小型挖掘机液压控制系统分析与仿真
摘要
小型液压挖掘机主要用于城市等狭窄地区,代替人力劳动,在世界工程机械市场,属于销量最大的工程机械产品之一。考虑到小挖的工作空间小、作业地形复杂、方便操作、可控性要求高,就要求小挖具有良好的复合动作、精简的液压系统以及优越的精细作业能力。博世力士乐公司开发的独立流量分配系统(LUDV)为单回路系统,具有装配费用低、占用空间小、系统紧凑等特点,仅用1台变量泵即满足了所有作业功能要求,同时小挖复合动作时各负载相近,LUDV系统引起的能量损失较大挖少。
文中以样机PZ70-7的研发、设计、制造及试验为基础,对小型液压挖掘机的液压控制系统进行研究。本机所采用的液压系统即为博世力士乐的带LUDV控制的系统。文章从整机液压系统的设计入手,详细地分析了该液压系统各组成部分的工作原理,并以此为基础,从两个方面分析了LUDV系统的控制特性,一是针对理论分析,对节流控制系统、LS控制系统与LUDV控制系统进行了详细的比较,得出在流量供应充足的情况下,LS系统与LUDV系统都具有良好的控制特性;另一方面是利用动态仿真,运用AMESim软件对饱和情况下的LS系统与LUDV系统进行动态仿真,仿真结果证明LUDV系统比LS系统的速度刚度好,与理论分析相符。并把此时的LUDV模型按照样机的液压原理图进一步完善,外界的输入根据样机测试数据设定,通过分析可知仿真结果与试验结果具有较好的一致性。
理论分析、AMESim仿真和样机测试结果充分说明了LUDV系统适合小挖。因仿真结果是符合理论分析与测试结果,证明了仿真模型的准确性,为挖掘机液压系统更完善的建模仿真与液压系统的进一步优化提供了设计参考。AMESim软件的运用有利于挖掘机的系统设计与液压配件的选择,能充分减少调试时间,因此本文提出了一种减轻设计人员劳动强度与提高效率的设计方法。
The mini hydraulic excavator replace the manpower work is mainly used in cabined area such as city, in the whole engineering machinery market, it belongs to one of maximum sales volume engineering machinery products. Considered the small working space, complex terrain, convenient operation and controllable of the mini excavator, it requests mini excavators possess the good compound movement, the simplification hydraulic system as well as superior fine work ability. The LUDV control system of BOSCH REXROTH Corporation is the single return route system and possesses characteristics of lower assembly expense, taking smaller space, compact system and so on, only one variable displacement pump can be used to satisfy all functional requirements, simultaneously various loads are approximate during the compound movements, the energy loss caused by the LUDV system is smaller than the large excavator.
In the paper, based on the prototypical PZ70-7's research, design, manufacture and experiment, hydraulic control systems of the mini hydraulic excavator were studied. We adopt the BOSCH REXROTH LUDV control system in this prototype. Starting from the complete machine hydraulic system's design, the paper analyzed the operating principle of hydraulic system detailedly, then, LUDV control characteristics was analyzed from two aspects. Firstly, in terms of the theoretical analysis, the throttle control system, the LS control system and the LUDV control system were compared detailedly, the results show, in the flow unsaturated situation, the LS system and the LUDV system possess good control characteristics; On the other hand, the dynamic simulation of LS system and the LUDV system was carried on under the flow saturated situation using AMESim Software, the simulation results conform to the theoretical analysis and demonstrate that the LUDV system possess better speed rigidity than LS system. Then the LUDV model was consummated ulteriorly according to hydraulic schematic diagram of the prototype, the outside inputs were hypothesized according to the basis prototyping testing data, it obtains that the simulation results and the test results have good uniformity through the comparison.
The theoretical analysis results, the AMESim simulation results and the prototyping testing results show the LUDV system adapt to the mini excavator. Because the simulation results conform to the results of the theoretical analysis and the test, it proves that the simulation models are accuracy and it provides design reference for modeling simulation of the complete machine hydraulic system and optimization of hydraulic system. Using the software of AMESim is propitious to design of hydraulic system and choice of hydraulic equipments and can also reduce the debug time fully. So the paper provides a design method of reducing the labor intensity and improving design efficiency.
