Construction machine

Provided is a construction machine capable of detecting a stuck-open state of a surplus flow control valve in real time during operation without involving a reduction in the operational speed. The construction machine is equipped with: a surplus flow control valve control section configured to output a closing command to a first surplus flow control valve at the operation start when an operation amount signal of an operation lever device is detected; a pump delivery control section configured to output a delivery flow rate command to an adjustment section of an open circuit pump; an assist valve control section configured to continue to output a closing command from before to an assist valve; a sticking detection determination section configured to compare a pressure signal with a previously set threshold value and determining that the surplus flow control valve is in a stuck-open state when the pressure signal is less than the threshold value and determining that the surplus flow control valve is normal when the pressure signal exceeds the threshold value; and a stop signal generating section configured to input therein a sticking determination signal, output in the case of a stuck-open state a control signal maintaining a closed state of the assist valve to the assist valve control section, and output in the case of a normal state a control signal causing the assist valve to perform an opening operation to the assist valve control section.

TECHNICAL FIELD

The present invention relates to a construction machine.

BACKGROUND ART

In the field of a construction machine such as a hydraulic excavator, there exists a closed circuit hydraulic drive system in which, in order to achieve energy saving for the hydraulic system, a both-way tilting hydraulic pump (hereinafter also referred to as the closed circuit pump) and a hydraulic actuator are connected to each other in a closed-circuit-like fashion and in which the drive speed of the hydraulic actuator is controlled through delivery flow rate control of the both-way tilting hydraulic pump to return the return fluid from the hydraulic actuator to the closed circuit pump (see, for example, Patent Document 1).

There is a failure diagnosis device detecting sticking failure of a hydraulic proportional valve (hereinafter also referred to as the proportional valve) used in hydraulic devices in general (see, for example, Patent Document 2). This failure diagnosis device for the proportional valve is a failure diagnosis device for the proportional valve of a vehicle hydraulic device having a pump, accumulator, and proportional valve, and is equipped with proportional valve drive direction means for outputting a proportional valve direct current for driving the proportional valve, pressure measurement means for measuring the pump pressure of the pump, and proportional valve sticking determination means for making sticking determination of the proportional valve based on the proportional valve direct current and the pump pressure. The proportional valve sticking determination means has first pressure storage means storing the pump pressure when the pump stops, second pressure storage means storing the pump pressure when a predetermined period of time has elapsed since the stopping of the pump, and first pressure difference calculation means calculating the difference between the pump pressure stored in the first pressure storage means and the pump pressure stored in the second pressure storage means; and in the case where when the pump is stopped and “close” direction is given to the proportional valve after increasing the pressure through the operation of the pump for a predetermined period of time, the difference in the pump pressure calculated by the first pressure difference calculation means is equal to or more than a predetermined value, it is determined that the proportional valve suffers from stuck-open failure.

PRIOR ART DOCUMENT

Patent Document

SUMMARY OF THE INVENTION

Problem to be Solved by the Invention

In the closed circuit hydraulic drive system described in Patent Document 1 mentioned above, in the case where the hydraulic actuator is a one-rod hydraulic cylinder, the head fluid chamber side pressure portion and the rod fluid chamber side pressure receiving portion of the piston differ in area, so that the amount of working fluid flowing into the hydraulic cylinder differs from the amount of working fluid flowing out of the hydraulic cylinder with the operation of the piston. As a result, inside the closed circuit, there are generated a portion where there is an excessive amount of working fluid and a portion where there is a shortage of working fluid.

In order to suppress such excess/shortage of working fluid inside the closed circuit, there is connected to the head fluid chamber side of the hydraulic cylinder a one-side tilting hydraulic pump (hereinafter referred to as the open circuit pump) supplying shortage working fluid via a selector valve, and, between the open circuit pump and the selector valve, there is provided a hydraulic proportional valve making it possible to discharge surplus working fluid to a tank. This hydraulic proportional valve is referred to as the surplus flow control valve.

For example, in the case where one hydraulic cylinder is driven in the expanding direction, the selector valve is opened to supply working fluid to the hydraulic cylinder head fluid chamber side from the open circuit pump as well as from the closed circuit pump, with the return fluid from the hydraulic cylinder rod fluid chamber side being sucked by the closed circuit pump. At this time, the surplus flow control valve is closed. On the other hand, in the case where the hydraulic cylinder is driven in contracting direction, working fluid is supplied to the hydraulic cylinder rod fluid chamber side from the closed circuit pump, with the return fluid from the hydraulic cylinder head fluid chamber side being sucked by the closed circuit. At this time, the selector valve and the surplus flow control valve are opened to discharge the return fluid from the hydraulic cylinder head fluid chamber side to the tank. At this time, the open circuit pump delivers no working fluid.

In the surplus flow control valve constituting this hydraulic drive system, when, for example, the valve is stuck open to cause the inner line to remain open, the hydraulic fluid in the hydraulic cylinder is allowed to be discharged into the tank via the surplus flow control valve stuck open. As a result, there is generated the possibility of the hydraulic cylinder operating abruptly in an unintended direction, deteriorating the operability of the construction machine.

In the proportional valve failure diagnosis device disclosed in Patent Document 2, it is necessary to temporarily stop the device, and to give direction to stop the pump and to “close” the proportional valve. In the case where the failure diagnosis device of Patent Document 2 is applied to the work machine (construction machine) disclosed in Patent Document 1, in order to determine the stuck-open state of the surplus flow control valve, it is necessary to temporarily stop the device to close the selector valve, to start the open circuit pump, and to measure the pressure value of the open circuit pump generated when the surplus flow control valve is closed for the stuck-open state determination. Thus, all this while, it is impossible to drive the hydraulic cylinder by the open circuit pump, and the work by the construction machine needs to be stopped. This results in a reduction in the work speed of the machine as a whole and deterioration in productivity.

