Method to automatically detect the area ratio of an actuator

Systems and methods for estimating the area ratio of an actuator in static and dynamic states are disclosed. In one aspect, a metering valve is connected to each side of the actuator. In one example, one metering valve is held closed while the other metering valve incrementally pressurizes the actuator in discrete steps. The resulting work port pressures can be used to determine the actuator area ratio. Where counterbalance valves are installed in the system, the pressurizing metering valve can be placed in a pressure control mode to obtain the desired pressure values. In one example, the ratio of flows through each metering valve is used to determine the actuator ratio.

BACKGROUND

Work machines, such as off-highway vehicles, fork lifts, wheel loaders, track loaders, excavators, backhoes, bull dozers, and telehandlers are known. Work machines can be used to move material, such as pallets, dirt, and/or debris. The work machines typically include a work implement (e.g., a fork) connected to the work machine. The work implements attached to the work machines are typically powered by a hydraulic system. The hydraulic system can include a hydraulic pump that is powered by a prime mover, such as a diesel engine. Work machines are commonly provided with electronic control systems that rely upon a number of inputs and outputs, for example, pressure sensors, position sensors, and valve actuators. Electro-hydraulic valves often rely on sensed values, such as port pressure and/or valve position to provide a stable, controlled flow to and from a hydraulic actuator, such as a linear actuator or motor. During initial installation of a new valve or actuator, when a new valve assembly is installed, or when a work implement is changed, calibration of the assembly is required.

SUMMARY

The disclosed systems and methods provide methods for estimating the area ratio of an actuator. In one example, A method for estimating the area ratio of an actuator connected to a first metering valve on a first side of the actuator and a second metering valve on a second side of the actuator, the method comprising the steps of: preventing the actuator from moving; holding the first metering valve in a closed position; opening the second metering valve to pressurize the actuator to a first pressure; closing the second metering valve; recording the pressure at the first and second sides of the actuator; opening the second metering valve to pressurize the actuator to a second pressure; closing the second metering valve; recording the pressure at the first and second sides of the actuator; and calculating the area ratio of the actuator based on the recorded pressures.

In one example, a method for estimating the area ratio of a moving actuator connected to a first metering valve on a first side of the actuator and a second metering valve on a second side of the actuator is disclosed. The method can include the steps of: calculating a first flow through the first metering valve; calculating a second flow through the second metering valve; and calculating an area ratio of the actuator based on the ratio of the calculated first and second flows of the first and second metering valves.

In one example, a method can include the steps of: opening the first and second metering valves to respectively charge a first and second work port on each side of the actuator to a minimum pressure; recording work port pressures once the pressure equalizes on each side of the actuator; determining a load holding side of the actuator based on the recorded work port pressures; pressurizing the load holding side of the actuator with the metering valve associated with that side of the actuator; designating a reference pressure set point for the metering valve associated with the load holding side; regulating the metering valve associated with the load holding side to meet a pressure set point equal to the recorded work port pressure plus a pressure differential while holding the other metering valve in a closed position; recording work port pressures; and calculating the area ratio of the actuator based on the recorded work port pressures.

DETAILED DESCRIPTION

Certain key parameters related to control system applications need to be commissioned in associated valve assemblies to achieve premier valve performances. To properly control in the meter in/meter out flows, the area ratio of the actuator attached to the valve is required. This information is also utilized to determine the loading conditions of the associated actuators (e.g. passive vs. overrunning). An example valve assembly manufactured by the assignee of this application is the Eaton CMA Advanced Mobile Valve with Independent Metering (e.g. models CMA 90, CMA 200). Some valve assemblies, such as the CMA valve assembly, include functions to intelligently control the valve's attached actuator. Compared with traditional mobile valves, the commissioning for advanced mobile valves is not routine. Manual commissioning of the valve is costly and time consuming. In addition, it is also challenging to guarantee a robust and consistent commissioning accuracy. Therefore, an automatic commissioning method is preferred for the valve to automatically detect the area ratio of the actuator attached to it.