文中以样机PZ70-7的研发、设计、制造及试验为基础,对小型液压挖掘机的液压控制系统进行研究。本机所采用的液压系统即为博世力士乐的带LUDV控制的系统。文章从整机液压系统的设计入手,详细地分析了该液压系统各组成部分的工作原理,并以此为基础,从两个方面分析了LUDV系统的控制特性,一是针对理论分析,对节流控制系统、LS控制系统与LUDV控制系统进行了详细的比较,得出在流量供应充足的情况下,LS系统与LUDV系统都具有良好的控制特性;另一方面是利用动态仿真,运用AMESim软件对饱和情况下的LS系统与LUDV系统进行动态仿真,仿真结果证明LUDV系统比LS系统的速度刚度好,与理论分析相符。并把此时的LUDV模型按照样机的液压原理图进一步完善,外界的输入根据样机测试数据设定,通过分析可知仿真结果与试验结果具有较好的一致性。
理论分析、AMESim仿真和样机测试结果充分说明了LUDV系统适合小挖。因仿真结果是符合理论分析与测试结果,证明了仿真模型的准确性,为挖掘机液压系统更完善的建模仿真与液压系统的进一步优化提供了设计参考。AMESim软件的运用有利于挖掘机的系统设计与液压配件的选择,能充分减少调试时间,因此本文提出了一种减轻设计人员劳动强度与提高效率的设计方法。
The mini hydraulic excavator replace the manpower work is mainly used in cabined area such as city, in the whole engineering machinery market, it belongs to one of maximum sales volume engineering machinery products. Considered the small working space, complex terrain, convenient operation and controllable of the mini excavator, it requests mini excavators possess the good compound movement, the simplification hydraulic system as well as superior fine work ability. The LUDV control system of BOSCH REXROTH Corporation is the single return route system and possesses characteristics of lower assembly expense, taking smaller space, compact system and so on, only one variable displacement pump can be used to satisfy all functional requirements, simultaneously various loads are approximate during the compound movements, the energy loss caused by the LUDV system is smaller than the large excavator.
In the paper, based on the prototypical PZ70-7's research, design, manufacture and experiment, hydraulic control systems of the mini hydraulic excavator were studied. We adopt the BOSCH REXROTH LUDV control system in this prototype. Starting from the complete machine hydraulic system's design, the paper analyzed the operating principle of hydraulic system detailedly, then, LUDV control characteristics was analyzed from two aspects. Firstly, in terms of the theoretical analysis, the throttle control system, the LS control system and the LUDV control system were compared detailedly, the results show, in the flow unsaturated situation, the LS system and the LUDV system possess good control characteristics; On the other hand, the dynamic simulation of LS system and the LUDV system was carried on under the flow saturated situation using AMESim Software, the simulation results conform to the theoretical analysis and demonstrate that the LUDV system possess better speed rigidity than LS system. Then the LUDV model was consummated ulteriorly according to hydraulic schematic diagram of the prototype, the outside inputs were hypothesized according to the basis prototyping testing data, it obtains that the simulation results and the test results have good uniformity through the comparison.
The theoretical analysis results, the AMESim simulation results and the prototyping testing results show the LUDV system adapt to the mini excavator. Because the simulation results conform to the results of the theoretical analysis and the test, it proves that the simulation models are accuracy and it provides design reference for modeling simulation of the complete machine hydraulic system and optimization of hydraulic system. Using the software of AMESim is propitious to design of hydraulic system and choice of hydraulic equipments and can also reduce the debug time fully. So the paper provides a design method of reducing the labor intensity and improving design efficiency.
引文
[1]李启兵.博世力士乐小型液压挖掘机新技术讲座,2006.
