Abstract:
According to one aspect of the invention, a hydraulic system includes a controller connected to an operator interface, a pump operable in a first direction for supplying pressurized fluid, and a load-holding valve connected between the pump and a port for connection to an actuator. The load-holding valve may be controlled by the controller and operative in a first position to allow flow to the actuator to operate the actuator against a load and operative in a second position to block load-induced return flow from the actuator to the pump. The controller may be configured to receive a requested actuator stop, to control the first valve to move to the second position in response to the requested actuator stop, to monitor a first system condition in response to the requested actuator stop, to evaluate the monitored system condition with a prescribed criteria, and to determine whether or not to initiate a back-up control routine based on the evaluation.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/813,964 filed Apr. 19, 2013, which is hereby incorporated herein by reference. 
     
    
     FIELD OF INVENTION  
       [0002]    The present invention relates generally to electro-hydrostatic actuator systems, and more particularly to control algorithms for control of such machines. 
       BACKGROUND 
       [0003]    It is common for a work machine such as but not limited to hydraulic excavators, wheel loaders, loading shovels, backhoe shovels, mining equipment, industrial machinery and the like, to have one or more actuated components such as lifting and/or tilting arms, booms, buckets, steering and turning functions, traveling means, etc. Commonly, in such machines, a prime mover drives a hydraulic pump for providing fluid to the actuators. Open-center or closed-center valves control the flow of fluid to the actuators. 
         [0004]    Some modern machines have replaced the traditional hydraulic system described above with an electro-hydrostatic actuator system (EHA). An electro-hydrostatic actuator includes a reversible, variable speed electric motor that is connected to a hydraulic pump, generally fixed displacement, for providing fluid to an actuator for controlling motion of the actuator. The speed and direction of the electric motor controls the flow of fluid to the actuator. Power for the electric motor is received from a power unit, for example a generator, a power storage unit, such as a battery, or both. At, for example, deceleration and/or lowering motion of a load, the power unit may receive power from the said electric motor that is then operated as a generator. A system that includes an electro-hydrostatic actuator is referred to herein as an electro-hydrostatic actuator system. 
       SUMMARY OF INVENTION 
       [0005]    When the load holding valve is closed to hold a load, the pressure between the actuator holding the load and the load holding valve will remain, but the pressure between valve and pump should reduce quickly due to pump leakage in an electro-hydraulic system in which the pump is not being operated to supply pressure. However, if instead the load torque at the pump/electric motor/inverter remains present, this indicates that the pressure has not decreased and that the load holding valve has failed to close fully or at all. In such case, exemplary systems still allow the load to be lowered in a controlled fashion and a warning may be issued to the operator. 
         [0006]    According to one aspect of the invention, a hydraulic system includes a controller connected to an operator interface; a pump operable in a first direction for supplying pressurized fluid; and a load-holding valve connected between the pump and a port for connection to an actuator. The load-holding valve may be controlled by the controller and operative in a first position to allow flow to the actuator to operate the actuator against a load and operative in a second position to block load-induced return flow from the actuator to the pump. The controller may be configured to receive a requested actuator stop, to control the first valve to move to the second position in response to the requested actuator stop, to monitor a first system condition in response to the requested actuator stop, to evaluate the monitored system condition with a prescribed criteria, and to determine whether or not to initiate a back-up control routine based on the evaluation. 
         [0007]    Optionally, the back-up routine includes operating the pump to control load-induced movement of the actuator. 
         [0008]    Optionally, the controller is further configured to generate an alert indicating failure of the first valve. 
         [0009]    Optionally, the controller is further configured to run the pump to depressurize hydraulic fluid between the pump and the first valve after the first valve is controlled to close. 
         [0010]    Optionally, the hydraulic system further includes a second valve selectively fluidly connecting a hydraulic passage between the pump and the first valve to a reservoir. The controller may be further configured to connect the fluid passage to the reservoir after the first valve is controlled to close. 
         [0011]    Optionally, the pump is a bi-directional pump operable in a first direction for supplying pressurized fluid through the first valve to the hydraulic actuator for operating the actuator in one direction, and operable in a second direction opposite the first direction for supplying pressurized fluid through a second valve to the hydraulic actuator for operating the actuator in a direction opposite the first direction. 