This disclosure includes proposed methods for auto-commissioning, including procedures to automatically detect the area ratio of the actuator attached to the advanced mobile valve by performing an automated test. In the examples shown, the advanced mobile valve consists of a pair of three position, three way independent metering valves. Each valve is equipped with valve spool position sensor, and pressure sensors at its work port. In addition, the valve can also measure the flow crossing it. The also valve has signal processing/calculation capabilities. Notably, the auto-commissioning test does not require additional sensors or ECUs (no hardware is required). The detail auto-commissioning procedures are described in the attached file.

Descriptions of the system in general, the hydraulic systems, the related control systems, and the aforementioned auto-commissioning methods follow.

General System Description

As depicted atFIG. 1, a work machine10is shown. Work machine10includes a work attachment12for performing a variety of lifting tasks associated with a load44. In one embodiment, work machine10is a telehandler having a telescoping boom42that supports the work attachment12. In one embodiment, the work attachment12includes a pair of forks. However, one skilled in the art will appreciate that work attachment may be any hydraulically powered work implement.

Work machine10is also shown as including at least one drive wheel14and at least one steer wheel16. In certain embodiments, one or more drive wheels14may be combined with one or more steer wheels16. The drive wheels are powered by an engine18. Engine18is also configured to power a hydraulic system including a work circuit200and a steering circuit (not shown) of the work machine10via at least one hydraulic pump210. In one embodiment, pump32is mechanically coupled to the engine18, such as by an output shaft or a power take-off. In one embodiment, pump32is powered indirectly by the engine18via a hydraulic system. The work circuit200actuates the work attachment12by operation of the pump in cooperation with a number of hydraulic actuators40and control valves20,120. In one embodiment, the work machine includes hydraulic actuators and valves for effectuating lifting, extending, tilting, and sideways motions of the work attachment12.

Hydraulic System

Referring toFIG. 2, an example of a hydraulic system including a work circuit200and other components are shown. Work circuit200is for activating a work attachment of a work machine. As shown, work circuit200includes a first valve assembly20and a second valve assembly120for enabling a work function, such as an attachment lift function. Work circuit200may also include a plurality of additional valves and/or fluid power consuming components for enabling other functions in the hydraulic system. Furthermore, the work circuit may include a single valve assembly that combines the functions of the first and second valve assemblies20,120. In the particular embodiment shown, the first and second valve assemblies20,120are proportional valves having a sleeve22,122within which a spool24,124is disposed.

The first valve assembly20is configured and arranged to selectively provide pressurized fluid from pump210to one or more actuators40are shown. In the particular example presented, the actuator40is a hydraulic lift or work cylinder40mechanically coupled to the work attachment. Although cylinders40are characterized in this disclosure as being lift cylinders, it should be understood that cylinders40may be any type of work cylinder, and that the disclosure is not limited to only applications involving lift cylinders. Additionally, any type of actuator or combinations thereof may be used, for example, linear hydraulic actuators and motors. An example of a hydraulic actuator40that is a motor40usable with the disclosed concepts herein is presented atFIG. 2A. The operation of first valve assembly20causes the work attachment12to be selectively raised or lowered in a lifting function. The lifting speed of the lift cylinder(s)40is a result of the flow through the first valve assembly20. Flow through the first valve assembly20can be controlled by a pair of variable solenoid actuators58,60acting on each end of the spool24of the valve20. The variable solenoid actuators58,60can be operated by the control system50via control lines66,70, respectively. Additionally where solenoids or solenoid actuators are referenced in the application, it should be noted that the associated valves could be voicecoil driven valves. Additionally, multi-stage valves incorporating a main stage valve that is pilot operated by valves utilizing solenoids and/or voicecoils may be used.

As shown, the first valve assembly20is a three-position, three-way valve in fluid communication with the pump210, a tank reservoir230, and the lift cylinder(s)40. In the embodiment shown, first valve assembly20is movable from a closed or neutral position A, to a lifting position B, and to a lowering position C.

