CN-117328527-B - Control system and control method for improving working efficiency of loader

CN117328527BCN 117328527 BCN117328527 BCN 117328527BCN-117328527-B

Abstract

The invention discloses a control system and a control method for improving the working efficiency of a loader, wherein the control system comprises an electric control handle of a working device, a movable arm angle sensor, a bucket angle sensor, a movable arm angle calibration switch, a bucket angle calibration switch and a hydraulic system controller, and the hydraulic system controller is respectively connected with the electric control handle of the working device, the movable arm angle sensor, the bucket angle sensor, the movable arm angle calibration switch, the bucket angle calibration switch and an electromagnetic proportional control valve of the working device. The invention has low cost, avoids the condition that the movable arm is in a floating position state by continuously operating the handle of the working device of the loader manually, liberates the right hand of a driver, solves the problem that the movable arm and the bucket are gradually controlled to move to a shovel state by manually operating the handle for a long time, reduces the operation time, improves the operation efficiency, the operation convenience and the operation efficiency, and simultaneously improves the comfort of the driver and the service life of the whole loader.

Inventors

LIU ZHOU
DONG WENWEN
WANG CHICHEN
WANG SUDONG

Assignees

徐工集团工程机械股份有限公司科技分公司

Dates

Publication Date: 20260512
Application Date: 20230928

Claims (8)

