Patent Description:
There is known a hydraulic drive system, see <CIT>. Here, pressure adjusting valves control outlet pressures of variable throttle portions of directional control valves of closed center type to be kept substantially equal to a maximum load pressure detected by a detecting line. A variable throttle valve and a pressure adjusting valve are disposed in a bypass line branched from a pump supply line for controlling an outlet pressure of the variable throttle valve to be also kept substantially equal to the maximum load pressure. The variable throttle valve has an opening area controlled to be reduced with an increase in the input amount by which a control lever unit is operated, and a pump delivery rate is controlled by a tilting control device to become a flow rate corresponding to the input amount of the control lever unit.

A control method for a variable volume pump is known in which, instead of an ordinary bleed control for controlling a hydraulic actuator speed by changing a bleed flow rate according to an operation amount of a control valve, a directional control valve of a closed center type is used, while a virtual bleed opening is set in the control valve and an area of the bleed opening (virtual bleed opening area) is changed according to the operation amount, see Patent Document <NUM>, for example. According to the control method, a necessary pump discharge pressure is calculated using the virtual bleed opening area and a virtual bleed amount derived therefrom to perform the pump control such that the pump discharge pressure is implemented.

However, according to the technique described in Patent Document <NUM>, because only the virtual bleed opening is set and a negative control restriction is not assumed, a virtual negative control system is not replicated. As is generally known, the negative control system is in touch with human sensibilities, because the speed of the hydraulic actuator is low when a load is high while the speed of the hydraulic actuator is high when the load is low.

Therefore, an object of the present invention is to provide a hydraulic control apparatus and a method that can virtually replicate a negative control system in a hydraulic circuit for a construction machine in which a hydraulic actuator is connected to a hydraulic pump via a directional control valve of a closed center type.

The object is achieved by the subject-matter of independent claims <NUM> or <NUM>. Further preferred embodiments are described by dependent claims <NUM> to <NUM>, and the following description exemplifies best modes for carrying out the present invention.

According to the present invention, it is possible to virtually replicate a negative control system in a hydraulic circuit for a construction machine in which a hydraulic actuator is connected to a hydraulic pump via a directional control valve of a closed center type.

In the following, the best mode for carrying out the present invention will be described in detail by referring to the accompanying drawings.

<FIG> is a diagram for illustrating an example of a configuration of a construction machine <NUM> according to an embodiment of the present invention. The construction machine <NUM> is a machine that has a hydraulic system operated by a human installed thereon, such as a hydraulic shovel, a folk lift, a crane. In <FIG>, the construction machine <NUM> includes an upper rotating body <NUM> mounted on a lower traveling body of a crawler type via a rotating mechanism such that the upper rotating body <NUM> is rotatable around an X axis. Further, the upper rotating body <NUM> includes an excavation attachment at a forward center thereof that includes a boom <NUM>, an arm <NUM> and a bucket <NUM> as well as a boom cylinder <NUM>, an arm cylinder <NUM> and a bucket cylinder <NUM> as hydraulic actuator for driving them, respectively. The excavation attachment may be another attachment such as a breaker, a crusher, etc..

<FIG> is a diagram for illustrating a hydraulic circuit of a hydraulic control system <NUM> according to the embodiment. The hydraulic control system <NUM> includes a hydraulic pump <NUM> of a variable volume type with which a discharge amount per a revolution (cc/rev) is variable. The hydraulic pump <NUM> is connected to an engine <NUM> and driven to rotate by the engine <NUM>. The hydraulic pump <NUM> is connected to the boom cylinder <NUM>, the arm cylinder <NUM> and the bucket cylinder <NUM> (examples of the hydraulic actuator) via a supply line <NUM> and directional control valves of a closed center type (control valves) <NUM>, <NUM> and <NUM> in parallel. Further, a return line <NUM>, which is connected to a tank T, is connected to the boom cylinder <NUM>, the arm cylinder <NUM> and the bucket cylinder <NUM> via the control valves <NUM>, <NUM> and <NUM>. The hydraulic pump <NUM> is controlled by a regulator apparatus <NUM>. It is noted that the control valves <NUM>, <NUM> and <NUM> may be of a type in which a position control is hydraulically performed or a type in which a position control is electronically performed with an electric signal (drive signal) from the controller <NUM> as illustrated.

It is noted that the hydraulic control system <NUM> may include another actuator such as a hydraulic motor for traveling and a hydraulic motor for rotating. Further, the number of the hydraulic actuators is three in the example illustrated in <FIG>; however, the number of the hydraulic actuators may be arbitrary including <NUM>.