The present invention has been made in view of the above problem. It is an object of the present invention to provide a construction machine capable of detecting a stuck-open state of the surplus flow control valve in real time during operation without involving a reduction in the operational speed of the construction machine.

Means for Solving the Problem

To achieve the above object, there is adopted, for example, the structure as described in the appended claims. The present application includes a plurality of means for solving the above problem, an example of which is a construction machine including: a first closed circuit unit equipped with a first closed circuit pump, and a first hydraulic cylinder connected to the first closed circuit pump in a closed-circuit-like fashion; a first open circuit unit equipped with a first open circuit pump connected to a head fluid chamber side line of the first hydraulic cylinder via a first assist valve that is a selector valve, and a first surplus flow control valve arranged in a line branching off from a first open circuit pump delivery side line that is a line between the first open circuit pump and the first assist valve, the first surplus flow control valve enabling a working fluid from a head fluid chamber of the first hydraulic cylinder to be discharged into a tank; and a control unit equipped with a first operation lever device directing an operation of the first hydraulic cylinder, a first pressure sensor measuring a pressure of the first open circuit pump delivery side line, a plurality of adjustment sections each adjusting delivery flow rates of the first closed circuit pump and the first open circuit pump, and a controller outputting command signals to the first surplus flow control valve, the first assist valve, and the plurality of adjustment sections. The controller is equipped with: a pressure detection section configured to take in a first pressure signal of the first open circuit pump delivery side line measured by the first pressure sensor; an operation amount detection section configured to take in an operation amount signal from the first operation lever device; a surplus flow control valve control section configured to output a closing command to the first surplus flow control valve at an operation start when the operation amount detection section detects an operation amount signal of the first operation lever device; a pump delivery control section configured to output a delivery flow rate command to the adjustment section of the first open circuit pump at the operation start; an assist valve control section configured to output a closing command to the first assist valve at the operation start; a sticking detection determination section configured to compare a first pressure signal from the pressure detection section with a previously set threshold value and determining that the first surplus flow control valve is in a stuck-open state when the first pressure signal is less than the threshold value and determining that the first surplus flow control valve is normal when the first pressure signal exceeds the threshold value; and a stop signal generating section configured to input therein a sticking determination signal from the sticking detection determination section, output in a case of a stuck-open state a control signal maintaining a closed state of the first assist valve to the assist valve control section, and output in a case of a normal state a control signal causing the first assist valve to perform an opening operation to the assist valve control section.

Effect of the Invention

According to the present invention, it is possible to detect a stuck-open state of a surplus flow control valve in real time during operation of a construction machine, so that it is possible to suppress a reduction in operational efficiency.

MODES FOR CARRYING OUT THE INVENTION

In the following, embodiments of the present invention will be described, taking a hydraulic excavator as an example of the construction machine. The present invention is applicable not only to a hydraulic excavator but also to a construction machine in general that is equipped with a hydraulic cylinder connected to a closed circuit pump in a closed-circuit-like fashion, an open circuit pump connected to a head fluid chamber side of a hydraulic cylinder, and a surplus flow control valve.

In a hydraulic cylinder drive circuit based on a closed circuit using a conventional surplus flow control valve, when the surplus flow control valve is in a stuck-open state, the working fluid on the hydraulic cylinder head fluid chamber side is discharged into a tank, with the result that the hydraulic cylinder performs an unintended contracting operation.

In view of this, in a first embodiment of the present invention, a construction machine includes: a first closed circuit unit equipped with a first closed circuit pump, and a first hydraulic cylinder connected to the first closed circuit pump in a closed-circuit-like fashion; a first open circuit unit equipped with a first open circuit pump connected to a head fluid chamber side of the first hydraulic cylinder via a first assist valve that is a selector valve, and a first surplus flow control valve arranged between the first open circuit pump and the first assist valve and enabling a surplus hydraulic fluid from a head fluid chamber side of the first hydraulic cylinder to be discharged into a tank; and a control unit equipped with a first operation lever device directing an operation of the first hydraulic cylinder, a controller equipped with a pump delivery control section, an assist valve control section, and a surplus flow control valve control section, and a pressure sensor provided in the first open circuit pump delivery side line and measuring the delivery pressure of the first open circuit pump.

When the first hydraulic cylinder expansion signal due to the first operation lever device is input, the controller outputs a closing command to the first surplus flow control valve before outputting an opening command to the first assist valve, and closes the first surplus flow control valve. Then, it increases the delivery flow rate of the first open circuit pump, so that the delivery pressure signal of the first open circuit pump being input increases. In the case where the increase amount of the delivery pressure signal is equal to or less than a previously determined threshold value, the controller determines that the first surplus flow control valve is stuck open. Having determined that the first surplus flow control valve is stuck open, the controller prohibits the output of an opening command to the first assist valve, and maintains the closed state of the first assist valve.

As a result, it is possible to detect the stuck-open state of the surplus flow control valve in real time during the operation of the construction machine. As a result, it is possible to suppress a reduction in availability factor. Further, when the stuck-open state of the surplus flow control valve is detected, the assist valve is closed, so that it is possible to suppress an unintended contracting operation of the hydraulic cylinder, making it possible to provide a construction machine in which a front work device operation unintended by the operator is further suppressed.

FIG. 1is a side view of a hydraulic excavator according to a first embodiment of the construction machine of the present invention, andFIG. 2is a schematic drawing illustrating a hydraulic drive system constituting the first embodiment of the construction machine of the present invention.