In the closed position A, ports26A,28A, and30A are closed such that the pump210and tank reservoir230are both isolated from the lifting cylinder(s)40. In this position the work attachment12is held in a static position and can be neither raised nor lowered.

In the lifting position B, the first valve assembly20is positioned such that ports26B and30B are placed in fluid communication with each other. This position allows for the pump210to be placed in fluid communication with the lifting cylinder(s)40. Where the pump pressure exceeds the pressure induced by a load44, the hydraulic lift cylinder(s) will cause the load44to be raised. In the lifting position, the tank reservoir230is blocked at port28B.

In the lowering position C, the first valve assembly20is positioned such that ports28C and30C are placed in fluid communication with each other. This position allows for the tank reservoir230to be placed in fluid communication with the lifting cylinder(s)40. The lowering position C allows for fluid to drain from the lifting cylinder(s)40to the tank reservoir230, thereby allowing for the load44to be lowered.

The second valve assembly120is configured and arranged to selectively provide fluid communication between the pump210or reservoir230and one or more hydraulic lift or work cylinders40which are mechanically coupled to the work attachment. The operation of second valve assembly120allows for hydraulic fluid to cause the work attachment12to be selectively raised or lowered in a lifting function. The lowering speed of the lift cylinder(s)40can be a result of the flow through the second valve assembly120. Flow through the second valve assembly120can be controlled by a pair of variable solenoid or voicecoil actuators158,160acting on each end of the spool124of the valve120. The variable solenoid or voicecoil actuators158,160can be operated by the control system50via control lines166,170, respectively.

As shown, the second valve assembly120is a three-position, three-way valve in fluid communication with the pump210, a tank reservoir230, and the lift cylinder(s)40. In the embodiment shown, second valve assembly120is movable from a closed or neutral position A, to a position B, and to position C. Positions B and C could be used for lifting or lowering, depending upon whether pump pressure is needed to prevent cavitation and whether the tank pressure is sufficient. In one embodiment, position B is typically used for lowering.

In the closed position A, ports126A,128A, and130A of the second valve assembly120are closed such that the pump210and tank reservoir230are both isolated from the lifting cylinder(s)40. In this position the work attachment12can generally be held in a static position and can be neither raised nor lowered. However, it the work attachment12could lower to some extent if the gravity load is such that a sufficient vacuum condition would be created. In one operational control scheme, the second valve assembly120would be in the closed position A when the first valve assembly20is also in its closed position A.

In the lowering position B, the second valve assembly120is positioned such that ports126B and130B are placed in fluid communication with each other. This position allows for the pump210to be placed in fluid communication with the lifting cylinder(s)40such that pump can provide fluid power to lower the load beyond what would be achieved by gravity alone. In the lowering position, the tank reservoir230is blocked at port28B. In one operational control scheme, the second valve assembly120would be in the lowering position B when the first valve assembly20is also in its lowering position C.

In the lifting position C, the second valve assembly120is positioned such that ports128C and130C are placed in fluid communication with each other. This position allows for the tank reservoir230to be placed in fluid communication with the lifting cylinder(s)40. The lifting position C allows for fluid to drain from the rod side of the lifting cylinder(s)40to the tank reservoir230, thereby allowing for the load44to be raised. In one operational control scheme, the second valve assembly120would be in the lifting position C when the first valve assembly20is also in its lifting position B.

It is noted that the work machine10and work circuit200may contain a plurality of work sections, each of which including an actuator40and valves20,120for performing various tasks of the work machine (e.g. lifting, side shift, tilt, etc.). In some examples, the valves20,120are packaged together in a single housing assembly. In some examples, multiple housing assemblies are assembled together such that all of the valves associated with the work sections are provided as an overall assembly, as is the case for some models of the Eaton CMA Advanced Mobile Valve.

