TEACHING/PLAYBACK METHOD OF WORKING MACHINE

Abstract: The teaching/playback method of a working machine in accordance with the present invention is the method which is used for automating the operations of a hydraulic excavator and other construction equipment. The operations of a working machine actuator by an operator are stored and are played back in order to carry out automatically the same operation. Particularly, the present method makes it possible to carry out the same operation as the operation at the time of teaching even when a load condition to the working machine actuator at the time of teaching changes at the time of playback. To this end, a pump delivery quantity at the time of teaching and a feed flow rate to each working machine actuator are stored. When the pump delivery quantity changes due to the change of the load at the time of playback, an output control of an engine is conducted so that the pump delivery quantity is in conformity with the delivery quantity at the time of teaching. When the feed flow rate to the working machine actuator changes, a flow rate regulating valve disposed in its inflow circuit is controlled so that the pump delivery quantity is also in conformity with the flow rate at the time of teaching.

Description: The present invention relates to a teaching and playback method for a work machine and, more particularly, to such a method capable of assuring that construction equipment such as a hydraulic excavator performs a playback operation exactly as has been taught, even when a variation has occurred in the load on the machine. The method thus enables the machine to operate with improved accuracy even in such an event. A method with the features disclosed in the preamble of claim 1 is already known from JP-A-59-220534. Recently, it has often been the case with construction machines that they are required to perform work by repeating a certain operation. This particularly applies to a hydraulic excavator which is required, by the nature of its work, to perform repeated operations during, for example, earth excavation or loading. On the other hand, automatization of construction machines has been propelled by recent development in electronics, as shown in, e.g., JP-A-1-318621 (an application previously filed by the same applicant). A conventional teaching and playback method intended to automatize a construction machine of the above-described type has the following arrangement. During teaching, a locus of the work machine is taught by converting, into an electrical signal, the amount by which a work machine operation lever (hereinafter abbreviated to "work machine lever") is operated to move the machine along the locus, and storing the signal in a memory. During reproduction driving, the stored data is read from memory so that the machine performs a playback operation, which is an operation exactly the same as the taught operation. With the conventional method, however, the following problem may be encountered in the event that, during a playback operation, the load on the machine should vary from the level upon which the teachings have been formulated. When the load on the machine has varied, particularly when it has increased from the above-mentioned level, there is the risk that the engine output may fall short. The engine rotational speed drops, causing a corresponding drop in the pump discharge. The insufficient pump discharge causes the work machine to move along a locus different from what has been taught. Thus, the machine operates with degraded accuracy. If a load variation occurs during multiple-actuator operation in which a plurality of work machine actuators are operated, there is a risk that the amount of flow supplyed to the actuators may change, also resulting in movement of the machine along a locus different from the taught locus, hence, in degraded accuracy of operation. The present invention has been accomplished with a view to overcoming the above-described problem. It is an object of the present invention to provide a teaching and playback method for a work machine that is capable of assuring that a playback operation is performed exactly as specified during teaching, even when, during the playback operation, the machine has encountered a variation in the load from the level applied during the teaching. In order to achieve the above-stated object, a teaching and playback method for a work machine according to the present invention comprises the steps of: effecting a teaching mode during teaching where an operation signal indicative of the operator's operation of a plurality of work machine actuators is stored, effecting a playback mode in which the actuators are operated in accordance with the data stored during the teaching mode so that the actuators perform the same operation as that by the operator; and effecting a control mode in which, when a variation in the load has been detected during the playback mode a correction is generated, characterized in that the teaching mode being effected in such a manner as to store the pump discharge amount and the amounts of flow supplied to the actuator that are present during the teaching