1. A control method for improving the working efficiency of a loader is characterized by adopting a control system for improving the working efficiency of the loader, comprising an electric control handle of a working device, a control device and a control device, wherein the electric control handle is used for sending control instructions for controlling the lifting, falling, bucket collecting and tipping bucket of the working device of the loader, and the control instruction content comprises four direction signals of the handle and an opening signal of 0-100%; The sensor comprises a movable arm angle sensor and a bucket angle sensor, wherein the movable arm angle sensor is used for acquiring the relative angle between a movable arm of a working device of the loader and a front frame of the loader, and the bucket angle sensor is used for acquiring the relative angle between a rocker arm of the working device of the loader and the movable arm of the working device of the loader; The angle calibration switch comprises a movable arm angle calibration switch and a bucket angle calibration switch, wherein the movable arm angle calibration switch is used for sending a trigger signal to calibrate and store the current angle value of the movable arm angle sensor, and the bucket angle calibration switch is used for sending the trigger signal to calibrate and store the current angle value of the bucket angle sensor; The hydraulic system controller is respectively connected with the working device electric control handle, the sensor, the angle calibration switch and the working device electromagnetic proportional control valve, and is used for receiving a position signal and an opening signal of the working device electric control handle and outputting control current to control the working device electromagnetic proportional control valve so as to drive a movable arm of the working device to lift, the movable arm to fall, the bucket to be retracted and the bucket to be turned; the hydraulic system controller combines the boom angle value and the bucket angle value which are stored in a calibrated mode, the geometric parameters of a working device which are stored in the system, and the real-time angle of the boom angle sensor and the bucket angle sensor to calculate and obtain the real-time length of the boom cylinder, the minimum length of the boom cylinder, the maximum length of the boom cylinder, the moving speed of the boom cylinder, the real-time length of the bucket cylinder, the minimum length of the bucket cylinder, the maximum length of the bucket cylinder and the moving speed of the bucket cylinder; The method comprises the following steps: 1) The hydraulic system controller obtains a position signal and an opening signal of an electric control handle of the working device through a built-in control system, and outputs driving current to control an electromagnetic proportional control valve of the working device, so that a movable arm of the working device is driven to lift, fall down, receive and turn over a bucket; 2) The control system receives angle signals acquired by the movable arm angle sensor and the bucket angle sensor, and receives trigger signals of the movable arm angle calibration switch and the bucket angle calibration switch to store and memorize the movable arm angle value and the bucket angle value; 3) The control system calculates real-time length of the movable arm cylinder, minimum length of the movable arm cylinder, maximum length of the movable arm cylinder, length of the movable arm cylinder at a target position, movement speed of the movable arm cylinder, real-time length of the bucket cylinder, minimum length of the bucket cylinder, maximum length of the bucket cylinder, length of the bucket cylinder at the target position and movement speed of the bucket cylinder according to the real-time angle of the movable arm, the bucket angle value, the geometric parameters of the working device, the real-time angle of the movable arm angle sensor and the real-time angle of the bucket angle sensor which are stored in a calibrated mode; the control system calculates the maximum length of the movable arm cylinder, the minimum length of the movable arm cylinder, the maximum length of the bucket cylinder and the minimum length of the bucket cylinder according to geometrical parameters of the working device; wherein, the step of continuous floating position control of movable arm whereabouts is: 1) The electric control handle of the manual operation working device controls the movable arm of the working device to fall to the lowest position; 2) Pressing a movable arm angle calibration switch, and storing the currently acquired angle value of the movable arm angle sensor; 3) The control system calculates the minimum length of the movable arm cylinder and the real-time length of the movable arm cylinder by combining the stored movable arm angle value with the acquired real-time movable arm angle value with the geometric parameters of the loader working device; 4) Operating an electric control handle of the working device to control the working device to lift the movable arm, fall the movable arm, retract the bucket and turn over the bucket to normally operate; When the electric control handle of the manual operation working device falls down the movable arm, the control system judges whether the length of the current movable arm oil cylinder is less than or equal to (the minimum length of the movable arm oil cylinder is +50mm) in real time, if not, the control system continues to operate the handle to control the movable arm to fall down, if so, the electric control handle of the manual operation working device passes through a hard point structure in the direction of the falling arm and is kept at the hard point structure for more than 2 seconds, the control system judges that the electric control handle of the manual operation working device falls down to keep a floating position function, after the electric control handle of the working device returns to the neutral position, the hydraulic system controller still continuously outputs the maximum falling arm current to control the electromagnetic valve of the working device of the falling arm to enter a floating state and keep the electromagnetic valve in the floating state, and when the opening of the electric control handle of the working device is at any position is more than or equal to 5%, the control system immediately withdraws from the electric control arm to fall to keep the floating position function, and the electric control working device of the working device can perform normal operation of lifting, receiving and turning.