Referring toFIG. 1, a hydraulic excavator100will be described as an example of a construction machine according to the present embodiment. The hydraulic excavator100is equipped with a lower track structure103equipped with crawler type track devices8aand8bon both sides in the right-left direction, and an upper swing structure102as a machine body swingably mounted on top of the lower track structure103. The upper swing structure102is provided with a cab101as an operation chamber boarded by the operator. The lower track structure103and the upper swing structure102are swingable via a swing hydraulic motor7.

The proximal end portion of a front work device104which is a work device for performing, for example, an excavation work is rotatably mounted to the front side of the upper swing structure102. Here, the front side refers to the direction in which the operator boarding the cab101faces (the left direction inFIG. 1).

The front work device104is provided with a boom2the proximal end portion of which is connected to the front side of the upper swing structure102so as to be capable of boom hoisting. The boom2operates via a boom cylinder1which is a one-rod type hydraulic cylinder driven by a working fluid (hydraulic fluid) as the fluid supplied. In the boom cylinder1, the distal end portion of a boom rod1bis connected to the upper swing structure102, and the proximal end portion of a boom head1ais connected to the boom2.

Connected to the distal end portion of the boom2is the proximal end portion of an arm4so as to be capable of hoisting. The arm4operates via an arm cylinder3which is a one-rod type hydraulic cylinder. In the arm cylinder3, the distal end portion of an arm rod3bis connected to the arm4, and an arm head3aof the arm cylinder3is connected to the boom2.

Connected to the distal end portion of the arm4is the distal end portion of a bucket6so as to be capable of hoisting. The bucket6operates via a bucket cylinder5which is a one-rod type hydraulic cylinder as the hydraulic actuator driven by the working fluid supplied. In the bucket cylinder5, the distal end portion of a bucket rod5bis connected to a bucket6, and the proximal end of a bucket head5aof the bucket cylinder5is connected to the arm4.

Arranged in the cab101is a first operation lever device13(seeFIG. 2) which is an operation member for operating the boom2, the arm4, and the bucket6constituting the front work device104.

Next, the system configuration of the hydraulic drive system shown in the schematic drawing ofFIG. 2will be described.

Each of a first closed circuit pump11and a first open circuit pump12driven by power from an engine (not shown) is equipped with, as flow rate adjustment means, a tilting swash plate mechanism having a pair of input/output and regulators11aand12awhich adjust the tilting angle of the swash plate to adjust the pump displacement volume. The regulators11aand12arespectively control the delivery flow rates of the first closed circuit pump11and the first open circuit pump12in accordance with a pump delivery flow rate command value received from a controller14via a signal line.

One delivery port of the first closed circuit pump11is connected to the rod fluid chamber side of the boom cylinder1as the first hydraulic cylinder via a line201, and the other delivery port of the first closed circuit pump11is connected to the head fluid chamber side of the boom cylinder1via a line200, thus constituting a closed circuit. In the present embodiment, the first closed circuit pump11and the boom cylinder1connected to the closed circuit constitute a first closed circuit unit.

The delivery port of the first open circuit pump12is connected to a line200via a line202and a first assist valve15which is a selector valve. The suction port of the first open circuit pump12is connected to a tank17.

In the line202between the first open circuit pump12and the first assist valve15, there is provided a branching portion, and connected to this branching portion is one end side of a line203the other end side of which is connected to the tank17. In the line203, there is provided a first surplus flow control valve16which is a hydraulic proportional valve. The opening/closing of each of the first assist valve15and the first surplus flow control valve16is controlled in accordance with a command signal received from the controller14via a signal line. In the present embodiment, the first open circuit pump12, the first assist valve15, and the first surplus flow control valve16constitute a first open circuit unit.

In the line202, there is provided a first pressure sensor18measuring the delivery pressure of the first open circuit pump12. The delivery pressure signal of the first open circuit pump12detected by the first pressure sensor18is inputted to the controller14via a signal line. An operation signal of the first operation lever device13due to the operator is inputted to the controller14via a signal line. In the present embodiment, the first operation lever device13, the first pressure sensor18, the regulators11aand12a, and the controller14constitute the control unit.

Next, the controller14constituting the present embodiment will be described with reference toFIGS. 3 and 4.FIG. 3is a conceptual drawing illustrating the structure of a controller constituting the first embodiment of the construction machine of the present invention.FIG. 4is a flowchart illustrating the processing of a sticking detection determination section of the controller constituting the first embodiment of the construction machine of the present invention.

The controller14inputs an operation signal of the first operation lever device13and a delivery pressure signal of the first open circuit pump12of the first pressure sensor18, and controls the first assist valve15and the first surplus flow control valve16in accordance with these signals. It determines the presence/absence of the stuck-open state of the first surplus flow control valve, and respectively controls the delivery flow rates of the first closed circuit pump11and the first open circuit pump12. As shown inFIG. 3, the controller14is equipped with an operation amount detection section14a, a pressure detection section14b, an assist valve control section14c, a surplus flow control valve control section14d, a pump delivery control section14e, a sticking detection determination section14f, and a stop signal generating section14g.

The operation amount detection section14ainputs an operation amount signal from the first operation lever device13, and outputs it to the sticking detection determination section14fand the control sections14c,14d, and14eas an expansion drive command value amount or a contraction drive command value amount of the boom cylinder1.

The pressure detection section14binputs the delivery pressure signal of the first open circuit pump12from the first pressure sensor18, and outputs it to the sticking detection determination section14fas the pressure signal of the line202.