An oil pressure sensor <NUM> for detecting a discharge pressure (pump discharge pressure) of the hydraulic pump <NUM> is provided in the hydraulic line from the hydraulic actuator <NUM>. The pressure sensor <NUM> may input an electrical signal according to the pump discharge pressure to the controller <NUM>.

An unloading valve <NUM> is provided in the supply line <NUM>. The unloading valve <NUM> is connected to the return line <NUM> connecting to the tank T. In this way, the supply line <NUM> is in fluid communication with the tank T via the unloading valve <NUM>. The unloading valve <NUM> switches, according to the position thereof, between a state in which the supply line <NUM> is in fluid communication with the tank T and a state in which the supply line <NUM> is disconnected from the tank T. The unloading valve <NUM> may be controlled according to open/closed statees of fluid paths in the control valves <NUM>, <NUM> and <NUM> to the respective actuators (the boom cylinder <NUM>, the arm cylinder <NUM> and the bucket cylinder <NUM>). For example, the unloading valve <NUM> may be closed when at least one of the actuator lines in the control valves <NUM>, <NUM> and <NUM> is open such that the oil discharged from the hydraulic pump <NUM> is not discharged to the tank T. On the other hand, the unloading valve <NUM> may be opened when all the actuator lines in the control valves <NUM>, <NUM> and <NUM> are closed to form such a state in which the oil discharged from the hydraulic pump <NUM> is discharged to the tank T. It is noted that the unloading valve <NUM> may be of a type in which a position control is hydraulically performed or of a type in which a position control is electronically performed with an electric signal as illustrated.

Further, a relief valve <NUM> is provided in the supply line <NUM>. Further, the return line <NUM> is connected to head sides and rod sides of the boom cylinder <NUM>, the arm cylinder <NUM> and the bucket cylinder <NUM> via corresponding relief valves 21a, 21b, 23a, 23b, 25a and 25b. It is noted that, in the illustrated example, the relief valves 21a, 21b, 23a, 23b, 25a and 25b include supplementary feed check valves. The relief valves 21a, 21b, 23a, 23b, 25a and 25b may be of a type in which a position control is hydraulically performed or of a type in which a position control is electronically performed with an electric signal as illustrated.

The controller <NUM> mainly includes a microprocessor that includes a CPU, a ROM in which control programs are stored, a RAM in which calculation results are stored, a timer, a counter, an input interface, an output interface, etc., for example.

Operation members <NUM>, <NUM> and <NUM> are electrically connected to the controller <NUM>. The operation members <NUM> and <NUM> are to be operated by a user for changing the positions of the control valves <NUM>, <NUM> and <NUM> to operate the construction machine <NUM>. The operation members <NUM> and <NUM> may be in a form of a lever or a pedal, for example. In this example, the operation members <NUM>, <NUM> and <NUM> are an arm operation lever for operating the arm <NUM>, a boom operation lever for operating the boom4, and a bucket operation lever for operating the bucket <NUM>, respectively. Operation amounts (strokes) of the operation members <NUM>, <NUM> and <NUM> by the user is input to the controller <NUM> as electric signals. A way of detecting the operation amounts of the operation members <NUM>, <NUM> and <NUM> by the user may be a way of detecting pilot pressures with pressure sensors or a way of detecting lever angles.

The controller <NUM> controls the control valves <NUM>, <NUM> and <NUM> and the unloading valve <NUM> based on the operation amounts of the operation members <NUM>, <NUM> and <NUM>, etc. It is noted that if the control valves <NUM>, <NUM> and <NUM> are of a type in which a position control is hydraulically performed, the control valves <NUM>, <NUM> and <NUM> are controlled directly by the pilot pressures that are changed according to the operations of the operation members <NUM>, <NUM> and <NUM>. Thus, when the arm operation amount LS1, the boom operation amount LS2 and the bucket operation amount LS3 are less than or equal to corresponding predetermined thresholds LSth1 , LSth2 and LSth3, respectively, the unloading valve <NUM> may be opened, but when at least one of the arm operation amount LS1, the boom operation amount LS2 and the bucket operation amount LS3 is greater than the corresponding predetermined thresholds LSth1, LSth2 or LSth3, the unloading valve <NUM> may be closed. The predetermined thresholds LSth1, LSth2 and LSth3 may correspond to the operation amounts when the actuator lines of the directional control valves <NUM>, <NUM> and <NUM> start to open.

Further, the controller <NUM> controls the hydraulic pump <NUM> via the regulator apparatus <NUM> based on the operation amounts of the operation members <NUM>, <NUM> and <NUM>, etc. It is noted that a method of controlling the hydraulic pump <NUM> is described hereinafter in detail.

Next, features of a control method by the controller <NUM> according to the embodiment is described.