2. The control method for improving the working efficiency of the loader according to claim 1, wherein the step of land-based leveling control is: 1) Operating the electric control handle of the working device to control the working device of the loader to move to a shovel material state; 2) Pressing a movable arm angle calibration switch and a bucket angle calibration switch, and storing the currently acquired angle value of the movable arm angle sensor and the currently acquired angle value of the bucket angle sensor; 3) The control system calculates and obtains the length of the movable arm cylinder in the stored and memorized shovel state and the length of the bucket cylinder, the real-time length of the movable arm cylinder and the real-time length of the bucket cylinder in the shovel state according to the stored movable arm angle value and the bucket angle value, the acquired real-time movable arm angle value and the real-time bucket angle value and by combining with the geometrical parameters of the working device of the loader; 4) Operating an electric control handle of the working device to control the working device to lift the movable arm, fall the movable arm, retract the bucket and turn over the bucket to normally operate; 5) When the electric control handle of the manipulator operating device triggers a ground pasting leveling function enabling signal, the control system judges whether the current length of the movable arm cylinder is equal to (the maximum length of the movable arm cylinder plus the minimum length of the movable arm cylinder)/2 after receiving the triggering signal, if so, the step 6) is entered, and if not, the step 8 is entered; 6) If so, the hydraulic system controller outputs proportional control current to control the movable arm of the working device to move towards the length of the movable arm cylinder in the stored and memorized shovel state, and the bucket adjusts the extension/retraction of the bucket cylinder to move towards the calibrated target position in real time according to the difference between the real-time length of the bucket cylinder and the length of the bucket cylinder in the stored and memorized shovel state; 7) Judging whether the absolute value of the difference between the real-time length of the movable arm oil cylinder, the real-time length of the bucket oil cylinder and the real-time length of the movable arm oil cylinder in the shoveling state of the calibrated storage memory is less than or equal to 5mm, if so, finishing the ground pasting leveling function, otherwise, entering the step 6); 8) If not, judging whether the absolute value of the difference between the real-time length of the bucket cylinder and the length of the bucket cylinder in the calibrated stored and memorized shovel state is less than 100mm, if not, entering the step 9), and if so, entering the step 6); 9) If not, the bucket adjusts the extension/retraction of the bucket cylinder to move towards the calibrated target position in real time according to the difference between the real-time length of the bucket cylinder and the length of the bucket cylinder in the stored and memorized shovel state.
3. The control method for improving the working efficiency of the loader according to claim 2, wherein after the electric control handle of the working device is operated to trigger the ground pasting leveling function, the electric control handle of the working device is manually operated to ensure that the opening of the electric control handle of the working device at any position is more than or equal to 5%, the ground pasting leveling function is canceled, and the electric control handle of the working device can be manually operated by a manipulator to control the working device to lift, retract and turn over for normal operation or trigger the ground pasting leveling function again.
4. The control method for improving the working efficiency of the loader according to claim 1, wherein the step of leveling the ground into the floating position control comprises the steps of: 1) Operating the electric control handle of the working device to control the working device of the loader to move to a shovel material state; 2) Pressing a movable arm angle calibration switch and a bucket angle calibration switch, and memorizing and storing the currently acquired angle value of the movable arm angle sensor and the angle value of the bucket angle sensor; 3) The control system calculates and obtains the length of the movable arm cylinder in the stored and memorized shovel state and the length of the bucket cylinder, the real-time length of the movable arm cylinder and the real-time length of the bucket cylinder in the shovel state according to the stored movable arm angle value and the bucket angle value, the acquired real-time movable arm angle value and the real-time bucket angle value and by combining with the geometrical parameters of the working device of the loader; 4) Operating an electric control handle of the working device to control the working device to lift the movable arm, fall the movable arm, retract the bucket and turn over the bucket to normally operate; 5) When an electric control handle of the working device is operated to trigger a ground pasting leveling floating position function enabling signal, after receiving the triggering signal, the control system judges whether the current length of the movable arm cylinder is equal to (the maximum length of the movable arm cylinder plus the minimum length of the movable arm cylinder)/2, if so, the step 6) is carried out, and if not, the step 9) is carried out; 6) If so, the hydraulic system controller outputs proportional control current to control the movable arm of the working device to move towards the position with the minimum length of +50mm of the movable arm cylinder, and the bucket adjusts the extension/retraction of the bucket cylinder to move towards the calibrated target position in real time according to the difference between the real-time length of the bucket cylinder and the bucket cylinder length in the stored and memorized shovel state, and then the step 7 is entered; 7) Judging whether the length of the current movable arm oil cylinder is < (the minimum length of the movable arm oil cylinder is +50mm), if not, continuously outputting proportional current by the hydraulic system controller to control the movable arm to continuously fall, and if so, outputting stable small current by the hydraulic system controller to control the movable arm to stably slowly fall, and continuously entering the step 8); 8) Judging whether the length of the movable arm oil cylinder is changed within 500ms, if so, continuously