A similar system to that shown inFIG. 2is shown atFIG. 2B. The only difference between the two shown systems is that the system shown inFIG. 2Badditionally shows the presence of counterbalance valves. Counterbalance valves perform a safety function and prevent flow to the actuator unless pressure exists in the line on the opposite side of the actuator. Thus, if a hose bursts or fluid pressure is otherwise lost, the counterbalance valve will close and prevent fluid from entering or leaving the other side of the actuator to prevent the actuator from moving. While counterbalance valves provide a means for increasing safety, they also increase the difficulty in knowing the actual pressure at the actuator as they are installed between the pressure sensors56,156and the actuator.

The Electronic Control System

The hydraulic system operates in various modes depending on demands placed on the work machine (e.g., by an operator). The electronic control system monitors and allows for the various modes to be initiated at appropriate times.

An electronic controller50monitors various sensors and operating parameters of the hydraulic system214to configure the hydraulic system214into the most appropriate mode. Examples of operational modes are a work circuit lifting mode and a fail operational mode.

Referring toFIG. 3, the electronic controller50is schematically shown as including a processor50A and a non-transient storage medium or memory50B, such as RAM, flash drive or a hard drive. Memory50B is for storing executable code, the operating parameters, the input from the operator interface while processor50A is for executing the code.

Electronic controller50may have a number of inputs and outputs that may be used for implementing the work circuit lifting mode and the work circuit fail operational mode. For example, inputs and outputs may be in the form of pressure and position sensors on the first and second control valves20,120. Another example of an input is engine speed, which may be provided as a direct input into the electronic controller50or may be received from another portion of the control system via a control area network (CAN). The measured pump displacement, for example via a displacement feedback sensor, may also be provided.

One input into the electronic controller50is the lever position input from a lifting lever62. In one embodiment, the lever position input is a direct digital signal from an electronic lever. The lifting lever62provides a user indication to the controller50that a load lifting operation by hydraulic lift cylinder(s)40is desired and also provides a means to control the raising and lowering of the load44. Although lever62is characterized as a lifting lever, it should be understood that the disclosure is not limited to only lifting levers and that lever62can be any type of work lever without departing from the concepts disclosed herein. Other inputs to the controller are the signals from sensors56,59,156, and159. An optional load-sense signal57may also be provided to the controller or directly to the pump210. In the embodiment shown, the load-sense demand is derived from the pressure sensors. The pressure and position inputs can also be used by the valve controller to calculate a flow rate through the valve itself.

Still referring toFIG. 3, a number of outputs from the electronic controller50are shown. One output is a valve position command108to the first control valve20. In the particular embodiment shown, the valve command output108is a proportional signal to the solenoid or voicecoil valves58,60of control valve20via control lines66,70. Another output is a valve position command110to the second control valve120. In the particular embodiment shown, the valve command output110is a proportional signal to the solenoid or voicecoil valves158,160of control valve120via control lines166,170. Another output may be a pump command output111to control the flow and/or pressure generated by the pump210.

The electronic controller50may also include a number of algorithms or control schemes to correlate the inputs and outputs of the controller502. In one embodiment, the controller50includes an algorithm to control the system in a work mode, as described further in the Method of Operation section below.

The electronic controller50may also store a number of predefined and/or configurable parameters and offsets for determining when each of the modes is to be initiated and/or terminated. As used herein, the term “configurable” refers to a parameter or offset value that can either be selected in the controller (i.e. via a dipswitch) or that can be adjusted within the controller.

Method of Operation

Referring toFIGS. 4-6, methods1000,1100,1200are shown for determining the area ratio of the actuator40for the systems shown inFIGS. 2(no counterbalance valves) and2B (with counterbalance valves). These methods allow for the area ratio of the actuator connected to the valve to be automatically detected. This automatic determination can reduce set-up time and can allow for the attachment of unknown implements to the valve without requiring operator input. Additionally, these methods can also reduce set-up time for a new replacement valve being installed in an existing system and can automatically account for a new work implement being installed on the work machine. The general principle of the disclosed methods is that different pressures are applied to the actuator and the resulting pressure differences are measured on both sides of the actuator. The relationship of the relative pressure differences can be used to calculate the area ratio of the actuator, as discussed below.