The controller <NUM> according to the embodiment replicates control characteristics of an open center type (negative control system) in the hydraulic circuit including the control valves <NUM>, <NUM> and <NUM> of a closed center type illustrated in <FIG>. Such a system is referred to as "a virtual bleed system" hereinafter.

<FIG> is a diagram for schematically illustrating a directional control valve used in a (negative control) system of an open center type. In the negative control system, when the directional control valve is in its nominal state, an overall discharge flow rate of the hydraulic pump is unloaded to the tank via a center bypass line, as illustrated in <FIG>. For example, when the directional control valve is moved to the right side by the operation of the operation member, the flow path to the hydraulic actuator is opened and the center bypass line is narrowed. In the fully operated state, the center bypass line is fully closed such that the overall discharge flow rate of the hydraulic pump is supplied to the hydraulic actuator, as illustrated in <FIG>. These relationships can be expressed as follow. <MAT> ρ is a density, Qd and pd are discharge flow rate and discharge pressure of the hydraulic pump, cb and Ab are a flow coefficient and an opening area (bleed opening area) in the directional control valve related to the center bypass line, ca and Aa are a flow coefficient and an opening area in the directional control valve related to the actuator line, and pact is a actuator line pressure. In the negative control system, the center bypass line has a negative control restriction downstream from the directional control valve to be in fluid communication with the tank via the negative control restriction (see <FIG>).

As is clear from the formula <NUM>, when the actuator line pressure increases due to the increased load, a differential pressure (pd-pact) decreases, and thus the flow rate to the hydraulic actuator decreases. If the discharge flow rate Qd from the hydraulic pump is the same, the flow rate through the center bypass line is decreased. This means that the hydraulic actuator speed differs according to the load of the hydraulic actuator even at the same operation amount.

<FIG> is a block diagram for illustrating a negative control system that is replicated in a virtual bleed system implemented by a controller <NUM> according to the embodiment. It is noted that, in <FIG>, Qb is a flow rate flowed through the unloading valve, K is a modulus of elasticity of volume, Vp is a pump - control valve volume, Va is a control valve - cylinder volume, A is a cylinder pressure applied area, M is a cylinder volume, and F is a disturbance.

According to the embodiment, in order to replicate the negative control system in the virtual bleed system, a directional control valve of a closed center type (see <FIG>) is assumed as indicated by a block <NUM> in <FIG>, a bleed part at this virtual directional control valve is calculated to calculate a virtual bleed amount Qb, and a target value Qdt of the discharge amount of the hydraulic pump based on a control rule of the negative control system is subtracted the virtual bleed amount Qb to generate an command value to control the hydraulic pump <NUM>.

The virtual bleed amount Qb may be calculated as follow, considering a fact that there is a back pressure in the center bypass line due to the negative control restriction in the actual negative control system. In other words, in the virtual bleed system, in order to model the actual negative control system, it is assumed that the negative control restriction is provided in the center bypass line from the virtual directional control valve, and the back pressure due to the negative control restriction may be considered. <MAT> pn is a the back pressure (referred to as "virtual negative control pressure" hereinafter) due to the negative control restriction.

On the other hand, at a virtual negative control restriction, the following equation holds. <MAT> Pt is a tank pressure and <NUM> in this example. A predetermined upper limit pnmax is set for the virtual negative control pressure pn. The virtual negative control pressure pn may correspond to a setting pressure of the relief valve in the assumed negative control system.

The virtual negative control pressure pn can be expressed from the formula <NUM> and the formula <NUM> as follow. <MAT> From the formula <NUM>, it can be seen that the virtual negative control pressure pn can be calculated from the discharge pressure pd of the hydraulic pump <NUM> based on a flow coefficient cb and an opening area Ab in the directional control valve related to the center bypass line, and a flow coefficient cn and an opening area An at the negative control restriction. The flow coefficient cb, the opening area Ab, the flow coefficient cn and the opening area An can be initially set to virtual values (thus, these are known values). The flow coefficient cn and the opening area An are based on the assumed characteristics of the negative control restriction. An example of a characteristic of the opening area Ab is described hereinafter.

In this way, even without an actual bleed opening (i.e., even without a center bypass line nor a negative control restriction), the virtual negative control pressure pn can be calculated from the discharge pressure pd of the hydraulic pump <NUM> (a detection value of the oil pressure sensor <NUM>, for example) based on the assumed characteristics of the negative control system (the flow coefficient cb, the opening area Ab, the flow coefficient cn and the opening area An), and the discharge flow rate of the hydraulic pump <NUM> can be controlled based on the virtual negative control pressure pn. In other words, the negative control system can be replicated by controlling the discharge flow rate of the hydraulic pump <NUM> such that the virtual negative control pressure pn is treated as a negative control pressure to be obtained in the negative control system.