outputting a stable current by the hydraulic system controller to control the movable arm to stably and slowly drop, and if not, continuously outputting a maximum movable arm falling current by the hydraulic system controller contacted with the ground at the bottom of the bucket to control the movable arm falling working device electromagnetic valve to enter a floating state and keep the electromagnetic valve in the floating state, so as to finish the functions of leveling and floating by pasting the ground; 9) If not, judging whether the absolute value of the real-time length of the bucket cylinder and the real-time length difference of the bucket cylinder in the calibrated stored and memorized shovel state is less than 100mm, if not, regulating the extension/retraction of the bucket cylinder to move towards the calibrated target position in real time according to the real-time length of the bucket cylinder and the difference of the bucket cylinder length in the stored and memorized shovel state, and if so, entering step 6; 10 After the electric control handle of the operating device triggers the functions of leveling and floating the ground, the opening of the electric control handle of the manual operating device at any position is more than or equal to 5 percent, the functions of leveling and floating the ground are canceled, and the electric control handle of the manual operating device controls the normal operation of lifting, falling, turning over or triggering the functions of leveling and floating the ground again.
5. The control method for improving the working efficiency of the loader according to claim 1, wherein the steps of limiting buffering and bucket control of the tipping bucket are as follows: 1) Operating a handle of the working device to control the bucket of the working device to move to a discharging state; 2) Pressing a bucket angle calibration switch, and memorizing and storing the currently acquired angle value of the bucket angle sensor; 3) The control system calculates and obtains the minimum length of the bucket cylinder, the real-time length of the bucket cylinder and the movement speed of the bucket cylinder in a stored and memorized unloading state according to the stored bucket angle value and the acquired real-time bucket angle value and by combining with the geometric parameters of the loader working device; 4) The control system calculates PID current = set minimum skip current+ (bucket cylinder real-time length-bucket cylinder minimum length) kp+bucket cylinder movement speed kv in real time; wherein kp is a position feedback coefficient, the numerical range is 0-1, kv is a speed feedback coefficient, and the numerical range is 0-1; 5) The electric control handle of the manual operation working device controls the bucket of the working device to perform tipping bucket; 6) Judging whether the tipping bucket current output by an electric control handle of the manual operation working device is less than PID current in real time, if not, entering the step 7), and if so, entering the step 8); 7) If not, judging that the bucket is in the buffer zone of the tipping bucket state, outputting a current formed by operating a handle of the working device by the hydraulic system controller to control the bucket cylinder to retract the bucket tipping bucket, and realizing the collision between the bucket and the movable arm limiting block; 8) If yes, the hydraulic system controller outputs proportional current for operating the electric control handle of the working device to control the bucket cylinder of the working device to retract; 9) The control system judges whether the tipping bucket current output by the electric control handle of the manual operation working device is less than PID current in real time in the tipping bucket process, if not, the hydraulic system controller outputs the proportional current for controlling the bucket cylinder of the working device to retract by the electric control handle of the operation working device, and if so, the step 10 is continued; 10 If so, judging that the tipping bucket state enters a buffer zone, taking the current at the moment of entering the buffer zone and the length of the bucket cylinder as references, and controlling the working device to tip the tipping bucket along with an operation handle, wherein the current is reduced and output in a single parabolic form, and the current reaches a position with a distance of +5mm from the minimum tip cylinder length and is output as 0; 11 After the unloading is finished, the handle of the working device is operated to return to the middle position or the bucket collecting operation is performed, and when the bucket tipping bucket of the working device is controlled again, the control system can perform the judgment and the treatment again.
6. The control method for improving the working efficiency of the loader according to claim 1, wherein the hydraulic system controller is connected with an electric control handle of the working device, a movable arm angle sensor, a bucket angle sensor, a movable arm angle calibration switch, a bucket angle calibration switch and an electromagnetic proportional control valve of the working device through a CAN bus or hard wiring.
7. The control method for improving the working efficiency of the loader according to claim 1, wherein the electric control handle of the working device is arranged in a right armrest position in a cab of the loader, the movable arm angle calibration switch and the bucket angle calibration switch are respectively arranged on a right upright post in the cab of the loader, the movable arm angle sensor is arranged at the joint of a movable arm of the working device and a front frame, the bucket angle sensor is arranged at the joint of the movable arm of the working device and a rocker arm of the working device, the hydraulic system controller is arranged in a rear cover plate in the cab of the loader, and the electromagnetic proportional control valve of the working device is arranged at the joint of the front frame and a pipeline of the hydraulic system of the whole loader.
8. The control method for improving the working efficiency of the loader according to claim 1, wherein the electromagnetic proportional control valve of the working device adopts an integrated electrically controlled hydraulic system multi-way valve, is arranged in a front frame of the loader and is used for receiving a movable arm lifting current, a movable arm falling current, a bucket receiving current and a bucket turning current which are output by a hydraulic system controller and are used for controlling the working device of the loader.