and that for the correction the output of the engine linked with the pump is controlled and the flows supplied to the individual actuators are adjusted in such a manner that the actual pump discharge and the actual flows supplied to the actuators become equal to the stored pump discharge amount and the stored actuator flow supply amounts, respectively. The method according to the invention is such that, even when, during playback, the load changes to become different from the level applied during the teaching, pump discharge compensation through the engine output control, as well as compensation for the flows supplied to the actuators, enables a playback operation to be performed exactly as specified by teachings. The method thus overcomes the above-described problem. For this purpose, the engine output during teaching is reduced to a level of the order of 80 % of the rated output, thereby providing a certain margin. When, during playback, the load has increased, the variation in the load causes a drop in the engine output and a corresponding drop in the pump discharge. According to the present invention, when the pump discharge has dropped, the engine output is automatically increased to maintain the pump discharge at the amount that was present during the teaching, thereby assuring that the same operation as specified by the teachings will be performed. If a variation in the load has occurred during multiple-actuator operation, the method uses a pressure compensated flow control valve disposed in an inflow circuit through which the actuators are supplied with flow. The valve is operated to adjust, i.e., increase or decrease, the flows supplied to the actuators in such a manner that the actual flows will become equal to the amounts that were present during the teaching, thereby assuring that exactly the same operation as the taught operation will be performed. Therefore, the method according to the present invention is capable of, in addition to various advantages inherent in a teaching and playback method, overcoming the problem conventionally encountered, i.e., a variation in the load causing a deviation in the playback movement, more specifically, a discrepancy in the locus of the work machine from that taught during teaching. The method overcomes the problem by maintaining, through engine output control, the pump discharge at a certain amount and by maintaining, through flow adjustment, the flows supplied to the actuators at certain amounts. Consequently, the operation during playback can be performed with improved accuracy. This is a great improvement in the automatization of work machines. Fig. 1 is a circuit diagram of a circuit for the teaching and playback control of a work machine to which an embodiment of the present invention is applied; Fig. 2 is a circuit diagram of a control circuit having electronic poppet valves substituting an electronic hydraulic valve of the circuit shown in Fig. 1; and Fig. 3 is a flowchart showing control performed in the embodiment shown in Fig. 1. Certain embodiments of the present invention will now be described with reference to the drawings. Fig. 1 shows a circuit for the teaching and playback control of a work machine (not shown), such as a hydraulic excavator, to which an embodiment of the present invention is applied. The control circuit includes a work machine lever 1, a device 2 for converting the operation amount of the work machine lever 1 into an electrical signal, an automatization controller 3, an electronic controller 4, a device 5 for controlling the amount of fuel injected into an engine 6, and a variable-displacement pump 8 connected to the engine 6. The pump 8 has a regulator 7. An actuator 10, an electronic hydraulic valve 11 and a pressure compensated flow control valve 12 are connected to an inflow circuit 9 which is in turn connected to the pump 8. Although not shown, the hydraulic excavator has a plurality of work machine pump levers, and a plurality of actuators corresponding thereto. Since the levers or the actuators have the same construction, only one of the levers and the corresponding actuator are illustrated and will be described so as to avoid reader's confusion. The automatization controller 3 (hereinafter abbreviated to "AC") comprises an input interface 13, a circuit 14 for performing calculation and control on the basis of the signal input through the interface 13, a circuit 15 for storing processing procedures, constants, etc., and an output interface 16 for outputting the values obtained by the calculation and control. During teaching, the AC 3 converts the work machine lever operation amount into an electric signal, stores the signal, and performs the necessary calculation. During playback, the AC 3 transmits the stored data to the electronic controller 4 by generating an output signal. The AC 3 is connected with switches 17, 18 and 19. The switch 17 is a mode changeover switch for changing from one of the manual mode (designated by "OFF" in Fig. 1), the automatic teaching mode ("T"), and the automatic playback mode (P).to another of these three modes. The switches 18 and 19 are each a teaching or playback