         [0012]    Optionally, the hydraulic system may further include a hydraulic actuator to and from which hydraulic fluid is supplied and returned in opposite directions to operate the actuator in opposite directions. 
         [0013]    Optionally, the hydraulic system may further include a boost system for accepting fluid from or supplying fluid to a hydraulic circuit of the hydraulic system. The boost system may include a boost pump for supplying fluid to a fluid make-up/return line that selectively is in fluid communication with the hydraulic actuator, and a boost electric machine for driving the boost pump, the electric machine connected to a boost electric power source through a boost inverter. 
         [0014]    Optionally, the hydraulic system may include an electric machine operated by the controller and connected to an electrical source through an inverter to drive the pump. 
         [0015]    Optionally, the monitored system condition is pressure between the pump and the first valve. 
         [0016]    Optionally, the monitored system condition is electric machine torque. 
         [0017]    According to another aspect of the invention, a method of detecting a failure of hydraulic valve configured to control flow between a pump and an actuator in a hydraulic system may include the steps of receiving a requested stop of the actuator; controlling the valve to close in response to the requested stop of the actuator; monitoring a first system condition in response to the requested stop of the actuator; evaluating the monitored system condition with a prescribed criteria; and determining whether or not the valve has failed based on the evaluation. 
         [0018]    Optionally, the method may further include determining whether or not to operate the pump to stop the actuator based on the evaluation. 
         [0019]    Optionally, monitoring a first system condition includes monitoring pressure between the pump and the valve. 
         [0020]    Optionally, monitoring a first system condition includes monitoring electric machine torque, wherein the electric machine operated the pump. 
         [0021]    Optionally, the method may further include operating the pump to reduce pressure between the pump and the hydraulic valve after the controlling. 
         [0022]    Optionally, the method may further include opening a bleed valve to reduce pressure between the pump and the hydraulic valve after the controlling. 
         [0023]    Optionally, the method may further include operating the pump in one direction for supplying pressurized fluid through the valve to the hydraulic actuator for operating the actuator in a first direction, and operating the pump in a second direction opposite the first direction for supplying pressurized fluid through a second valve to the hydraulic actuator for operating the actuator in a direction opposite the first direction. 
         [0024]    Optionally, the method may further include driving the pump via an electric machine connected to an electrical source through an inverter. 
         [0025]    Optionally, the method may further include generating an alert indicating failure of the hydraulic valve based on the determination. 
         [0026]    The foregoing and other features of the invention are hereinafter described in greater detail with reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]      FIG. 1  illustrates an exemplary schematic electro-hydrostatic actuator system; 
           [0028]      FIG. 2  illustrates an exemplary, simplified schematic embodiment of a system showing an actuator extension motion, direction of fluid flow indicated by arrows and load holding valve states to enable this motion; 
           [0029]      FIG. 3  illustrates an exemplary, simplified embodiment of a system showing an actuator retraction motion, direction of fluid flow indicated by arrows and load holding valve states to enable this motion; 
           [0030]      FIG. 4  illustrates a simplified exemplary embodiment of the system including an optional pressure sensor; 
           [0031]      FIG. 5  illustrates another simplified exemplary embodiment of the system including an optional hydraulic fluid drain valve; 
           [0032]      FIG. 6  illustrates an example signal control flow diagram depicting an exemplary method for lowering an actuator in an exemplary hydraulic system. 
       
    
    
     DETAILED DESCRIPTION 
       [0033]    Exemplary embodiments of the invention relate generally to hydraulic actuation systems for extending and retracting at least one asymmetric hydraulic cylinder in a work machine, such as but not limited to hydraulic excavators, wheel loaders, loading shovels, backhoe shovels, mining equipment, industrial machinery and the like, having one or more actuated components such as lifting and/or tilting arms, booms, buckets, steering and turning functions, traveling means, etc. 
         [0034]    When a load holding valve is commanded open, the pump/electric motor inverter will experience a load torque representing hydraulic cylinder pressure. 