Description

Control system and control method for improving working efficiency of loader Technical Field The invention relates to a control system and a control method for improving the working efficiency of a loader, and belongs to the technical field of loaders. Background At present, the requirements on the working efficiency, the comfort and the intellectualization of the loader are continuously improved in the market, and the control of the working efficiency and the comfort of the loader is an intelligent key part of the loader, so that a control system capable of effectively improving the working comfort and the working efficiency of the loader is researched and developed, and the control system has important significance and can effectively optimize the driving experience of a manipulator. Disclosure of Invention Aiming at the problems in the prior art, the invention provides a control system and a control method for improving the working efficiency of a loader, which can effectively improve the working efficiency and the driving comfort of the loader. In order to achieve the above object, a control system for improving the working efficiency of a loader according to the present invention includes: The electric control handle of the working device is used for sending control instructions for controlling lifting, falling, bucket receiving and tipping bucket of the working device of the loader, and the control instruction comprises four direction signals of the handle and an opening signal of 0-100%; The sensor comprises a movable arm angle sensor and a bucket angle sensor, wherein the movable arm angle sensor is used for acquiring the relative angle between a movable arm of a working device of the loader and a front frame of the loader, and the bucket angle sensor is used for acquiring the relative angle between a rocker arm of the working device of the loader and the movable arm of the working device of the loader; The angle calibration switch comprises a movable arm angle calibration switch and a bucket angle calibration switch, wherein the movable arm angle calibration switch is used for sending a trigger signal to calibrate and store the current angle value of the movable arm angle sensor, and the bucket angle calibration switch is used for sending the trigger signal to calibrate and store the current angle value of the bucket angle sensor; The hydraulic system controller is respectively connected with the working device electric control handle, the sensor, the angle calibration switch and the working device electromagnetic proportional control valve, is used for receiving a position signal and an opening signal of the working device electric control handle, outputting control current to control the working device electromagnetic proportional control valve so as to drive a working device movable arm to lift, the movable arm to fall, receive a bucket and turn over the bucket, receives an angle signal acquired by the sensor, receives a trigger signal of the angle calibration switch and stores and memorizes the movable arm angle value and the bucket angle value, and the hydraulic system controller calculates and obtains the real-time length of the movable arm cylinder, the minimum length of the movable arm cylinder, the movement speed of the movable arm cylinder, the real-time length of the bucket cylinder, the minimum length of the bucket cylinder, the maximum length of the bucket cylinder and the movement speed of the bucket cylinder by combining the movable arm angle value and the bucket angle value which are stored in calibration, and the geometric parameters of the working device stored in the system, the movable arm angle sensor and the real-time angle of the bucket angle sensor. As an improvement, the hydraulic system controller is connected with the electric control handle of the working device, the movable arm angle sensor, the bucket angle sensor, the movable arm angle calibration switch, the bucket angle calibration switch and the electromagnetic proportional control valve of the working device through a CAN bus or hard wiring. The automatic control device is characterized in that an electric control handle of the working device is arranged at a right armrest position in a cab of the loader, a movable arm angle calibration switch and a bucket angle calibration switch are respectively arranged on a right upright post in the cab of the loader, a movable arm angle sensor is arranged at the joint of a movable arm of the working device and a front frame, a bucket angle sensor is arranged at the joint of the movable arm of the working device and a rocker arm of the working device, a hydraulic system controller is arranged in a rear cover plate in the cab of the loader, and a working device electromagnetic proportional control valve is arranged at the joint of the front frame and a hydraulic system pipeline of the whole loader. As improvement, the electromagnetic proportional control valve of the working de