ON/OFF switch for starting and terminating a teaching or playback operation. The electronic controller 4 (hereinafter abbreviated to "EC") is connected, via signal circuits 20 and 21, with the electronic hydraulic valve 11. During playback, the EC 4 operates the valve 11 on the basis of the signal input from the AC 3 so as to control, through the actuator 10, a playback operation of the work machine. During playback, in order to cope with a variation in the load, the EC 4 receives feedback input signals and sends, on the basis of these input signals, command signals for the control of various members. For this purpose, the EC 4 is connected with the engine fuel injection control device 5 via input/output signal circuits 22 and 23, with the regulator 7 of the variable-displacement pump 8 via input/output signal circuits 24 and 25, and with the pressure compensated flow control valve 12 via input/output signal circuits 26 and 27. When a variation has occurred in the load during a playback operation, commands from the EC 4 cause the engine output and/or pump discharge to be controlled in proportion to a value indicative of the variation, so that the pump discharge will be maintained at the discharge amount that was present during the teaching. If a load variation has occurred during a multiple-actuator operation, the pressure compensated flow control valve 12 is controIled in a similar manner in proportion to a variation value, so that the flow supplied to the actuator 10 will be maintained at the flow supply amount that was present during the teaching. Specifically, the EC 4 stores signals output from the pump 8 and the flow control valve 12 during the teaching. When a change in the discharge of the pump 8, caused by a variation in the load on the actuator, has been detected, the EC 4 operates to output an engine rotational speed adjusting signal to the fuel injection control device 5 of the engine 6 which is directly connected to the pump 8, thereby performing control in such a manner that the discharge of the pump 8 will become equal to the discharge amount that was present during the teaching. On the other hand, there are a plurality of actuators 10, each associated with a flow control valve 12 and an electronic hydraulic valve 11, which actuators 10 may be driven in a suitable combination thereof during a multiple-actuator operation. If such an operation is performed during playback, the actual flows which are present during the playback operation are compared with the flow amounts which were present during the teaching. The EC 4 performs control, with or without a variation in the load, in such a manner that the actual flows will become equal to the flow amounts during the teaching. The EC 4 has a construction similar to that of the above-described AC 3, and comprises an input interface 28, a control circuit 29 for performing calculation and control on the basis of the signal input through the interface 28, a circuit 30 for storing processing procedures, constants, etc., and an output interface 31 for outputting the values obtained by the calculation and control. The electronic hydraulic valve 11 is, as described above, used to control the operation of the actuator 10. A voltage indicative of the operation amount of the work machine lever 1 is input to the valve 11, and command currents are applied to two solenoids 32 and 33 of the valve 11, with the relationship of the command currents being calculated and controlled. The electronic hydraulic valve 11 may be substituted by electronic poppet valves 34a to 34d, as shown in Fig 2. With this substitution, when signals expressing the command currents from the EC 4 are input to two solenoids 35a and 35b, a meter-in poppet valve 34a and a meter-out poppet valve 34b open in response to and in accordance with the signals, whereby a command flow in accordance with the command currents is supplied to the actuator 10. Next, description will be given of the manner and procedure of operations performed by the teaching and playback control circuit. (1) Teaching Operation: The teaching mode (T) is selected by switching the position of the mode changeover switch 17. Subsequently, the teaching switch 18 is turned on to start a teaching operation. When the work machine lever 1 is moved to the desired direction, the amount by which the lever is operated is input, as an electrical signal, to the AC 3, and is then stored therein. The electrical signal indicative of the lever operation amount is also input, through the EC 4, to the solenoids 32 and 33 of the electronic hydraulic valve 11. Through the control of the valve 11, the actuator 10 is operated in such a manner that the work machine moves along a predetermined locus, the machine thus being taught. The teaching mode is terminated by turning off the switch 18. (2) Playback Operation: Prior to the start of a playback operation, the posture of the work machine is set. Thereafter, the mode changeover switch 17 is operated to select the playback mode (P). Then, the playback switch 19 is turned on, thereby starting a playback operation. The playback operation is repeated until the playback switch 19 is turned