The assist valve control section14cand the surplus flow control valve control section14dinput the signal of the expansion drive command value amount or the contraction drive command value amount of the boom cylinder1from the operation amount detection section14a, and in the case where the first surplus flow control valve16is determined to be stuck open, input a stop signal described below from the stop signal generating section14g, outputting a control command signal to the first assist valve15and the first surplus flow control valve16in accordance with these signals.

More specifically, each of the assist valve control section14cand the surplus flow control valve control section14dis equipped, for example, with a table previously set based on the expansion drive command value amount or the contraction drive command value amount from the operation amount detection section14a. In the case where the stop signal from the stop signal generating section14gis not input, they compute a control command signal in accordance with these tables and output the same.

When the expansion drive command value amount or the contraction drive command value amount from the operation amount detection section14abecomes larger than 0, that is, when the first operation lever device13is operated (at the time of operation start), the surplus flow control valve control section14dimmediately outputs a closing signal as a control command value to the first surplus flow control valve16. On the other hand, when the expansion drive command value amount or the contraction drive command value amount from the operation amount detection section14abecomes larger than 0, that is, when the first operation lever device13is operated (at the time of operation start), the assist valve control section14ccontinues to output the closing signal as before as the control command value to the first assist valve15. After a predetermined time difference (Δt) has elapsed from the time of operation start, it outputs a totally opening signal as the control command value to the first assist valve15.

The pump delivery control section14einputs the signal of the expansion drive command value amount or the contraction drive command value amount for the boom cylinder1from the operation amount detection section14a, and, in the case where the first surplus flow control valve16is determined to be stuck open, inputs the stop signal described below from the stop signal generating section14g. In accordance with these signals, it computes control command signals respectively controlling the delivery flow rates of the first closed circuit pump11and the first open circuit pump12, outputting the control command signals respectively to the regulators11aand12a.

When the expansion drive command value amount or the contraction drive command value amount from the operation amount detection section14ais larger than 0, that is, when the first operation lever device13is operated (at the time of operation start), the pump delivery control section14eimmediately outputs control command signals respectively controlling the delivery flow rate of the first closed circuit pump11and that of the first open circuit pump12.

The sticking detection determination section14fis endowed with a function by which it detects the stuck-open state of the first surplus flow control valve16. More specifically, with a predetermined timing, a previously determined pressure threshold value and the pressure signal of the line202from the pressure detection section14bare compared with each other. In the case where the pressure signal is equal to or less than the threshold value, the first surplus flow control valve16is determined to be in the stuck-open state, and a stuck-open state determination flag is outputted to the stop signal generating section14g.

Here, the operation of the controller14will be described. When, through the operation of the first operation lever device13by the operator, the expansion drive command value amount or the contraction drive command value amount from the operation amount detection section14abecomes larger than 0 (at the time of operation start), that is, when the first operation lever device13is operated, the surplus flow control valve control section14dimmediately outputs a totally closing signal as the control command value to the first surplus flow control valve16. At this time, the pump delivery control section14eimmediately outputs control command signals respectively controlling the delivery flow rate of the first closed circuit pump11and that of the first open circuit pump12. At this time, the first assist valve15also receives a totally closing command, and has not received an opening command signal yet. Thus, in the schematic diagram ofFIG. 2, the hydraulic fluid from the first open circuit pump12flows into the line202. However, the first assist valve15and the first surplus flow control valve16are in the closed state, so that the pressure of the line202measured by the first pressure sensor18is expected to be increased. After the predetermined time difference (Δt) has elapsed, an opening command is outputted to the first assist valve15, and the first open circuit pump12is connected to the boom cylinder. Thus, in the case where the pressure of the line202is equal to or less than the predetermined threshold value during this predetermined time difference (Δt), it is determined that the first surplus flow control valve16is stuck open.

In the case where the stuck-open state determination flag of the first surplus flow control valve16is input from the sticking detection determination section14f, the stop signal generating section14ggenerates stop signals and output them to the respective control sections. For example, a signal closing the first assist valve15is outputted to the assist valve control section14c, and a signal reducing the delivery command value of the first open circuit pump12to 0 is outputted to the pump delivery control section14e, with the line202being interrupted from the boom cylinder1. As a result, it is possible to prevent the working fluid from being discharged from the boom head1aof the boom cylinder1into the tank17via the first surplus flow control valve16. As a result, it is possible to prevent abrupt contraction of the boom cylinder1.

Next, the processing of the sticking detection determination section14fwill be described with reference toFIG. 4.

The sticking detection determination section14fdetermines whether or not the operation amount of the first operation lever device13is larger than 0 (step S1). More specifically, it is determined whether or not the expansion drive command value amount or the contraction drive command value amount from the operation amount detection section14ahas become larger than 0 (whether or not the first operation lever device13has been operated), and the operation start time is specified. In the case where the operation amount is larger than 0, the procedure advances to step S2. Otherwise, the procedure advances to step S5.

The sticking detection determination section14fdetermines whether or not the predetermined time difference (Δt) has elapsed since the operation of the first operation lever device13(at the time of operation start) (step S2). In the case where the predetermined time difference (Δt) has not elapsed, the procedure advances to step S3. Otherwise, the procedure advances to step S5.

The sticking detection determination section14fdetermines whether or not the pressure measured by the first pressure sensor18is less than the previously set threshold value Ps (step S3). More specifically, it determines whether or not the pressure signal of the line202which is the delivery pressure of the first open circuit pump12from the pressure detection section14bis less than the previously determined pressure threshold value Ps. In the case where the measured pressure is less than the threshold value Ps, the procedure advances to step S4. Otherwise, the procedure advances to step S5.