         [0035]    When the load holding valve is commanded to close by a controller, the pressure between cylinder and valve will remain but the pressure between valve and pump should reduce quickly due to pump leakage. However, if instead the load torque at the pump/electric motor inverter remains present, this indicates that the load holding valve has failed to close. In such case, exemplary systems still allow the load to be lowered in a controlled fashion and a warning may be issued to the operator. 
         [0036]    Referring in detail to  FIG. 1 , an exemplary embodiment of an electro-hydrostatic actuator system  100  is shown. The system includes at least one actuator  190  to be mechanically connected to a work machine and hydraulically connected to the system  100 . 
         [0037]    An inverter  110  may be connected to an electrical energy source or energy unit such as an electrical storage (e.g., one or more batteries) or a generator and controls an electric machine  120  (e.g., an electric motor) in bi-directional speed or torque control mode. The electric machine  120  may be mechanically coupled to and drive a hydraulic pump  130 , which may be any appropriate type, but is generally a fixed displacement, variable speed pump. The inverter may also store energy generated by the electrical machine in the storage when the pump is back-driven by hydraulic fluid, for example, during a down motion of the actuator when under an external load. 
         [0038]    The operator of the system may command a desired actuator speed or force through an input device such as a joystick  150  connected to a controller  140 . In other embodiments, a separate command controller may generate the command signal that is passed to the controller  140 , for example if the work machine is being remotely or autonomously controlled. 
         [0039]    The controller  140  issues commands to the inverter  110  which in conjunction with the motor  120  and pump  130  allows generation of bi-directional flow and pressure via the hydraulic pump  130 . The flow is then directed through load holding valves  170 ,  180  to the actuator  190  yielding the desired actuator motion. 
         [0040]      FIG. 1  shows the load holding valves  170 ,  180  as being ON/OFF type valves, however either or both of these valves could also be flow-control valves, orifice valves or any other proportionally adjustable valve. Exemplary valves are poppet valves so as to prevent leakage through the valves when the valves are closed. 
         [0041]    Because most mobile machinery uses un-balanced actuators with a large and small volume chamber, a flow management system  200 , for example as presented in U.S. Patent Application Publication No. 2011/0030364 A1 (incorporated herein by reference), controlled by a second inverter  210  and second electric machine  220  and second hydraulic pump  230 , provides whatever input flow required by the actuator pump  130  via the shuttle valve  160 . 
         [0042]    During an actuator extend motion to lift a load, the actuator pump  130  provides flow into the large volume of the actuator  190  (the piston side) and the flow management system  200  is connected to the actuator pump inlet via the shuttle valve  160 , ensuring that the flow difference of large volume minus small volume (the rod side) is provided to the actuator pump  130 . 
         [0043]    During an actuator retraction motion to lower a load, the actuator pump  130  consumes flow from the large volume of the actuator  190  and the flow management system  200  is connected to the actuator pump outlet via the shuttle valve  160 , diverting excess flow of large volume minus small volume back to the flow management system  200  and ultimately to the hydraulic reservoir  135 . 
         [0044]    Although the actuator depicted is a cylinder, it is contemplated that other actuators are possible. Further, the orientation of the cylinder may be reversed from that which is shown. 
         [0045]    In general, when the operator does not command an actuator motion, both load holding valves  170 ,  180  may be closed to remove the hydraulic load from the pump, reduce consumption of electrical energy and prevent the load from dropping in case the pump drive source is turned off. This may cause the pressure between the load holding valves and pump to decay over time, largely due to leakage in the pump. The pressure between the load holding valves and actuator, however, remains at a level to support the external load without actuator motion. 
         [0046]    Referring now in detail to  FIG. 2 , an exemplary embodiment of an electro-hydrostatic actuator system  100  is shown. The system is the same as that shown in  FIG. 1 , except that the flow management system  200  is hidden to focus on operation of the remaining system. Hydraulic connection  214  indicates the to/from connection to the flow management system  200  shown in  FIG. 1 . 