<FIG> is a diagram for illustrating an example of characteristics of a virtual directional control valve and a directional control valve. Specifically, a characteristic C1 is a curve that represents a relationship between the operation amount (stroke) in the virtual directional control valve and the opening area (virtual bleed opening area) Ab. A characteristic C2 indicates an opening characteristic on a meter-in side in the directional control valve, and a characteristic C3 indicates an opening characteristic on a meter-in side in the directional control valve. A table that represents the characteristic C1 is prepared for each of the directional control valves <NUM>, <NUM> and <NUM> as bleed opening data tables.

<FIG> is a block diagram for illustrating an example of a virtual bleed system implemented by a controller <NUM> according to the embodiment. It is noted that in the following such a configuration in which a positive control system and the negative control system are selectively implemented; however, only the negative control system is implemented in the virtual bleed system according to the invention. It is noted that the negative control system corresponds to a block <NUM> in <FIG> and the positive control system corresponds to a block <NUM> in <FIG>. A control block of the positive control system is the same as an ordinary positive control system, and thus a control block of the negative control system, in particular, is described hereinafter. It is noted that the block <NUM> in <FIG> corresponds to a part of the block <NUM> in <FIG>.

In this virtual bleed system, as an example, such a negative control system as illustrated in <FIG> is replicated. In this negative control system, directional control valves V1, V2 and V3 of an open center type (corresponding to the virtual directional control valves in the virtual bleed system) that correspond to the directional control valves <NUM>, <NUM> and <NUM> of a closed center type, respectively, are connected in series, and a negative control restriction <NUM> (corresponding to the virtual negative control restriction in the virtual bleed system) is disposed on a downstream side of a center bypass line <NUM>. It is noted that in <FIG> the illustration of the hydraulic actuators (the boom cylinder <NUM>, the arm cylinder <NUM> and the bucket cylinder <NUM>) which are provided for the corresponding directional control valves V1, V2 and V3 is omitted.

As illustrated in <FIG>, signals representing the operation amounts of the operation members <NUM>, <NUM>, that is to say, an arm operation amount LS1, a boom operation amount LS2 and a bucket operation amount LS3 are input to the blocks <NUM> and <NUM> of the negative and positive systems. Further, the discharge pressure pd of the hydraulic pump <NUM> (merely referred to as "pump discharge pressure pd" hereinafter) are input to the blocks <NUM> and <NUM> of the negative and positive systems. It is noted that the pump discharge pressure pd may be a detection value of the oil pressure sensor <NUM>.

The arm operation amount LS1, the boom operation amount LS2 and the bucket operation amount LS3 are converted to the opening areas Ab at the corresponding bleed opening data tables (see <FIG>) <NUM>-<NUM>, respectively, and multiplied by corresponding flow coefficients cb to be input to a block <NUM>-<NUM>. The block <NUM>-<NUM> calculates a parameter ceAe of the virtual directional control valves as a whole based on a fact that an equivalent opening area Ae of restrictions connected in series can be expressed as follow. <MAT> Ai corresponds to virtual bleed opening areas of the respective virtual directional control valves (i.e., the respective virtual directional control valves corresponding to the directional control valves <NUM>, <NUM> and <NUM>). When the flow coefficients are additionally considered, the following formula is given. <MAT> ci corresponds to flow coefficients of the respective virtual directional control valves (i.e., the respective virtual directional control valves corresponding to the directional control valves <NUM>, <NUM> and <NUM>). It is noted that i corresponds to the number of the directional control valves (and thus the number of the hydraulic actuators). For example, in the case of a configuration in which only the directional control valve <NUM> exists, the sigma in the formula is not used (i.e., the product of the flow coefficient c and the opening area A related to the directional control valve <NUM> is merely calculated).

ceAe thus obtained is input to a block <NUM>-<NUM>. Ancn and the pump discharge pressure pd are also input to the block <NUM>-<NUM>. Ancn are obtained by multiplying the opening area An at the virtual negative control restriction by the flow coefficient cn at the virtual negative control restriction, and are input from blocks <NUM>-<NUM> and <NUM>-<NUM>. In a bock <NUM>-<NUM>, the virtual negative control pressure pn is calculated based on the formula <NUM> described above. The virtual negative control pressure pn thus calculated is input to blocks <NUM>-<NUM> and <NUM>-<NUM>.