[2]王星.本土化使命—小型挖掘机战国时代来临的前夜.今日工程机械,2006(03)
[3]王丽霞.不断升温的小型挖掘机市场.建筑机械,2005(01)
[4]张宏,张箭.国内外小型挖掘机发展漫谈.建筑机械化,2006(09)
[5]Jack Roberts.MiniExcavators.Equipment World Magazine,2005(07)
[6]尹振.小型挖掘机的特点和用途.交通世界,2004(07)
[7]王谦.小型挖掘机大市场.建筑机械化,2007(12)
[8]张启君.小型挖掘机市场与发展现状.建筑机械化,2006(01)
[9]阎季常.浅议小型挖掘机液压件的发展—认识和思考.工种机械,2006(11)
[10]张栋.基于功率匹配的挖掘机节能控制技术的研究.吉林大学博士学位论文.2005(4)
[11]Allen Myers.Controlling Variable Displacement Hydraulic Pumps for Energy Conservation.SAE 750807
[12]曹善华等.单斗液压挖掘机.北京:建筑工业出版社,1988
[13]Russ Henke,P.E.Hydraulic System Trends:Hydraulic Excavator Technology.Diesel Progress:Engine & Drives,V54.n9,sep 1988.4
[14]魏中奎.液压挖掘机功率匹配控制系统研究.吉林大学硕士学位论文,2003(4)
[15]张铁,张文海,姜武杰,赵文华.小型挖掘机液压控制模式研究.山东交通学院学报,2006(09)
[16]张铁.液压挖掘机结构、原理及使用[M].石油大学出版社,2002
[17]Kazuo U,Hiroyoshi T.Energy saving on hydraulic systems of excavators,SAE Paper 821057,1982.
[18]A.Mylers,"Controlling Variable Displacement Hydraulic Pumps for Energy Conservation"Paper 750807,SAE Meeting,Milwaukee,Sept.1975
[19]W.T.Stephens and H.N.Underwood,"New Concept in Hydraulic Control Controls for Mobile Equipment",Paper 650669,SAE Meeting,Milwaukee,Sept.1965
[20]R.N.Hancox,Hydraulic System for Excavator,U.S.Patent 3406850,OCT.22,1968
[21]S.H.Johnson and L.L.Wlliam E.P.A,0279356,Nov.2,1988
[22]Yasuo Aoki,Kazuo Uehara,Kazuyuki Hirose,Tadao KaraKama,Kouichi Modta,Teruo Akiyama,And Yosuke Oda,Load Sensing Fluid Power System,SAE941714
[23]赵代柱.PC200-6,PC220-6EXCEL型履带式液压挖掘机.工程机械,1997(10)
[24]日立建机,EX200—2使用说明书
[25]陈欠根,纪云锋,吴万荣.负载独立流量分配(LUDV)控制系统.液压与气动,2003(10)
[26]张润利,刘伯颖,武政.工种机械专利信息之小型挖掘机.工程机械文献,2006(04)
[27]张海涛,何清华,施圣贤,阳昶.LUDV负荷传感系统在液压挖掘机上的应用.设计制造,2002
[28]Bosch-Rexroth行走机械用液压及电子控制元件产品样本[Z].
[29]洪江林.中国小挖液压件配套事业发展的挑战.工程机械与维修,2006(11)
[30]崔向华.全新小型挖掘机液压系统.建筑机械,2007(08)
[31]王满增,祖炳洁,贾粮棉.液压挖掘机的负荷传感技术.石家庄铁道学院学报,2003(07)
[32]马健.博世力士乐LUDV技术在小型挖掘机上的应用.建筑机械,2003(06)
[33]高峰,潘双夏.液压挖掘机负流量负荷传感控制策略.农业机械学报,2005(07)
[34]CATERPILLAR.Systems Operation.SENR5464,May,1992
[35]川崎重工.川崎斜板型轴向活塞泵K3V系列用调节器(KR3*-2N09)使用说明书.