         [0047]    Referring back to  FIG. 2 , the hydraulic actuator  190  is mechanically connected to a work machine and the arrow above the actuator is used to indicate the direction of motion: extension of the actuator. The remaining arrows indicate hydraulic fluid flow direction in the system. 
         [0048]    In order to enable an actuator extension motion, load holding valve  170  needs to be commanded open as indicated to allow fluid flow from the small volume of the actuator back to the electrically driven pump  130 . Load holding valve  180  does not have to be commanded open in this case, since the type of valve used in this example includes a check valve that will pass flow freely from pump  130  into the large volume of the actuator. 
         [0049]    Referring now in detail to  FIG. 3 , an exemplary embodiment of an electro-hydrostatic actuator system is shown. The system is the same as that shown in  FIG. 1 , except that the flow management system  200  is hidden to focus on operation of the remaining system. Hydraulic connection  214  indicates the to/from connection to the flow management system shown as item  200  in  FIG. 1 . The arrow above the actuator is used to indicate the direction of motion: retraction of the actuator. 
         [0050]    In order to enable an actuator retraction motion, load holding valve  180  needs to be commanded open as indicated to allow fluid flow from the large volume of the actuator back to the electrically driven pump  130 . Load holding valve  170  does not have to be commanded open in this case, since the type of valve used in this example includes a check valve that will pass flow freely from pump  130  into the large volume of the actuator. 
         [0051]    Referring now in detail to  FIG. 4 , a simplified exemplary embodiment of an electro-hydrostatic actuator system is shown at  300 . The system  300  is substantially the same as the above-referenced system  100 , and consequently the same reference numerals but indexed by  100  are used to denote structures corresponding to similar structures in the system. In addition, the foregoing description of the system  100  is equally applicable to the system  300  except as noted below. Moreover, it will be appreciated upon reading and understanding the specification that aspects of the systems may be substituted for one another or used in conjunction with one another where applicable. 
         [0052]    If the load holding valve  370  is closed as shown in  FIG. 4 , the pressure between the load holding valves and pump  330  will decay over time, largely due to leakage in the pump, in which case the electric machine  320  will be “disconnected” from the hydraulic load and experience no or only very little torque. The pressure between the load holding valves and actuator  390  however remains at a level to support the external load without actuator motion. 
         [0053]    Otherwise, if the load holding valve  370  is opened to support a cylinder extension motion, the electric machine  320  will be exposed or “connected” to the load. 
         [0054]    An optional pressure sensor  371  may be included in exemplary embodiments and is shown here for example. This pressure sensor may be of any type known to those skilled in the art and may be fluidly connected between the motor and the load holding valve. This sensor may be used to directly sense pressure rather than indirectly sensing pressure via the motor torque by way of the inverter. It may optionally be used additionally to sensing motor torque to provide system redundancy. 
         [0055]    Referring now in detail to  FIG. 5 , a simplified exemplary embodiment of an electro-hydrostatic actuator system is shown at  400 . The system  400  is substantially the same as the above-referenced systems  100  and  300 , and consequently the same reference numerals but indexed by  100  are used to denote structures corresponding to similar structures in the system. In addition, the foregoing description of the systems  100  and  300  is equally applicable to the system  400  except as noted below. Moreover, it will be appreciated upon reading and understanding the specification that aspects of the systems may be substituted for one another or used in conjunction with one another where applicable. 
         [0056]    The addition of a small valve  413  to fluid line  417  allows the pressure between the pump  430  and valve  470  to drain when the valve  470  is commanded closed. This allows for potentially faster draining of the line and, therefore, faster response time. 
         [0057]    Referring now in detail to  FIG. 6 , a signal control flow diagram is shown to support the detailed illustration of process flow of the invention. Although discussed in reference to an “operator” or “user”, it is contemplated that such method may be employed by an on-site human operator, a remote human operator, or in an autonomous or semi-autonomous mode in which an “operator command” is generated by the autonomous or semi-autonomous control program. Further, it should be understood that references to the stopping of a “lowering command” or the like encompass any command indicating a stop of the motion of an actuator being acted upon by an external force in an unbalanced manner (i.e., resulting in a net external force on the actuator). 
         [0058]    The logic starts at the initial Start block  620 . 