In a block <NUM>-<NUM>, the virtual bleed amount Qb is calculated from the pump discharge pressure pd and the virtual negative control pressure pn based on the formula <NUM> described above. In a block <NUM>-<NUM>, the target value Qdt of the discharge flow rate of the hydraulic pump <NUM> is calculated from the virtual negative control pressure pn based on a given a virtual negative control pressure versus flow rate table (see <FIG>). The target value Qdt of the discharge flow rate of the hydraulic pump <NUM> is determined based on a control rule of the negative control system. Specifically, the virtual negative control pressure versus flow rate table represents a relationship between the virtual negative control pressure pn and the target value Qdt of the discharge flow rate of the hydraulic pump <NUM>, and this relationship may be determined based on the assumed control rule of the negative control system. The virtual negative control pressure versus flow rate table illustrated in <FIG> has such a relationship that the target value Qdt of the discharge flow rate becomes small when the virtual negative control pressure pn is high while the target value Qdt of the discharge flow rate becomes great when the virtual negative control pressure pn is low. According to the virtual bleed system, the virtual bleed amount Qb is redundant unlike the actual negative control system, and thus the virtual bleed amount Qb is subtracted from the target value Qdt of the discharge flow rate of the hydraulic pump <NUM> to calculate an command value (virtual negative control target value) of the discharge flow rate of the hydraulic pump <NUM>. It is noted that a maximum flow rate (horsepower control target value) for a horsepower control is calculated based on an engine rpm and a setting torque, and the smaller of the virtual negative control target value and the horsepower control target value is selected as a final target value, although it is not illustrated.

It is noted that the mode selector <NUM> switches between a positive control mode for implementing the positive control system and a negative control mode for implementing the negative control system. The mode selector <NUM> may switch the mode according to the operation of the user or may automatically switch the mode according to a predetermined condition. It is noted that in the positive control mode, the opening area of the actuator line is calculated based on the arm operation amount LS1, the boom operation amount LS2 and the bucket operation amount LS3 in a block <NUM>-<NUM>, and command values (positive control target value) of actuator demand flow rates of the hydraulic actuators is calculated based on an opening area versus flow rate table (see <FIG>) that represents a relationship between the opening area and the actuator demand flow rate in a block <NUM>-<NUM>. It is noted that the actuator demand flow rates of the hydraulic actuators may be calculated directly from an operation amount versus flow rate table based on the arm operation amount LS1, the boom operation amount LS2 and the bucket operation amount LS3. Further, as is the case with the virtual negative control target value, a maximum flow rate (horsepower control target value) for a horsepower control is calculated based on an engine rpm and a setting torque, and the smaller of the positive control target value and the horsepower control target value is selected as a final target value.

In this way, by setting the mode selector <NUM>, it becomes possible to selectively use the positive control system that enables a precise operation or the negative control target value that is in touch with human sensibilities, if necessary.

According to the hydraulic control apparatus of the present embodiment described above, the following effect among others can be obtained.

As is described above, because the directional control valves <NUM>, <NUM> and <NUM> of a closed center type are used, bleeding, which is necessary in the case of the negative control system, becomes unnecessary, which enhances energy conservation. Further, the characteristics of the directional control valve are based on electronic data and thus can be easily changed. Therefore, it becomes possible to easily adjust the characteristics of the directional control valve (the characteristic of the virtual bleed opening area, in particular, see the characteristic C1 in <FIG>). This holds true for the characteristics of the negative control restriction. Further, because the directional control valves <NUM>, <NUM> and <NUM> of a closed center type are used, bleed lines for the directional control valves become unnecessary, which reduces cost of the directional control valves.

In the virtual bleed system described above, it is preferred in terms of the control principle that the oil pressure sensor <NUM> is provided near (immediately before) the directional control valves <NUM>, <NUM> and <NUM>. However, such an arrangement of the directional control valves <NUM>, <NUM> and <NUM> may not be implemented due to mechanically available space, cost, etc. For example, there is a case where the oil pressure sensor <NUM> is provided in the hydraulic pump <NUM>. In such a case, the pump discharge pressure detected by the oil pressure sensor <NUM> corresponds to a pressure after pressure loss due to pipe resistance in a section from the hydraulic pump <NUM> to the directional control valves <NUM>, <NUM> and <NUM> has been added. For this reason, preferably, an real pressure added to the directional control valves <NUM>, <NUM> and <NUM> is predicted by referring to the command value for the discharge flow rate of the hydraulic pump <NUM> to previously add a gain or bias to the pump discharge pressure detected by the oil pressure sensor <NUM>. As a result of this, even if the oil pressure sensor <NUM> is not disposed near the directional control valves <NUM>, <NUM> and <NUM>, the virtual negative control pressure, which is adapted to an actual negative control pressure with high accuracy, can be calculated by predicting the real pressure added to the directional control valves <NUM>, <NUM> and <NUM>, which enhances the reproducibility of the negative control system in the virtual bleed system.

More preferably, a change in a viscosity of the oil due to a secular variation of the oil or increased leakage loss of the hydraulic pump <NUM> due to a secular variation of apparatuses (and thus the command value cannot be implemented) are considered to be compensated for.