[36]Allen Myers.Controlling Variable Displacement Hydraulic Pumps for Energy Conservation.SAE 750807
[37]王长江.当今挖掘机对液压系统的要求及液压系统的发展方向[J].工程机械与维修,1997
[38]黄宗益,李兴华等.分流比负载敏感阀系统.建筑机械,2004(3)
[39]付永领,祁晓野.AMESim系统建模和仿真—从入门到精通[M].北京:北京航空航天大学出版社,2006。
[40]Wilfrid Marquis-Favre,Eric Bideaux,Serge Scavarda.A planar mechanical library in the AMESim simulation software.Part Ⅰ:Formulation of dynamics equations.Simulation Modeling Practice and Theory.17 March 2005
[41]Wilfrid Marquis-Favre,Eric Bideaux,Serge Scavarda.A planar mechanical library in the AMESim simulation software.Part Ⅱ:Library composition and illustrative example.Simulation Modeling Practice and Theory.17 March 2005
[42]程安宁.液压仿真技术的应用与发展.机床与液压,2004(05)
[43]秦家升,游善兰.AMESim软件的特征及其应用[J].工程机械,2004(12)
[44]AMESim User Manual.IMAGINE S.A.2003
[45]Imagine SA:AMESet version 4.0.1,June 2002.
[46]P.Nanua,'Applications of AMESim(?)in Transmission systems analysis',GM Powertrain,2~(nd)AMESim(?)users conference,Paris 2002
[47]刘海丽.基于AMESim的液压系统建模与仿真技术研究.西北工业大学硕士学位论文,2006(03)
[48]丘铭军,赵航,姚培.AMEsim软件及其应用.设备管理与维修技术,2005(08)
[49]彭伟春.小型多功能液压挖掘机研究.吉林大学硕士学位论文,2004(04)
[50]张珊珊.挖掘机液压系统的分析与研究.同济大学硕士学位论文,2005(03)
[51]邦立重机,CE1000-6液压挖掘机计算书
[52]唐伯尧,李加文,李从心.挖掘机液压系统及功率损失分析.机床与液压,2004(05)
[53]祁雪乐,宋健,王会义,李亮.基于AMESim的汽车ESP液压控制系统建模与分析.机床与液压,2005(08)
[2]王星.本土化使命—小型挖掘机战国时代来临的前夜.今日工程机械,2006(03)
[3]王丽霞.不断升温的小型挖掘机市场.建筑机械,2005(01)
[4]张宏,张箭.国内外小型挖掘机发展漫谈.建筑机械化,2006(09)
[5]Jack Roberts.MiniExcavators.Equipment World Magazine,2005(07)
[6]尹振.小型挖掘机的特点和用途.交通世界,2004(07)
[7]王谦.小型挖掘机大市场.建筑机械化,2007(12)
[8]张启君.小型挖掘机市场与发展现状.建筑机械化,2006(01)
[9]阎季常.浅议小型挖掘机液压件的发展—认识和思考.工种机械,2006(11)
[10]张栋.基于功率匹配的挖掘机节能控制技术的研究.吉林大学博士学位论文.2005(4)
[11]Allen Myers.Controlling Variable Displacement Hydraulic Pumps for Energy Conservation.SAE 750807
[12]曹善华等.单斗液压挖掘机.北京:建筑工业出版社,1988
[13]Russ Henke,P.E.Hydraulic System Trends:Hydraulic Excavator Technology.Diesel Progress:Engine & Drives,V54.n9,sep 1988.4
[14]魏中奎.液压挖掘机功率匹配控制系统研究.吉林大学硕士学位论文,2003(4)
[15]张铁,张文海,姜武杰,赵文华.小型挖掘机液压控制模式研究.山东交通学院学报,2006(09)
[16]张铁.液压挖掘机结构、原理及使用[M].石油大学出版社,2002
[17]Kazuo U,Hiroyoshi T.Energy saving on hydraulic systems of excavators,SAE Paper 821057,1982.