The sticking detection determination section14fsets the stuck-open state determination flag to 1 (step S4). More specifically, in the case where the above steps S1through S3are all YES, that is, when the first operation lever device13has been operated (step S1), when the time having elapsed is within the predetermined time difference (Δt) (step S2), and when the pressure value measured by the first pressure sensor18is less than the threshold value Ps, the sticking detection determination section14fsets the stuck-open state determination flag to 1, and determines that the first surplus flow control valve16is stuck open.

On the other hand, in the case where the result of one of the above steps S1through S3is NO, the sticking detection determination section14fsets the stuck-open state determination flag to 0 (step S5). When it is 1, the stuck-open state determination flag indicates the stuck-open state, and when it is 0, it indicates the normal state.

After the completion of the processing of step S4or step S5, the procedure of the sticking detection determination section14fadvances to RETURN, with the next procedure being executed starting from step1.

Next, an example of a sticking detection method for the first surplus flow control valve16in a series of operations for driving the hydraulic actuator will be described with reference toFIGS. 5 and 6.FIG. 5is a characteristic chart illustrating an example of a chronological operation when a boom cylinder according to the first embodiment of the construction machine of the present invention performs an expanding operation, andFIG. 6is a characteristic chart illustrating an example of a chronological operation when the boom cylinder according to the first embodiment of the construction machine of the present invention performs a contracting operation.

First, the hydraulic circuit in the state in which the boom cylinder1is at rest will be described.

In the case where the first operation lever device13shown inFIG. 2is in a non-operating state, the controller14inputs the operation amount signal of the first operation lever device13via the signal line. Based, for example, on a previously set table, the assist valve control section14coutputs a closing signal to the first assist valve15, and the surplus flow control valve control section14doutputs an opening command to the first surplus flow control valve16. In accordance with the operation amount, the pump delivery control section14ereduces the pump delivery flow rate command value of the first closed circuit pump11and the first open circuit pump12to 0 and outputs the same. Since the delivery flow rate of the first closed circuit pump11and the first open circuit pump12is 0, and the first assist valve15is controlled to be in the interrupted state, the boom cylinder1comes to a stop.

Next, to be described will be the case where the boom cylinder1is expanded with the first surplus flow control valve16being stuck open.

FIG. 5shows an example of the control signals and the pressure value of the line202in the case where the boom cylinder1is placed in the expanded state. InFIG. 5, the horizontal axes indicate time, and the vertical axes respectively indicate (a) the first operation lever device13boom cylinder expansion command, (b) the first open circuit pump12delivery command value, (c) the first surplus flow control valve16control command value, (d) the first assist valve15control command value, and (e) the first pressure sensor18detection pressure. Time t1is the time when the first operation lever device13is operated, and time t2is the time when the predetermined time difference (Δt) has elapsed since time t1.

When the operation amount command value for expanding the boom cylinder1is input from the first operation lever device13, the operation amount detection section14aof the controller14outputs the expansion drive command value to the surplus flow control valve control section14d, the pump delivery control section14e, and the assist valve control section14c(time t1). Based on a previously set table, the surplus flow control valve control section14dimmediately outputs a totally closing signal as the control command value to the first surplus flow control valve16, and the pump delivery control section14eimmediately outputs a control command signal respectively controlling the delivery flow rates of the first closed circuit pump11and the first open circuit pump12, causing the working fluid to be delivered. At this time, based on the previously set table, the assist valve control section14ccontinues to output a closing signal as the control command value to the first assist valve15, and at time t2, when the predetermined time difference (Δt) has elapsed since time t1, outputs an opening command to the first assist valve15.

The pressure detection section14bof the controller14outputs the pressure signal of the line202to the sticking detection determination section14f, and, in accordance with the characteristic chart ofFIG. 5, the sticking detection determination section14fcompares the pressure of the line202with the previously determined threshold value Ps during the period of time in which time t2of the predetermined time difference (Δt) is attained. When the pressure is higher than the threshold value Ps, it is determined that the first surplus flow control valve16is normal. On the other hand, in the case where the pressure is lower than the threshold value Ps, it is determined that the first surplus flow control valve16is stuck open.

Further, to be described will be the case where the boom cylinder1is contracted with the first surplus flow control valve16being stuck open.

FIG. 6shows an example of the control signals and the pressure value of the line202in the case where the boom cylinder1is placed in the contracting operation state. InFIG. 6, the horizontal axes indicate time, and the vertical axes respectively indicate (a) the first operation lever device13boom cylinder contraction command, (b) the first open circuit pump12delivery command value, (c) the first surplus flow control valve16control command value, (d) the first assist valve15control command value, and (e) the first pressure sensor18detection pressure. Time t1is the time when the first operation lever device13is operated, and time t2is the time when the predetermined time difference (Δt) has elapsed since time t1.

When the operation amount command value causing the boom cylinder1to contract is input from the first operation lever device13, the operation amount detection section14aof the controller14outputs a contraction drive command value to the surplus flow control valve control section14d, the pump delivery control section14e, and the assist valve control section14c(time t1). Based on a previously set table, the surplus flow control valve control section14dimmediately outputs a totally closing signal as the control command value to the first surplus flow control valve16, and the pump delivery control section14eimmediately outputs a control command signal respectively controlling the delivery flow rate of the first closed circuit pump11and that of the first open circuit pump12, and causes the working fluid to be delivered. At this time, the assist valve control section14ccontinues to output a closing signal, and at time t2, when the predetermined time difference (Δt) has elapsed since time t1, outputs an opening command to the first assist valve15.

The pressure detection section14bof the controller14outputs the pressure signal of the line202to the sticking detection determination section14f, and, in accordance with the characteristic chart ofFIG. 6, the sticking detection determination section14fcompares the pressure of the line202with the previously determined threshold value Ps during the period of time in which time t2of the predetermined time difference (Δt) is attained. When the pressure is higher than the threshold value Ps, it is determined that the first surplus flow control valve16is normal.

