installation from affecting the cab space and visibility. Sensor installation interfaces are provided at the rear of the cylinders of the boom cylinder, stick cylinder, and bucket cylinder for embedding cylinder displacement sensors. Sensor cables are routed through the cylinder's built-in protective channels to ensure cable safety during operation.
[0032] Each cylinder, main valve, travel motor, and swing motor of the excavator is equipped with a signal receiving interface that matches the main controller. The main valve adopts an electro-hydraulic proportional control structure, which can accurately receive the PWM control signal output by the main controller and realize stepless adjustment of cylinder extension and retraction and motor movement. The original controller of the excavator has a built-in control switching protocol, which can communicate and interact with the main controller of the test system through the CAN bus. It supports temporary takeover and automatic release of control, ensuring smooth connection between the automated execution of the attitude adjustment stage and subsequent manual operation, without affecting the excavator's normal operating functions.
[0033] Through the above-mentioned adaptation design, the excavator can directly use the testing system to complete the maximum digging force test without the need for additional dedicated testing equipment. This reduces testing costs, improves the convenience and timeliness of testing, and maintains the original operating performance and structural reliability of the excavator. It is suitable for various scenarios such as production line inspection, after-sales maintenance performance verification, and daily working condition performance monitoring.
[0034] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.
Claims
1. A maximum digging force testing system for excavators, characterized in that, include: The tension gauge has two ends for connecting the bucket teeth of the excavator to the ground anchor, and the tension gauge is equipped with a tension gauge attitude sensor for collecting the attitude information of the tension gauge. The detection components include a working device attitude sensor, a cylinder displacement sensor, and a vehicle body attitude sensor. The working device attitude sensor is installed on the excavator boom, stick, bucket, and connecting rod to collect attitude information of the corresponding structural components. The cylinder displacement sensor is installed on the boom cylinder, stick cylinder, and bucket cylinder to collect the extension and retraction displacement of the corresponding cylinders. The vehicle body attitude sensor is installed on the excavator body to collect the vehicle body attitude information. The main controller is connected to the tension gauge attitude sensor, the working device attitude sensor, the cylinder displacement sensor, the body attitude sensor, and the excavator's actuator. The main controller is configured to read the data collected by each sensor, combine it with the pre-stored target attitude parameters of the excavator's maximum digging force and the size parameters of the excavator's structural components, calculate the deviation between the excavator's real-time attitude and the target attitude, and output control signals to the actuator to automatically adjust the excavator's attitude. The main controller can temporarily take over the control of the excavator and adopt a PID feedback adjustment mechanism to dynamically correct attitude deviations based on real-time feedback data from various sensors, thereby achieving attitude calibration. The actuator includes the excavator's travel motor, swing motor, boom cylinder, stick cylinder, bucket cylinder, and main valve that controls the movement of the above components. The actuator is used to receive control signals from the main controller and drive the excavator to complete the adjustment of the excavator's body posture and the posture adjustment of the working device.
2. The excavator maximum digging force testing system according to claim 1, characterized in that, The main controller includes a data reading module, a data storage module, and a data processing module; The main controller is connected to the data input module, which is communicatively connected to the tension gauge attitude sensor and the detection components. It is used to synchronously acquire tension gauge attitude data, working device attitude data, cylinder displacement data and vehicle body attitude data in real time and transmit them to the main controller. The data processing module is used to combine the excavator structural component size parameters, cylinder displacement data and working device posture data to calculate the real-time relative posture of the excavator working device, compare the posture information of the tension gauge posture sensor and the vehicle posture sensor to obtain the vehicle posture deviation, and generate the main valve control signal and motor control signal based on the total deviation between the target posture and the real-time posture. The data storage module is used to store target attitude parameters, raw data collected by each sensor, attitude calculation process data, and final test result data; The main controller is also equipped with a control output module, which is used to transmit the main valve control signal and the motor control signal to the actuator.
3. The excavator maximum digging force testing system according to claim 1, characterized in that, The PID feedback adjustment mechanism is as follows: the main controller dynamically adjusts the control signal based on the attitude data fed back by each sensor in real time, comparing the error between the excavator's real-time attitude and the target attitude, until the deviation between the real-time attitude and the target attitude meets the calibration requirements, thus completing the adjustment of the excavator's attitude.
4. The excavator maximum digging force testing system according to claim 1, characterized in that, The main controller temporarily takes over the control of the excavator by outputting control commands. After the attitude adjustment is completed, the main controller releases the control and the control of the excavator is returned to the original controller of the excavator.
5. The excavator maximum digging force testing system according to claim 1, characterized in that, The main controller outputs motor control signals to drive the travel motor and slewing motor based on the attitude information detected by the tension gauge attitude sensor, thereby adjusting the excavator's body attitude to match the tension gauge attitude.
6. The excavator maximum digging force testing system according to claim 1, characterized in that, The main controller outputs a main valve control signal according to the target posture, driving the boom cylinder, stick cylinder, and bucket cylinder to adjust the posture of the working device. Each sensor provides real-time feedback of posture data until the working device posture reaches the target posture.
7. The excavator maximum digging force testing system according to claim 1, characterized in that, The main controller continuously monitors the attitude information of the tension gauge throughout the entire process of excavator attitude adjustment. If the attitude of the tension gauge changes, the main controller will synchronously adjust the attitude of the excavator body and working device.
8. A method for testing the maximum digging force of an excavator, characterized in that, The excavator maximum digging force testing system according to any one of claims 1-7 includes the following steps: S1. Connect one end of the tension gauge to the ground anchor and the other end to the bucket teeth of the excavator to set up the test environment, start the test system and complete the initialization; S2. The main controller acquires the sensor data collected by the tension gauge attitude sensor and each detection component, and calculates the real-time attitude of the excavator by combining it with the pre-stored excavator structural component size parameters. S3. The main controller compares the deviation between the excavator's real-time posture and the target posture of maximum digging force, generates corresponding main valve control signals and motor control signals, and transmits them to the actuator. S4. The actuator responds to the control signal, drives the travel motor and swing motor to adjust the vehicle body posture, and drives the boom cylinder, stick cylinder and bucket cylinder to adjust the working device posture. During the adjustment process, a PID feedback adjustment mechanism is used to dynamically correct the posture deviation. S5. The main controller continuously monitors the attitude information of the tension gauge. If the attitude of the tension gauge changes, return to step S2 to readjust the excavator attitude. If the attitude of the tension gauge does not change, continue to verify whether the excavator attitude has reached the target attitude. S6. If the excavator reaches the target posture for maximum digging force, the main controller releases control of the excavator. The tester operates the bucket cylinder or stick cylinder until overflow, and collects and obtains the maximum digging force data of the excavator through the tension gauge to complete the test. If the target posture is not reached, return to step S2 to continue adjustment.
9. A method for testing the maximum digging force of an excavator according to claim 8, characterized in that, In step S6, the overflow state of the bucket cylinder or stick cylinder is used as the basis for determining the maximum digging force output by the excavator.
10. An excavator, characterized in that, The excavator is equipped with the maximum digging force testing system for the excavator as described in any one of claims 1-7; the boom, stick, bucket, connecting rod and body of the excavator are all adapted to install sensors with detection components, and each cylinder, main valve, travel motor and swing motor are all adapted to receive control signals from the main controller to realize the attitude adjustment of the body and working device.