Specifically, the problem related to the change in the viscosity of the oil may be solved by providing the unloading valve <NUM> near (immediately before) the directional control valves <NUM>, <NUM> and <NUM>. For example, in <FIG>, the unloading valve <NUM> may be provided immediately before a branch point P of the supply line <NUM>. If possible in terms of a construction, the unloading valve <NUM> may be attached to a block of the directional control valve <NUM> that is the nearest with respect to the hydraulic pump <NUM>. In this case, in a situation where the unloading valve <NUM> is operated (in its open state) and there is no restriction, the pump discharge pressure detected by the oil pressure sensor <NUM> substantially corresponds to the pressure loss itself in the pipe. Thus, by comparing a preset value of the pressure loss with the pump discharge pressure detected by the oil pressure sensor <NUM>, a difference or ratio of a dynamic viscosity before and after the change can be determined. It is noted that the following Hagen-Rubens formula can be utilized for the calculation, for example. The gain or bias added to the pump discharge pressure detected by the oil pressure sensor <NUM> may be set according to the difference or ratio of the dynamic viscosity. <MAT> Here, r is an inner diameter of the pipe, <NUM> is a length of the pipe, µ is a dynamic viscosity, and Δp is a pressure difference.

Further, the problem related to the secular degradation of the hydraulic pump <NUM> may be solved by using the unloading valve <NUM> of a proportional control valve type. In this case, the pump discharge pressure is increased by applying an command value of a constant discharge flow rate to the hydraulic pump <NUM> to cause the hydraulic pump <NUM> to discharge the constant discharge flow rate and then narrowing the unloading valve <NUM>. Because the narrowed opening position of the unloading valve <NUM> can be a known value, the flow rate that flows through the unloading valve <NUM>, that is to say, the actual flow rate of the hydraulic pump <NUM> can be calculated from the measured pump discharge pressure from the following restriction formula (formula <NUM>). The gain or bias for the command value of the discharge flow rate of the hydraulic pump <NUM> may be set based on the difference between the actual flow rate thus calculated and the command value of the discharge flow rate. <MAT> Cn and Au are a flow coefficient and a restriction opening position of the unloading valve <NUM>.

In the following, concrete examples for compensating such a change in the viscosity of the oil and the secular degradation of the apparatus are described.

<FIG> is a block diagram for illustrating another example of a virtual bleed system implemented by a controller <NUM> according to the embodiment. In <FIG>, unlike in <FIG>, only a part of the negative control system is illustrated. If a configuration in which the positive control system is selectively implemented, the mode selector <NUM> and the block <NUM> of the positive control system may be added as in <FIG>.

A block <NUM>' of the negative control system illustrated in <FIG> differs from the block <NUM> in the example illustrated in <FIG> in that a block <NUM>-<NUM> in which the pump discharge pressure pd is multiplied by a discharge pressure adjustment gain Kµ (also referred to as a pump discharge pressure correction coefficient Kµ) and a block <NUM>-<NUM> in which the discharge flow rate of the hydraulic pump <NUM> is multiplied by a discharge flow rate adjustment gain KQ (also referred to as a pump discharge instruction correction coefficient KQ) are added. In the following, the difference is mainly described in detail.

<FIG> is a flowchart for illustrating an example of a calculation process of a pump discharge pressure correction coefficient Kµ executed by a controller <NUM> according to the embodiment. <FIG> is a block diagram for illustrating a calculation block of the pump discharge pressure correction coefficient Kµ related to <FIG>.

In step <NUM>, an operating state of the construction machine <NUM> is detected.

In step <NUM>, it is determined whether the engine <NUM> is in an idle state. If the engine <NUM> is in an idle state, the process routine goes to step <NUM>. On the other hand, if engine <NUM> is not in an idle state, a state for waiting for the idling is formed. It is noted that, during the idling of the engine <NUM>, the arm operation amount LS1, the boom operation amount LS2 and the bucket operation amount LS3 are <NUM>, and the unloading valve <NUM> is kept in the open state (maximum opening position).

In step <NUM>, a predetermined command value of the discharge flow rate of the hydraulic pump <NUM> is calculated. The predetermined command value of the discharge flow rate of the hydraulic pump <NUM> may be arbitrary as long as the pump discharge pressure pd is appropriately detected in step <NUM>. Further, the predetermined command value of the discharge flow rate of the hydraulic pump <NUM> may be constant, or may increase or decrease with time (with a constant change rate, for example).

In step <NUM>, the pump discharge pressure pd is detected by the oil pressure sensor <NUM>.