Referring toFIG. 4, a method1000is shown. The method1000can be utilized with the system shown inFIG. 2, but is robust to the presence of counter-balance valves or PO-check valves, and thus could be applied to the system ofFIG. 2B. In the later cases, it may be advantageous to first pressurize the actuator to a minimum pressure prior to executing the further described steps in the method. Method1000can be referred to as a static method as the actuator is prevented from moving during the test. In a step1002, the actuator is secured to a static position such that no significant service movement is possible, although some movement due to fluid compressibility may be experienced. This can be accomplished by closing one of the valves associated with the actuator. In a step1004, one side of the actuator is pressurized to a first pressure while the other side of the actuator is held blocked. For example, valve20is placed in a closed position, while valve120is opened for a period of time to increase the fluid pressure in the actuator or vice-versa. In a step1006, after the actuator chamber pressure has stabilized, the pressure measured on both sides of the actuator is recorded as P1,1and P2,1. Measurements from sensors56,156can be used for this purpose. In a step1008, the actuator is pressurized to a second pressure while still holding the other side of the actuator blocked. At step1010, after the actuator chamber pressure has stabilized, the pressures on both sides of the actuator are again recorded as P1,2and P2,2. At each of steps1004and1008, it should be ensured that the actuator has not been moved to an end stop. Where the pressure one side of the actuator does not rise during the test, it may be an indication that this has occurred. Also, it is desirable to pressurize the non-load holding side of the actuator, but either side can be pressurized, as desired. This approach best keeps friction constant so that any influence on the area ratio calculation is minimized to the furthest extent possible.

At a step1012, the area ratio of the actuator based on the measured pressures is performed. As a basic principle, the following equation applies to an actuator system:
A1P1−A2P2=Fload+Ffriction

In the above equation, A1and P1are respectively the area and pressure of one side of the actuator (e.g. head-side area) while A2and P2are respectively the area and pressure of the other side of the actuator (e.g. head-side area). Floadis the force of the load exerted onto the actuator and Ffrictionis the friction that exists within the system. When multiple pressures are recorded using the method1000, the friction components, which are assumed constant, cancel out and the following equation can be developed to determine the actuator area ratio, which can be expressed as A1over A2:

Although method1000shows determining the area ratio at two different pressures, the test can be repeated at further different pressures. The additional data points can be used to obtain an average area ratio to increase accuracy of the result.

Referring toFIGS. 7-10, simulation results relating to method1000are shown.FIG. 7shows a graph showing fluid flow into the actuator being applied to pressurize the actuator at two discrete points corresponding to steps1004and1008in the method, wherein the valve is incrementally opened for a period of time and then closed. As shown, the period of time is about two seconds. In examples, the period of time can be a predetermined period of time or can be a function of a pressure set point.FIG. 8shows the corresponding head-side and rod-side pressure changes which rise when fluid is being fed into the actuator and stabilize after fluid flow is stopped.FIG. 9shows the actuator head and rod size with the actual diameters for the head and rod from which the actual area ratio can be calculated. In this instance, the area ratio is 1.273.FIG. 10shows the results from utilizing method1000to estimate the area ratio under a variety of different conditions (e.g. hose diameter (D), hose length (L), bulk modulus (Air), fluid temperature (Temp)). As can be seen, the application of method1000results in an estimated area ratio of 1.273 under all conditions and thus represents an accurate means by which the area ratio can be determined when the actual actuator parameters are not known.

