Hydraulic Excavator Sensor Calibration for Accurate Actuator Control
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Solution Overview
Problem
Existing hydraulic excavator systems face inaccuracies in controlling hydraulic actuators due to errors in pressure and position sensors, leading to potential inaccuracies in flow rate and operation velocity, necessitating a method for easy and accurate calibration of these sensors.
Innovation Solution
The system includes a hydraulic pump, sensors for pressure and position, and a controller that uses calibration maps to adjust sensor readings, allowing for precise calibration of pressure and position sensors by manipulating valve positions and pressures, thereby improving sensing precision and control accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pressure sensors and position sensors are used to control hydraulic actuators, then the operation velocity and flow rate can be adjusted, but sensor errors cause inaccuracies in flow rate control and actuator operation
Solution Approach 1:
The patent changes the parameters used for control by replacing direct reliance on sensor readings with physically measurable quantities (pressures at different points, valve opening areas) that can be combined through known relationships to calculate flow rates, thereby compensating for sensor errors
Solution Approach 2:
The system implements feedback by continuously monitoring pressures at multiple points and valve openings, calculating flow rates based on these measurements and known characteristics, and using this information to adjust valve positions for accurate actuator control
2Measurement precision
If sensor calibration is performed to improve measurement accuracy, then control precision improves, but the calibration process becomes complex and time-consuming
Solution Approach 1:
The system performs self-calibration by using its own operational data (pressures, valve positions) and known physical relationships to automatically calculate correction factors and adjust its control parameters without requiring external calibration equipment or procedures
Solution Approach 2:
The patent incorporates calibration functionality that can be executed preliminarily during system initialization or maintenance periods, establishing accurate calibration data before normal operation begins, thereby ensuring precision without adding complexity to ongoing operations
3Manufacturing precision
If sensor calibration is performed to improve control accuracy, then actuator operation precision improves, but the calibration process requires significant time
Solution Approach 1:
The system performs self-calibration using its own operational parameters and known characteristics, eliminating the need for time-consuming external calibration procedures and equipment setup
Solution Approach 2:
Calibration is performed preliminarily during system initialization or scheduled maintenance windows when the excavator is not in use, establishing accurate calibration data before production operations begin, thereby not impacting productivity
Data Source
AI summary
An object of the present invention is to provide a construction machine that allows easy and accurate calibration of a pressure sensor and enables accurate control of hydraulic actuators. A controller increases the delivery pressure of a hydraulic pump in a state in which first and second meter-out valves and a second meter-in valve are closed and in which a first meter-in valve is opened, and calibrates a first pressure-calculation map such that a pressure calculated on the basis of the first pressure-calculation map matches a pressure calculated on the basis of a supply-pressure-calculation map, and increases the delivery pressure of the hydraulic pump in a state in which the first and second meter-out valves and the first meter-in valve are closed and in which the second meter-in valve is opened, and calibrates a second pressure-calculation map such that a pressure calculated on the basis of the second pressure-calculation map matches the pressure calculated on the basis of the supply-pressure-calculation map.