[18]A.Mylers,"Controlling Variable Displacement Hydraulic Pumps for Energy Conservation"Paper 750807,SAE Meeting,Milwaukee,Sept.1975
[19]W.T.Stephens and H.N.Underwood,"New Concept in Hydraulic Control Controls for Mobile Equipment",Paper 650669,SAE Meeting,Milwaukee,Sept.1965
[20]R.N.Hancox,Hydraulic System for Excavator,U.S.Patent 3406850,OCT.22,1968
[21]S.H.Johnson and L.L.Wlliam E.P.A,0279356,Nov.2,1988
[22]Yasuo Aoki,Kazuo Uehara,Kazuyuki Hirose,Tadao KaraKama,Kouichi Modta,Teruo Akiyama,And Yosuke Oda,Load Sensing Fluid Power System,SAE941714
[23]赵代柱.PC200-6,PC220-6EXCEL型履带式液压挖掘机.工程机械,1997(10)
[24]日立建机,EX200—2使用说明书
[25]陈欠根,纪云锋,吴万荣.负载独立流量分配(LUDV)控制系统.液压与气动,2003(10)
[26]张润利,刘伯颖,武政.工种机械专利信息之小型挖掘机.工程机械文献,2006(04)
[27]张海涛,何清华,施圣贤,阳昶.LUDV负荷传感系统在液压挖掘机上的应用.设计制造,2002
[28]Bosch-Rexroth行走机械用液压及电子控制元件产品样本[Z].
[29]洪江林.中国小挖液压件配套事业发展的挑战.工程机械与维修,2006(11)
[30]崔向华.全新小型挖掘机液压系统.建筑机械,2007(08)
[31]王满增,祖炳洁,贾粮棉.液压挖掘机的负荷传感技术.石家庄铁道学院学报,2003(07)
[32]马健.博世力士乐LUDV技术在小型挖掘机上的应用.建筑机械,2003(06)
[33]高峰,潘双夏.液压挖掘机负流量负荷传感控制策略.农业机械学报,2005(07)
[34]CATERPILLAR.Systems Operation.SENR5464,May,1992
[35]川崎重工.川崎斜板型轴向活塞泵K3V系列用调节器(KR3*-2N09)使用说明书.
[36]Allen Myers.Controlling Variable Displacement Hydraulic Pumps for Energy Conservation.SAE 750807
[37]王长江.当今挖掘机对液压系统的要求及液压系统的发展方向[J].工程机械与维修,1997
[38]黄宗益,李兴华等.分流比负载敏感阀系统.建筑机械,2004(3)
[39]付永领,祁晓野.AMESim系统建模和仿真—从入门到精通[M].北京:北京航空航天大学出版社,2006。
[40]Wilfrid Marquis-Favre,Eric Bideaux,Serge Scavarda.A planar mechanical library in the AMESim simulation software.Part Ⅰ:Formulation of dynamics equations.Simulation Modeling Practice and Theory.17 March 2005
[41]Wilfrid Marquis-Favre,Eric Bideaux,Serge Scavarda.A planar mechanical library in the AMESim simulation software.Part Ⅱ:Library composition and illustrative example.Simulation Modeling Practice and Theory.17 March 2005
[42]程安宁.液压仿真技术的应用与发展.机床与液压,2004(05)
[43]秦家升,游善兰.AMESim软件的特征及其应用[J].工程机械,2004(12)
[44]AMESim User Manual.IMAGINE S.A.2003
[45]Imagine SA:AMESet version 4.0.1,June 2002.
[46]P.Nanua,'Applications of AMESim(?)in Transmission systems analysis',GM Powertrain,2~(nd)AMESim(?)users conference,Paris 2002
[47]刘海丽.基于AMESim的液压系统建模与仿真技术研究.西北工业大学硕士学位论文,2006(03)
[48]丘铭军,赵航,姚培.AMEsim软件及其应用.设备管理与维修技术,2005(08)
[49]彭伟春.小型多功能液压挖掘机研究.吉林大学硕士学位论文,2004(04)
[50]张珊珊.挖掘机液压系统的分析与研究.同济大学硕士学位论文,2005(03)
[51]邦立重机,CE1000-6液压挖掘机计算书
[52]唐伯尧,李加文,李从心.挖掘机液压系统及功率损失分析.机床与液压,2004(05)
[53]祁雪乐,宋健,王会义,李亮.基于AMESim的汽车ESP液压控制系统建模与分析.机床与液压,2005(08)