In this case, the pump delivery control section14eoutputs to the first open circuit pump12a control command signal reducing the delivery flow rate to 0, and the surplus flow control valve control section14dadjusts the opening amount of the surplus flow control valve. For example, it outputs a half-closing signal to control the contraction speed of the boom cylinder1. On the other hand, in the case where the pressure is lower than the threshold value Ps, the first surplus flow control valve16is determined to be in the stuck-open state.

Next, the effect of the present embodiment when expanding the boom cylinder1will be described.

For example, in the hydraulic circuit shown inFIG. 2, in the case where the first surplus flow control valve16operates normally without being stuck open, when the first operation lever device13is operated by the operator, the first surplus flow control valve16is closed in accordance with the command, and the first open circuit pump12delivers the working fluid. During the predetermined time difference (Δt) shown inFIG. 5, the first assist valve15is closed, so that the working fluid delivered from the first open circuit pump12is sealed in the line202in the closed state. Thus, the pressure in the line202is increased.

When the pressure in the line202increases to become higher than the pressure threshold value Ps shown inFIG. 5, the sticking detection determination section14fdetermines that the first surplus flow control valve16is normal. Since the stop signal due to the stuck-open state is not input thereto from the sticking detection determination section14fand the stop signal generating section14g, the assist valve control section14coutputs an opening command to the first assist valve15after the predetermined time difference (Δt) shown inFIG. 5has elapsed. As a result, the working fluid delivered from the first open circuit pump12flows into the boom head1a, making it possible to expand the boom cylinder1in accordance with the command of the first operation lever device13.

On the other hand, in the case where the first surplus flow control valve16gets stuck open, when the first operation lever device13is operated by the operator, the first surplus flow control valve16receives a closing command, but remains open. Even if in this state the first open circuit pump12delivers the working fluid, and the first assist valve15remains closed during the predetermined time difference (Δt) shown inFIG. 5, the working fluid is discharged into the tank17via the first surplus flow control valve16stuck open. As a result, the pressure in the line202does not increase. Generally speaking, it is a low pressure akin to the pressure of the tank. In the case where the pressure in the line202is less than the pressure threshold value Ps shown inFIG. 5, the sticking detection determination section14fdetermines that the first surplus flow control valve16is stuck open.

For example, in the case where no sticking detection determination section14fis provided, assuming that an opening command is outputted to the first assist valve15after the predetermined time difference (Δt) shown inFIG. 5has elapsed, the working fluid flows out of the boom head1asince the pressure acting on the boom head1ais higher than the pressure of the tank17. As a result, unlike the case of the cylinder expansion command of the first operation lever device13, the boom cylinder1is contracted. This results in deterioration of the operability of the construction machine and in a reduction in productivity. This is the same in the case where the operation to contract the boom cylinder1is performed.

In the present embodiment, in the case where the sticking detection determination section14fdetermines that the first surplus flow control valve16is stuck open, the stop signal generating section14goutputs a closing signal, for example, to the first assist valve15to interrupt the line202, so that the working fluid from the boom head1ais prevented from being discharged into the tank17via the first surplus flow control valve16. This helps to prevent abrupt contraction of the boom cylinder1. Further, each time the boom cylinder1is driven, the stuck-open state of the first surplus flow control valve16is checked in real time, so that it is possible to suppress a reduction in the operational efficiency of the construction machine.

In the first embodiment of the construction machine of the present invention, it is possible to detect the stuck-open state of the first surplus flow control valve16in real time during the operation of the construction machine, so that it is possible to suppress a reduction in operational efficiency.

It is possible to suppress a pressure shock generated when opening operation is performed on the first assist valve15through the same sequence as that of the present embodiment. More specifically, when expanding and contracting the boom cylinder1, the first assist valve15is closed, and the working fluid is delivered from the first open circuit pump12in the state in which the first surplus flow control valve16is closed. After the pressure in the line202has been increased to a predetermined value, the first assist valve15is caused to perform opening operation. As a result, the pressure difference between the line201and the line202is previously diminished, so that it is possible to suppress the pressure shock generated when the first assist valve15performs opening operation. In this case, the predetermined pressure in the target line202is set to a pressure substantially equal to that of the boom head1a. In contrast, the pressure Ps set in the embodiment of the present invention is a pressure of, for example, approximately 1 to 2 MPa, which is slightly higher than the pressure of the tank17.

While in the present embodiment described above the drive object of the hydraulic cylinder is the boom only, this should not be construed restrictively. The present invention is applicable to the hydraulic cylinder of one of the boom, the arm, and the bucket.

In the following, the construction machine according to the second embodiment of the present invention will be described with reference to the drawings.FIG. 7is a schematic diagram illustrating a hydraulic drive system constituting a second embodiment of the construction machine of the present invention, andFIG. 8is a conceptual drawing illustrating the structure of a controller constituting the second embodiment of the construction machine of the present invention. InFIGS. 7 and 8, the components that are the same as those ofFIGS. 1 through 6are indicated by the same reference numerals, and a detailed description thereof will be left out.

In the present embodiment, there is provided a structure having: a plurality of hydraulic closed circuits in which the boom cylinder1and the arm cylinder3as the first and second hydraulic cylinders and the first and second closed circuit pumps11and25are connected in a closed-circuit-like fashion and the first and second open circuit pumps12and26are connected to the cylinder head side lines of the respective hydraulic closed circuits such that the boom cylinder1and the arm cylinder3are driven while the first and second closed circuit pumps11and25and the first and second open circuit pumps are respectively operated in conjunction with each other; and the first and second surplus flow control valves16and28in association with the first and second open circuit pumps. There is further provided a degeneracy operation function in which when the first and second surplus flow control valves16and28are stuck open, it is possible to drive the boom cylinder1or the arm cylinder3by a degeneracy operation control section33of the controller14without having to stop the construction machine.