In step <NUM>, the viscosity (real viscosity) µP of the oil discharged from the hydraulic pump <NUM> is calculated (estimated) based on the predetermined command value for the discharge flow rate of the hydraulic pump <NUM> and the pump discharge pressure pd detected by the oil pressure sensor <NUM>. The viscosity µP may be calculated by using the Hagen-Rubens formula in the formula <NUM> (see a block <NUM>-9a in <FIG>). In this case, the pump discharge pressure pd detected by the oil pressure sensor <NUM> is substituted as the pressure difference Δp in the formula <NUM>. This is because the pump discharge pressure pd detected by the oil pressure sensor <NUM> substantially corresponds to the pressure loss itself in the pipe when the unloading valve <NUM> is in the open state as described above.

In step <NUM>, an oil temperature is detected by an oil temperature sensor (not illustrated).

In step <NUM>, the viscosity µT is calculated from a given oil temperature/temperature versus viscosity table based on the oil temperature detected by the oil temperature sensor and the pump discharge pressure pd detected by the oil pressure sensor <NUM>. The oil temperature/temperature versus viscosity table may be generated in advance utilizing values measured in a nominal state in which there is no degradation of oil, etc. Thus, the viscosity µT calculated here corresponds to an intended nominal value (reference viscosity).

In step <NUM>, an absolute value of a difference between the viscosity µP calculated in step <NUM> and the viscosity µT calculated in step <NUM> is greater than or equal to a predetermined threshold. The predetermined threshold is set for determining whether the difference is great enough to be compensated for by the correction with the pump discharge pressure correction coefficient Kµ described hereinafter. The predetermined threshold may be determined according to the required accuracy of the control. If the absolute value of the difference between the viscosity µP and the viscosity µT is greater than or equal to the predetermined threshold, the process routine goes to step <NUM>. On the other hand, if the absolute value of the difference between the viscosity µP and the viscosity µT is smaller than the predetermined threshold, the process routine ends, determining that the correction is not necessary now.

In step <NUM>, the pump discharge pressure correction coefficient Kµ is calculated and the previous value is changed (updated). The ratio between the viscosity µP and the viscosity µT may be calculated as the pump discharge pressure correction coefficient Kµ (Kµ=µP/µT) (see a block <NUM>-9c in <FIG>). In this way, when the conditions of step <NUM> and step <NUM> are met, the pump discharge pressure correction coefficient Kµ is calculated by blocks <NUM>-9a, 9b and 9c in <FIG>. The pump discharge pressure pd is multiplied by the pump discharge pressure correction coefficient Kµ in a block <NUM>-<NUM> in <FIG> to correct the pump discharge pressure pd.

According to the configuration illustrated in <FIG>, even if the viscosity of the oil has changed due to the secular degradation of oil, the virtual bleed system that can compensate for such a change in the viscosity can be implemented. In other words, by compensating for the change in the viscosity, the real pressure applied to the directional control valves <NUM>, <NUM> and <NUM> can be calculated with high accuracy, which enhances the reproducibility of the negative control system in the virtual bleed system.

<FIG> is a flowchart for illustrating an example of a calculation process of a pump discharge instruction correction coefficient KQ executed by a controller <NUM> according to the embodiment. <FIG> is a block diagram for illustrating a calculation block of the pump discharge instruction correction coefficient KQ related to <FIG>.

In step <NUM>, it is determined whether the engine is in an idle state. If the engine <NUM> is in an idle state, the process routine goes to step <NUM>. On the other hand, if engine <NUM> is not in an idle state, a state for waiting for the idling is formed. It is noted that, during the idling of the engine <NUM>, the arm operation amount LS1, the boom operation amount LS2 and the bucket operation amount LS3 are <NUM>, and the unloading valve <NUM> is kept in the opens state (maximum opening position).

In step <NUM>, a predetermined command value for the discharge flow rate of the hydraulic pump <NUM> is calculated. The predetermined command value Q<NUM> of the discharge flow rate of the hydraulic pump <NUM> may be arbitrary as long as the pump discharge pressure pd is appropriately detected in step <NUM>. Further, the predetermined command value Q<NUM> of the discharge flow rate of the hydraulic pump <NUM> may be constant, or may increase or decrease with time (with a constant change rate, for example).

In step <NUM>, the opening of the unloading valve <NUM> is changed with an arbitrary change rate. For example, the opening of the unloading valve <NUM> may be changed such that it gradually increases to the maximum opening position over a predetermined time (see an unloading valve opening position instruction AU in <FIG>). Alternatively, the opening position of the unloading valve <NUM> may be changed or kept at an arbitrary predetermined opening position between <NUM> and the maximum value.

In step <NUM>, the pump discharge pressure pd detected by the oil pressure sensor <NUM> is obtained during the change of the opening position of the unloading valve <NUM>. Alternatively, the pump discharge pressure pd may be obtained during the unloading valve <NUM> at an arbitrary predetermined opening position.