         [0059]    Continuous and/or intermittent monitoring of the operator input device occurs in block  621 . 
         [0060]    The operator input may be passed along to a decision block  622  to determine if the operator has commanded a lowering motion to come to a stop. If not, the routine continues to monitor the operator input. 
         [0061]    If a requested stop of the lowering motion is received, the pump may be controlled such that deceleration occurs and the actuator comes to a stop as desired at block  623 . Such stop may normally occur by way of the pump and motor controlling the stop, but it is also contemplated that one or more valves (such as, for example, the load holding valve  170 ,  370 ,  470 ) may also be involved in the deceleration. 
         [0062]    Then, the load holding valve may be commanded closed at block  624 . 
         [0063]    At block  625  a timer is started to keep track of time elapsed since the valve was commanded close. 
         [0064]    At block  626 , the residual electric machine torque may be continuously or intermittently monitored, while the pressure between closed load holding valve and pump is expected to decay due to pump leakage. This torque may be monitored as an indicator of this line pressure, although a direct pressure measurement may be used in addition to or alternatively to the torque measurement. A pressure transducer directly measuring this pressure may provide for redundant measurement of this value. 
         [0065]    At block  627 , the value of the timer within each time step may be compared against a pre-established TimeOut value. This value may be a fixed or manually or automatically adjustable value based on various factors such as line size, pump type, fluid contamination, fluid temperature, pump wear, and/or the like. Typical lengths for this value may preferably be in the 1-10 second range, and may be preferably about 5 seconds. 
         [0066]    As long as the TimeOut is not reached, another decision block  628  evaluates if electric machine torque has decreased below a pre-established torque threshold. Again, this prescribed criterion may be a fixed or manually or automatically adjustable value. For example, a pressure may also be measured between the actuator and the load holding valve in hydraulic line  316 ,  416 , and this pressure value may be compared with the electric machine torque. This comparison may increase reaction time because the alternative of using a fixed value may require a value that is very low so as to capture all or most instances. 
         [0067]    If the prescribed criteria is not met, the timer may be incremented at block  629  and the routine may continue in the loop as shown. If the electric machine torque has decreased below the prescribed criteria, it may be concluded that the load holding valve is closed, as desired, and valve status “OK” may be reported via block  630 . 
         [0068]    The routine may then end at block  633 . 
         [0069]    If block  627  recognizes that the timer value matches or exceeds TimeOut, it may cause block  631  to report a valve failure, which could then warn the operator of this failure. 
         [0070]    Optionally, a predefined routine  632  may then ensure that the load is safely lowered, for example, by operating the electric machine and pump to lower the load. Once accomplished, the routine may end at block  633 . 
         [0071]    An optional fail-safe routine at block  632  may be to provide a second, back-up valve (such as a load holding valve) to either hold the load or to lower the load in a controlled manner. 
         [0072]    Another alternative to increase the speed of the detection may include actively controlling the pump/motor to relieve the pressure between the load holding valve and pump as soon as the valve is commanded close at or around, for example, block  624 . This can be achieved, for example, by allowing the motor-pump to back-spin a certain amount of time or a certain number of revolutions. 
         [0073]    Another means of speeding this detection may include, as shown in  FIG. 5  above, adding a small bleed valve to hose and draining that hydraulic line by opening the bleed valve as soon as the valve is commanded closed, for example at or around block  624 . It is further contemplated that the valve can be on/off, proportional or any other technology that achieves the desired results by one having ordinary skill in the art. 
         [0074]    Exemplary methods can be used to detect valve functionality when stopping a retraction or extension (lowering or lifting) motion. In general, it is most suitable when load forces are such that a certain amount of pressure remains in the cylinder after the load holding valve is closed, for example, when the actuator is acted upon by an outside force. The method can also be used on machine functions controlled by valves other than load holding valves. 
         [0075]    While for purposes of simplicity of explanation, the illustrated method is shown and described above as a series of blocks, it is to be appreciated that the method is not limited by the order of the blocks, as some blocks can occur in different orders or concurrently with other blocks from that shown or described. Moreover, less than all the illustrated blocks may be required to implement an example methodology. Furthermore, additional or alternative methodologies can employ additional, not illustrated blocks. 