Unlike the first embodiment, the present embodiment is further equipped with a second closed circuit unit equipped with the second closed circuit pump25and the second hydraulic cylinder3connected to the second closed circuit pump25in a closed-circuit-like fashion, and a second open circuit unit equipped with a second open circuit pump26connected to the head fluid chamber side line of the second hydraulic cylinder3via a second assist valve27which is a selector valve, and a second surplus flow control valve28arranged in a line branching off from the second open circuit pump delivery side line which is the line between the second open circuit pump and the second assist valve27and making it possible to discharge the working fluid from the head fluid chamber of the second hydraulic cylinder3into a tank.

Roughly speaking, the construction machine according to the second embodiment shown inFIG. 7of the present invention is formed by apparatuses that are the same as those of the first embodiment. The differences are as follows.

In the present embodiment, there are provided a plurality of hydraulic closed circuits in which the boom cylinder1and the arm cylinder3as the first and second hydraulic cylinders are connected to the first and second closed circuit pumps11and25, respectively. The first and second closed circuit pumps11and25and the first and second open circuit pumps12and26are driven by an engine (not shown), and each of them is equipped with a both-way tilting swash plate mechanism having a pair of input/output ports as the flow rate adjustment device, and a regulator11a,25a,12a,26aadjusting the inclination angle of the swash plate to adjust the pump displacement volume. The regulators11a,25a,12a, and26arespectively control the delivery flow rate of the first and second closed circuit pumps11and25and the delivery flow rate of the first and second open circuit pumps12and26each in accordance with a pump delivery flow rate command value received from the controller14via a signal line. There are provided a first operation lever device13afor driving the boom cylinder1, and a second operation lever device13bfor driving the arm cylinder3.

In the present embodiment, there are provided line selector valves29through32as line selector circuits. One delivery port of the first closed circuit pump11is connected to the line selector valves29and30as line selector circuits via a line200. By a signal from the degeneracy operation control section33of the controller14via a signal line, the line selector valves29and30are controlled in the circulation and switching direction of the line. In the case where there is no signal, they are controlled to the interruption state. The other delivery port of the first closed circuit pump11is connected to the line selector valves29and30via a line201.

The line selector valve29is connected to the boom cylinder1via lines200aand201a. When the line selector valve29is placed in the circulation state, the first closed circuit pump11is connected to the boom cylinder1via the line. The line selector valve30is connected to the arm cylinder3via lines208,209,204a, and205a. When the line selector valve30is placed in the circulation state, the first closed circuit pump11is connected to the arm cylinder3via the lines.

Similarly, one delivery port of the second closed circuit pump25is connected to line selector valves31and32as line selector circuits via a line204. By a signal from the degeneracy operation control section33of the controller14via a signal line, the line selector valves31and32are controlled in the circulation and switching direction of the line. In the case where there is no signal, they are controlled to the interruption state. The other delivery port of the second closed circuit pump25is connected to the line selector valves31and32via a line205.

The line selector valve31is connected to the boom cylinder1via lines210,211,200a, and201a. When the line selector valve31is placed in the circulation state, the second closed circuit pump25is connected to the boom cylinder1via the lines. The line selector valve32is connected to the arm cylinder3via lines204aand205a. When the line selector valve32is placed in the circulation state, the second closed circuit pump25is connected to the arm cylinder3via the lines.

The delivery port of the first open circuit pump12is connected to the line200via the line202and the first assist valve15which is a selector valve, and the delivery port of the second open circuit pump26is connected to a line204via a line206and a second assist valve27which is a selector valve. Each of the lines202and206is provided with a branching portion, and connected to this branching portion is one end side of the line203,207and the other end side of which is connected to the tank17. The lines203and207are respectively provided with first and second surplus flow control valves16and28. The line202and the line206are respectively provided with a first pressure sensor18aand a second pressure sensor18b. The delivery pressure signals of the first and second open circuit pumps12and26, detected by the first and second pressure sensors18aand18bare input to the controller14via signal lines. Further, the operation signals of the first and second operation lever devices13aand13boperated by the operator are input to the controller14via signal lines.

Next, the controller14constituting the present embodiment will be described with reference toFIG. 8. The structure of the controller14of the present embodiment differs from that of the first embodiment in that there is additionally provided a selector valve control section14hcontrolling the opening/closing of the line selector valves29through32, and that the stop signal generating section14gfunctions as the degeneracy operation control section33.

The selector valve control section14hinputs therein the expansion drive command value amount signal or the contraction drive command value amount signal of the boom cylinder1or the arm cylinder3from the operation amount detection section14a. In the case where it is determined that one of the first and second surplus flow control valves16and28is stuck open, it inputs a control command signal described below from the degeneracy operation control section33. In accordance with these signals, it outputs a control command driving the line selector valves29through32.

The degeneracy operation control section33inputs the expansion drive command value amount signal or the contraction drive command value amount signal of the boom cylinder1or the arm cylinder3from the operation amount detection section14a, and the stuck-open state determination flags of the first and second surplus flow control valves16and28from the sticking detection determination section14f. In the case where the stuck-open state determination flag of one of the first and second surplus flow control valves16and28is input, the degeneracy operation control section33generates a control command value signal, and outputs it to each of the control sections14cthrough14eand14h. For example, it generates the control command value signal and performs control so as to realize a cylinder drive control in accordance with the operation amount by using a normal surplus flow control valve without using the open circuit pump and the closed circuit pump connected to the surplus flow control valve stuck open.