In step <NUM>, the actual discharge flow rate QR of the hydraulic pump <NUM> during the change of the opening position of the unloading valve <NUM> may be calculated based on the command value (unloading valve opening position instruction AU) for the opening position of the unloading valve <NUM> and the pump discharge pressure pd detected by the oil pressure sensor <NUM> during the change of the opening position of the unloading valve <NUM>. The actual discharge flow rate QR of the hydraulic pump <NUM> may be calculated utilizing the restriction formula (formula <NUM>) described above (see a block <NUM>-10a in <FIG>). In the block <NUM>-10a in <FIG>, the pressure difference between the pump discharge pressure pd and a tank pressure pt is used as the pressure difference in the restriction formula (formula <NUM>) described above. The tank pressure pt may be assumed to be <NUM>.

In step <NUM>, an absolute value of a difference between the instructed discharge flow rate Q<NUM> of the hydraulic pump <NUM> and the actual discharge flow rate QR calculated in step <NUM> is greater than or equal to a predetermined threshold. The predetermined threshold is set for determining whether the difference is great enough to be compensated for by the correction with the pump discharge instruction correction coefficient KQ described hereinafter. The predetermined threshold may be determined according to the required accuracy of the control. If the absolute value of the difference between the instructed discharge flow rate Q<NUM> of the hydraulic pump <NUM> and the actual discharge flow rate QR is greater than or equal to the predetermined threshold, the process routine goes to step <NUM>. On the other hand, the absolute value of the difference between the instructed discharge flow rate Q<NUM> of the hydraulic pump <NUM> and the actual discharge flow rate QR is less than the predetermined threshold, the process routine ends, determining that the correction is not necessary now.

In step <NUM>, the pump discharge instruction correction coefficient KQ is calculated and the previous value is changed (updated). The ratio between the instructed discharge flow rate Q<NUM> of the hydraulic pump <NUM> and the actual discharge flow rate QR may be calculated as the pump discharge instruction correction coefficient KQ (KQ=QR/Q<NUM>) (see a block <NUM>-10b in <FIG>). In this way, when the conditions of step <NUM> and step <NUM> are met, the pump discharge instruction correction coefficient KQ is calculated by blocks <NUM>-10a and 10b in <FIG>. The command value of the discharge flow rate of the hydraulic pump <NUM> is multiplied by the pump discharge instruction correction coefficient KQ thus calculated in a block <NUM>-<NUM> in <FIG> to correct the command value of the discharge flow rate.

According to the configuration illustrated in <FIG>, <FIG> and <FIG>, even if a deviation between the command value of the discharge flow rate and the actual discharge flow rate of the hydraulic pump <NUM> occurs due to the secular degradation, the virtual bleed system that can compensate for such a deviation can be implemented. In other words, by compensating for the change in the viscosity, the real pressure applied to the directional control valves <NUM>, <NUM> and <NUM> can be calculated with high accuracy, which enhances the reproducibility of the negative control system in the virtual bleed system.

The present invention is disclosed with reference to the preferred embodiments. However, it should be understood that the present invention is not limited to the above-described embodiments, and variations and modifications may be made without departing from the scope of the present invention as defined in the appended claims.

Claim 1:
A hydraulic control apparatus (<NUM>) for a construction machine (<NUM>) in which a hydraulic actuator (<NUM>, <NUM>, <NUM>) is connected to a hydraulic pump (<NUM>) via a directional control valve (<NUM>, <NUM>, <NUM>) of a closed center type, and in which a position of the directional control valve (<NUM>, <NUM>, <NUM>) is changed according to an operation amount of an operation member (<NUM>, <NUM>, <NUM>), characterized by the hydraulic control apparatus (<NUM>) comprising:
a virtual negative control pressure calculating part configured to calculate, based on the operation amount of the operation member (<NUM>, <NUM>, <NUM>) and a discharge pressure (pd) of the hydraulic pump (<NUM>), a virtual negative control pressure (pn) in a virtual bleed system, the virtual bleed system comprising a virtual directional control valve (V1, V2, V3) of an open center type and a virtual negative control restriction (<NUM>) disposed downstream from the virtual directional control valve (V1, V2, V3) in a center bypass line (<NUM>), the virtual negative control pressure (pn) being a back pressure in the center bypass line (<NUM>) due to the virtual negative control restriction (<NUM>); and
a part configured to calculate a control command value for the hydraulic pump (<NUM>) based on the virtual negative control pressure (pn), such that the discharge flow rate of the hydraulic pump (<NUM>) is decreased or increased in accordance with an increase or decrease of the virtual negative control pressure (pn).