off. When, during the playback, the load has varied from the level applied during the teaching, no special operation from the operator is required. Instead, the engine output is automatically controlled in such a manner as to maintain the pump discharge at the amount that was present during the teaching. When a load variation has occurred during a multiple-actuator operation, the pressure compensated flow control valve 12 is adopted to adjust the flows in such a manner that they are maintained at the amounts that were present during the teaching. Thus, the playback can be performed exactly as specified by the teaching. When, during the playback, the operator operates the work machine lever 1, an additional signal is added to the AC 3 so that the electronic hydraulic valve 11 and the actuator 10 are operated in accordance with the additional signal as well. Fig. 3 shows a flowchart illustrating the teaching and playback control. The flowchart shows basic procedures for carrying out a teaching and playback method for a work machine according to the present invention. In Step S1, initial setting is performed. A determination is made, in Step S2, as to whether or not the current mode is an automatic mode. If the current mode is an automatic mode, it is determined, in Step S3, whether it is the teaching mode or the playback mode. If the current mode is the teaching mode, it is determined, in Step S4, whether or not the teaching switch is turned on, and, in Step S5, whether or not the playback switch is turned off. If affirmative answers are obtained in both of Steps S4 and S5, the memory of the electronic controller is cleared in Step S6. When a signal indicative of the operation of the work machine lever 1 has been input, the lever signal is stored (Step S7). The teaching mode is terminated when the teaching switch is turned off. On the other hand, if the current mode is the playback mode, determinations are made as to whether or not the playback switch is turned on (Step S8) and whether or not the teaching switch is turned off (Step S9). If affirmative answers were obtained in both of Steps S8 and S9, the data stored in a memory of the electronic controller is read (Step S10). In Step S11, on the basis of the memory data, a driving signal is output to the electronic hydraulic valve 11. In this step, if an additional signal indicative of the operation of the work machine lever 1 has been added, this signal is also output to the valve 11. When the reading of the memory data has been completed, the playback operation is completed (Step S12). The teaching and playback method according to the present invention is applicable to construction equipment. The method can be particularly advantageously applied to the hydraulic drive apparatus of a hydraulic excavator. The method is applicable to a work machine of any type which has an hydraulic drive apparatus and which is required to perform repeated operations.

Claims: A teaching and playback method for a work machine comprising the steps of: effecting a teaching mode during teaching where an operation signal indicative of the operator's operation of a plurality of work machine actuators is stored, effecting a playback mode in which said actuators (1) are operated in accordance with the data stored during the teaching mode so that said actuators perform the same operation as that by the operator; and effecting a control mode in which, when a variation in the load has been detected during the playback mode, a correction is generated, characterized in that the teaching mode being effected in such a manner as to store the pump (8) discharge amount and the amounts of flow supplied to said actuator (1) that are present during the teaching; and that for the correction the output of the engine (6) linked with the pump (8) is controlled and the flows supplied to the individual actuators are adjusted in such a manner that the actual pump discharge and the actual flows supplied to said actuators become equal to the stored pump discharge amount and the stored actuator flow supply amounts, respectively. A teaching and a playback method for a work machine according to claim 1, wherein, in said teaching mode, the engine (6) output is reduced to a value smaller than the rated output of the engine, which value is then stored as the engine output to be used during said playback mode, and wherein, in said control mode entered upon the detection of a variation in the load during said playback mode, the actual engine output is controlled. A teaching and a playback method for a work machine according to claim 1, wherein, in said control mode entered upon the detection of a variation in the load during said playback mode, the actual flows supplied to said actuators are adjusted by a pressure compensated flow control valve disposed in an inflow circuit connected to said actuators.

Inventors: MORIYA YUKIO, ONODA TAKUMI, TAKAMURA FUJITOSHI, YOKOYAMA TOSHIO, MORIYA, YUKIO, ONODA, TAKUMI, TAKAMURA, FUJITOSHI, YOKOYAMA, TOSHIO
Applicants: KOMATSU MFG CO LTD, KABUSHIKI KAISHA KOMATSU SEISAKUSHO
Application year: 1989
Main classification: E02F9
IPC codes: E02F3, F15B21, G05D3, E02F9