         [0076]    In the flow diagram, blocks denote “processing blocks” that may be implemented with logic. The processing blocks may represent a method step or an apparatus element for performing the method step. A flow diagram does not depict syntax for any particular programming language, methodology, or style (e.g., procedural, object-oriented). Rather, a flow diagram illustrates functional information one skilled in the art may employ to develop logic to perform the illustrated processing. It will be appreciated that in some examples, program elements like temporary variables, routine loops, and so on, are not shown. It will be further appreciated that electronic and software applications may involve dynamic and flexible processes so that the illustrated blocks can be performed in other sequences that are different from those shown or that blocks may be combined or separated into multiple components. It will be appreciated that the processes may be implemented using various programming approaches like machine language, procedural, object oriented or artificial intelligence techniques. 
         [0077]    In one example, methodologies are implemented as processor executable instructions or operations provided on a computer-readable medium. Thus, in one example, a computer-readable medium may store processor executable instructions operable to perform a method. 
         [0078]    While  FIG. 6  illustrates various actions occurring in serial, it is to be appreciated that various actions illustrated in  FIG. 6  could occur substantially in parallel. 
         [0079]    “Logic,” as used herein, includes but is not limited to hardware, firmware, software or combinations of each to perform a function(s) or an action(s), or to cause a function or action from another logic, method, or system. For example, based on a desired application or needs, logic may include a software controlled microprocessor, discrete logic like an application specific integrated circuit (ASIC), a programmed logic device, a memory device containing instructions, or the like. Logic may include one or more gates, combinations of gates, or other circuit components. Logic may also be fully embodied as software. Where multiple logical logics are described, it may be possible to incorporate the multiple logical logics into one physical logic. Similarly, where a single logical logic is described, it may be possible to distribute that single logical logic between multiple physical logics. 
         [0080]    “Software,” as used herein, includes but is not limited to, one or more computer or processor instructions that can be read, interpreted, compiled, or executed and that cause a computer, processor, or other electronic device to perform functions, actions or behave in a desired manner. The instructions may be embodied in various forms like routines, algorithms, modules, methods, threads, or programs including separate applications or code from dynamically or statically linked libraries. Software may also be implemented in a variety of executable or loadable forms including, but not limited to, a stand-alone program, a function call (local or remote), a servelet, an applet, instructions stored in a memory, part of an operating system or other types of executable instructions. It will be appreciated by one of ordinary skill in the art that the form of software may depend, for example, on requirements of a desired application, the environment in which it runs, or the desires of a designer/programmer or the like. It will also be appreciated that computer-readable or executable instructions can be located in one logic or distributed between two or more communicating, co-operating, or parallel processing logics and thus can be loaded or executed in serial, parallel, massively parallel and other manners. 
         [0081]    Suitable software for implementing the various components of the example systems and methods described herein may be produced using programming languages and tools like Java, Java Script, Java.NET, ASP.NET, VB.NET, Cocoa, Pascal, C#, C++, C, CGI, Perl, SQL, APIs, SDKs, assembly, firmware, microcode, or other languages and tools. Software, whether an entire system or a component of a system, may be embodied as an article of manufacture and maintained or provided as part of a computer-readable medium. 
         [0082]    Algorithmic descriptions and representations used herein are the means used by those skilled in the art to convey the substance of their work to others. An algorithm or method is here, and generally, conceived to be a sequence of operations that produce a result. The operations may include physical manipulations of physical quantities. Usually, though not necessarily, the physical quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated in a logic and the like. 
         [0083]    It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like. It should be borne in mind, however, that these and similar terms are to be associated with the appropriate physical quantities and lo are merely convenient labels applied to these quantities. Unless specifically stated otherwise, it is appreciated that throughout the description, terms like processing, computing, calculating, determining, displaying, or the like, refer to actions and processes of a computer system, logic, processor, or similar electronic device that manipulates and transforms data represented as physical (electronic) quantities. 
         [0084]    Although the invention has been shown and described with respect to a certain embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.