Referring toFIG. 5, a method1100is shown. Method1100can be referred to as a dynamic test as the actuator is not required to be static in order to determine the actuator area ratio. Method1100is applicable for the system ofFIG. 2and is ideally performed when the actuator is in a passive state (e.g. actuator force is opposite direction of load force), but can be used in an overrunning condition (e.g. actuator force in same direction as load force). In a step1102one of the valves is placed in a flow control mode and the other valve is placed in a pressure control mode. In one example, the meter-in side operates in a flow control mode to control the motion of the actuator, and the meter-out side operates in a pressure control mode to guarantee a low meter out pressure. The meter-in and meter-out valves can be controlled in other modes as well without departing from the concepts herein. The meter-in valve is the valve from which fluid is being fed through the valve and to the actuator while the meter-out valve is the valve to which fluid flows from the opposite side of the actuator. The valves switch between these two designations depending upon the desired directional control of the actuator. By use of the term “flow control mode” it is meant to indicate that the valve is controlled to maintain a fluid flow setpoint. By use of the term “pressure control mode” it is meant to indicate that the valve is controlled to maintain a fluid pressure setpoint. By use of the term “passive condition” it is meant to indicate that the load is being forced in a direction by the actuator that is generally opposite the direction of an external opposing force, such as gravity (e.g. such as when a load is being lifted). Ideally, the test is performed when the actuator is moving at a constant speed.

In a step1104, the flow through the meter-in valve is calculated and recorded as Qin. The flow can be calculated from the position of the valve via the LVDT position sensor59/159and the pressure in the valve via pressure sensor56,156. In a step1106, the flow through the meter-out valve is calculated and recorded as Qout. At step1108the area ratio of the actuator is calculated based on the calculated flows. The ratio of flows Qin/Qoutis equal to the area ratio A1/A2.

This approach may have initially poor performance but subsequent iterations can be used to improve the result. To improve accuracy, the error term when achieving pressure control of one of the valves can be observed. If the pressure controller has a flow feed-forward term, any feedback terms needed to achieve pressure control can be used to adjust the area ratio estimate. The procedure could also have a “learning time” that allows area ratio estimation for a certain amount of use. After this period, the area ratio is saved and error terms can be used for fault detection.

Referring toFIG. 6, a method1200is shown that is applicable to the system shown inFIG. 2B, which includes counterbalance valves. As the counterbalance valves21are shown as being between the actuator40and the pressure sensors56,156the pressure in the actuator chambers cannot be directly measured. Thus, a modified strategy for such a configuration can be advantageous. Method1200can also be used where counterbalance valves are not present. Method1200is ideally performed with the actuator in a static state, but can be performed in a dynamic condition.

In a first step1202of the method, both valves are opened to supply a small opening to charge both hoses. In a second step1204, the work port pressures are monitored. At some point, the pressure raising slope will change indicating that the work port pressure of the valves is equalizing with the chamber pressures of the actuator. Once this occurs, the pressures at the work ports, as measured at56/156are recorded at step1206. In a step1208, the load holding chamber is pressurized to a small change in pressure ΔP1to the current recorded pressure from step1206. At a step1208, a new reference pressure for work port 1 (assume load holding side) is designed and the valve associated with the load holding side work port is placed in a pressure control mode, wherein Pwp1is regulated to P1,2_desired=P1,1+ΔP1. During this time, the other valve (i.e. valve associated with work port 2) is held closed and pressure is monitored as Pwp2At a step1214, the area ratio is calculated based on the measured pressures with the same calculation approach as described for method1000. Referring toFIGS. 11 and 12, a schematic representation of a simulation for method1200is shown, wherein the system model is shown atFIG. 11and the results, with and without the presence of counterbalance valves, is shown atFIG. 12. In this simulation, the cylinder head side diameter was modeled at 27 mm and the cylinder rod diameter was modeled at 16 mm for an actual area ratio of 1.5412. The presence of 30 meters of 11 mm inner diameter hose was also modeled. The total volume modeled includes the hose volume, dead volume in the cylinder, and the volume due to initial placement. The fluid was modeled as including 5% air and being at 50° C. As can be seen atFIG. 12, the results of the application of the method without the presence of counterbalance valves resulted in an estimated area ratio completely matching the true area ratio. Where counterbalance valves were modeled, the area ratio estimation was within 0.16% of the known, true area ratio, and thus represents a highly effective approach.