Hydraulic Regeneration Control Using Boom and Arm Angle Sensing
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Solution Overview
Problem
Existing work machines with hydraulic actuators face challenges in exercising regeneration control and achieving energy savings when abnormalities occur in pressure sensors, as the condition for regeneration valve operation relies on the magnitude relationship between boom bottom pressure and arm rod pressure detected by these sensors.
Innovation Solution
The implementation of a work machine with a controller that uses angle sensors and a regeneration control valve to regulate hydraulic fluid flow rates, allowing for regeneration control and energy saving even when pressure sensor abnormalities occur, by computing and adjusting the regeneration control valve position based on boom and arm angle signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If pressure sensors are used to detect boom bottom pressure and arm rod pressure for regeneration control, then regeneration control can be achieved and energy saving can be realized, but the system becomes vulnerable to sensor abnormalities that prevent regeneration control
Solution Approach 1:
The patent introduces angle sensors as intermediary devices that detect boom angle and arm angle instead of directly detecting pressure. The controller computes pressure information indirectly from angle data, serving as a mediator that bypasses the need for direct pressure sensor input while still enabling regeneration control functionality.
Solution Approach 2:
The patent replaces the mechanical pressure sensing system with an optical/electronic angle sensing system. Instead of using pressure sensors to directly measure hydraulic pressure, the system uses angle sensors to detect mechanical angles and computationally derives pressure information, substituting a mechanical measurement approach with an electronic computation approach.
2Loss of energy
If pressure sensors are installed to enable regeneration control, then energy saving can be achieved, but the device complexity increases due to additional sensors and control logic
Solution Approach 1:
The angle sensors serve multiple functions: they detect boom angle for regeneration control, detect arm angle for regeneration control, and provide positional information for overall system monitoring. This multi-functionality reduces the need for separate dedicated sensors for each measurement task, thereby reducing overall device complexity while maintaining energy saving capabilities.
Solution Approach 2:
The patent merges the functions of pressure detection and angle detection into a unified control approach. By using angle sensors to infer pressure conditions and combining this with existing angle information already present in the system, the patent consolidates multiple measurement functions into a single integrated control strategy, reducing system complexity.
3Use of energy by moving object
If regeneration control is implemented based on pressure sensor data, then fuel economy can be improved, but the system becomes sensitive to signal line breaking and sensor abnormalities
Solution Approach 1:
The patent prepares for potential sensor failures by implementing a backup measurement approach using angle sensors before pressure sensor abnormalities occur. This alternative measurement method is ready in advance to compensate if pressure sensors fail, cushioning against the harmful effects of sensor abnormalities and maintaining fuel economy improvements.
Solution Approach 2:
The controller continuously monitors angle sensor data and uses this feedback to compute pressure conditions and adjust regeneration control accordingly. This ongoing feedback mechanism allows the system to adapt to changing conditions and maintain reliable operation even when primary pressure sensors fail, as the angle-based feedback provides an alternative information source.
Data Source
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AI summary
Regeneration control is exercised and energy saving is realized even when an abnormality occurs to pressure sensors for hydraulic actuators. A work machine includes: a hydraulic pump (41b) that supplies a hydraulic fluid to a second hydraulic actuator (34); a regeneration circuit (47) that regenerates a return hydraulic fluid from a first hydraulic actuator (32) between the second hydraulic actuator (41b) and the hydraulic pump (41b); a discharge circuit (46) that discharges the return hydraulic fluid from the first hydraulic actuator (32) to a tank; a regeneration amount regulation device (45) that regulates a proportion of a flow rate of the return hydraulic fluid flowing to the regeneration circuit (47) and a flow rate of the return hydraulic fluid flowing to the discharge circuit (46); a controller (100) that controls the regeneration amount regulation device (45); a first operation amount sensor (53a) that detects an operation amount of the first operation device (51); and a first hydraulic actuator speed computing unit (111) that computes a speed of the first hydraulic actuator (32). The controller (111) controls the regeneration amount regulation device on the basis of the operation amount detected by the first operation amount sensor (53a) and the speed computed by the first hydraulic actuator speed computing unit (111).