Next, the operation when the first surplus flow control valve16shown inFIG. 7gets stuck open in the present embodiment will be described.

As in the case of the first embodiment, when the first surplus flow control valve16gets stuck open when the boom cylinder1is expanded by the first operation lever device13a, the detection pressure of the first pressure sensor18adoes not increase as in the case of the first embodiment shown inFIG. 5, so that the sticking detection determination section14fdetermines that the first surplus flow control valve16has got stuck open, and outputs the stuck-open state determination flag of the first surplus flow control valve16to the degeneracy operation control section33.

The degeneracy operation control section33outputs a command signal to the assist valve control section14cand the selector valve control section14h, and outputs a closing signal to the first assist valve15and the line selector valve29corresponding to the first open circuit pump12.

Further, in the case where the expansion operation signal of the boom cylinder1is input from the first operation lever device13aand where the operation signal driving the arm cylinder3is not input from the second operation lever device13b, the degeneracy operation control section33outputs a command signal to the pump delivery control section14e, and performs control such that the delivery flow rate of the second closed circuit pump25and that of the second open circuit pump26are in accordance with the operation amount of the first operation lever device13a, outputting an opening operation signal to the second assist valve27and a closing signal to the second surplus flow control valve28.

In the first embodiment described above, in the case where the first surplus flow control valve16gets stuck open, it is possible to stop the boom cylinder1by closing the first assist valve15, making it possible to suppress an unintended operation of the boom cylinder1. The boom cylinder1, however, becomes incapable of driving, disadvantageously resulting in deterioration in operational efficiency. In such a case, in the present embodiment, the boom cylinder1is made capable of driving by using another closed circuit, so that it is possible to drive the boom cylinder1even if the first surplus flow control valve16gets stuck, making it possible to suppress deterioration in operational efficiency.

In the construction machine according to the second embodiment of the present invention, it is possible to attain the same effect as that of the first embodiment described above.

Further, in the construction machine according to the second embodiment of the present invention described above, even in the case where one surplus flow control valve gets stuck open, the hydraulic cylinder is made capable of driving by using another closed circuit, so that it is possible to suppress deterioration in operational efficiency.

While in the present embodiment described above the drive object of the hydraulic cylinder solely consists of the boom and the arm, this should not be construed restrictively. The present embodiment may be applied to the hydraulic cylinder of one of the boom, the arm, and the bucket.

Further, while in the present embodiment described above the boom cylinder1is driven in the case where the first surplus flow control valve16gets stuck open, this should not be construed restrictively. Also in the case where the arm cylinder3is expanded and contracted, the arm cylinder3may be driven by controlling the closed circuit pump, the open circuit pump, and the selector valve connected to the surplus flow control valve operating in the normal fashion.

In the following, the construction machine according to the third embodiment of the present invention will be described with reference to the drawings.FIG. 9is a schematic diagram illustrating a hydraulic drive system constituting a third embodiment of the construction machine of the present invention, andFIG. 10is a conceptual drawing illustrating the structure of a controller constituting the third embodiment of the construction machine of the present invention. InFIGS. 9 and 10, the components that are the same as those ofFIGS. 1 through 8are indicated by the same reference numerals, and a detailed description thereof will be left out.

Roughly speaking, the construction machine according to the third embodiment shown inFIG. 9of the present invention is formed by the same apparatuses as those of the first embodiment except for the following differences.

In the present embodiment, the controller14is additionally provided with a failure notification section34, and there is provided a failure notification device35connected to the controller14via a signal line.

As shown inFIG. 10, the failure notification section34receives a stuck-open state determination flag from the sticking detection determination section14fvia the stop signal generating section14g, and, based on the value thereof, outputs information on the surplus flow control valve stuck open to the failure notification device35. The information on the surplus flow control valve stuck open consists, for example, of the arrangement position and serial number of the surplus flow control valve out of order and the time of failure occurrence.

In the case where the first surplus flow control valve16shown inFIG. 9gets stuck open, the failure notification section34of the controller14outputs information on the first surplus flow control valve16to the failure notification device35, so that the operator or the maintenance technician can grasp the arrangement position and the failure condition of the surplus flow control valve out of order from the failure notification device35.

In the construction machine according to the third embodiment of the present invention described above, it is possible to attain the same effect as that of the first embodiment described above.

Further, in the construction machine according to the third embodiment of the present invention described above, there are provided the failure notification section34and the failure notification device35, so that in the case where the first surplus flow control valve16gets stuck open, it is possible to quickly notify the operator or the maintenance technician of detailed information on the surplus flow control valve out of order such as its position and the failure condition. This helps to shorten the requisite time for maintenance work such as component replacement. As a result, it is possible to shorten the period of time during which the construction machine is at rest and to achieve an improvement in terms of availability factor.

The failure notification device35may consist of a display section such as a display or sound notification means such as a speaker. Further, while in the present embodiment described above the stuck-open state of the first surplus flow control valve16is notified, it is possible to notify not only the stuck-open state but also a stuck-closed state in which the first surplus flow control valve16remains closed.

The present invention is not restricted to the above-described embodiments but includes various modifications without departing from the scope of the gist of the invention. For example, while in the embodiments described above the present invention is applied to a hydraulic excavator, the present invention is also applicable to construction machines other than a hydraulic excavator. For example, the present invention is applicable to construction machines in general equipped with a hydraulic device in which a work device drives a plurality of hydraulic actuators by a closed circuit such as a hydraulic crane.

DESCRIPTION OF REFERENCE CHARACTERS