DESC:TECHNOLOGY CONCEPT IN CONTROLLED AREA NETWORK CONTROLLED SYSTEM IN HYDRAULIC SHOVEL

FIELD OF INVENTION

[0001] The technology disclosed in the present invention is implemented in hydraulic shovels. In particular, a technology integration for the concept of implementing the open loop hydraulic system with positive control system by a total electronically CAN control system in large Hydraulic Shovel having range of bucket size 4.5 to 6.5 Cu.M capacity and machine tonnage is 100 ton.

[0002] However, the concept is to eliminate the hydraulic pilot control system inside the operator cabin to main control valve and implementing the arrangement of electrical direct control of main control valve through integrated electronic proportional valve/CMA valve.

[0003] The CMA 200 is an advanced CAN enabled electro-hydraulic sectional mobile valve with independent metering that utilizes pressure and position sensors, on board electronics, and advanced software control algorithms. Where conventional mobile valves often compromise on precision or response, the CMA delivers both. CMA valve is the next generation in advanced mobile valves differentiate the machine capabilities. The program made in this shovel control system is unique which can control engine & hydraulic system and it is the property of HEC shovel.

[0004] The controller is communicated with other systems through CAN (Controlled Area Network) Bus on J1939 Protocol. All electrical system voltages are in the range of 9V to 32V at the connectors. The communication of the controller is at 250 Kbps baud rate. This CAN controlled hydraulic system is directly connected to the Engine EMS and program to act the corresponding system according to the load demand in the Shovel and avoid the engine stalling/stopping.

[0005] Electronic controlled hydraulic system, carter to response during function with precise control faster cycle time and efficient in performance. Integration of different technology concept such as CMA valves of Eaton hydraulics, EMS system of Scania engine/prime mover, Electro hydraulic controlled motored Gearbox of ZF through CAN (controlled area network) system.

BACKGROUND OF INVENTION
[0006] Hydraulic Shovel is one of the popular earth moving devices and finds wide application in construction and mining activities. Hydraulic Shovel is a multi-purpose earthmoving machine, which can perform many operations like: excavating, cutting, loading, levelling of earth etc.

[0007] The general operating principle of hydraulic Shovel is the mechanical energy transmitted from prime mover/engine to hydraulic Power Pack is converted into Fluid /hydraulic power by the pumps.

[0008] The main direction control valves shall be operated by pilot operation which can be controlled either by electronic system. The system must have adequate numbers of backup accumulators which will protect the system when power is shortfall.

[0009] The use of hydraulic circuit is the main backbone of the hydraulic Shovels. The kind of circuit and the hydraulic pump installed affects greatly to the operation and performance of the function.

[00010] The prime mover/engine and hydraulic circuit is the key to the design of hydraulic Shovel and design concepts varies from manufacturers to manufacturers based on the above. Also in this segment Shovel mostly made of closed loop negative hydraulic system which the hydraulic pilot control has control the main control valve. The number of hydraulic pilot control line is interconnected with operator cabin handle and foot pedal which is lead to leakage during maintenance inside the cabin.

[00011] According to the new developed Shovel the system is made of open loop positive electronic controlled hydraulic system has been implemented which is distinguished from other available machine in this market segment. Similar type of hydraulic control system is generally equipped with small capacity hydraulic Shovel (less than 90 ton capacity).

SUMMARY OF THE INVENTION

[00012] According to the present invention, the concept is to run the particular operation in hydraulic system in the Shovel even when the arrangement of independent metering valve fails in particular operation the system will work & operate the Shovel safely. Since, it is electronically controlled; effortless easily controlled operation made in the particular valve. Also in this invention the hydraulic line inside & below the cabin area are only electronic controls wiring connection only and hence the cabin area is free from hydraulic oil.

[00013] The hydraulic circuit of the hydraulic shovel of two main variable torque controlled pumps are being under total power control. One auxiliary pump is used for cooling of hydraulic oil & another auxiliary pump is for low pressure line used for other control of hydraulic oil.

[00014] The high pressure hydraulic oil is generated which is entered pressure relief block & it has been sent to direct electronic main control valve of the shovel. The main control valve has its own properties of flow control as well as direction controlled; the valve act based on the response of electronic proportional signal received from the controller. Then the main control valve responds according to the signal. The hydraulic oil has directed & controlled flow has been sent to actuator (i.e., motors, cylinders) for their corresponding functions.

[00015] According to the present invention, the hydraulic energy generated by the prime mover has been effectively utilized to avoid the loss of energy in hydraulic pilot control lines. This type of hydraulic system integration leads to optimum utilization energy, easy maintenance & control the data according to the system requirement.

[00016] This technology integration is new concept where the both hydraulic system & prime mover/engine is able to control in computer system. This type of concept to achieve the corresponding function the system runs, even failure of any one metered valve. This technology avoids machine idle/breakdown time.

[00017] This is new concept of main control valve introducing arrangement of metering valve concept to control & adapt the flow or load control architecture according to the requirement of the system functional operation. The built in flow sharing type of metering valve arrangement provides precise, coordinated motion control between services. These types of new technology with have monitor capabilities of pressure, load, flow, speed of the hydraulic system which is deviated from the traditional hydraulic system in Shovel of higher bucket capacity.

[00018] Before in detail explaining any embodiment of the present invention, should be appreciated that application of the present invention is not limited to set forth in the following description or the structure of graphic assembly and the details of layout in the following drawings. The present invention can be other embodiment, also can implement or carry out with various ways. In addition, should be appreciated that wording and term are for description as used herein, and should not regard restriction as "comprise" in this use, "comprising" or "having" with and modification mean to comprise the project listed thereafter and its equivalent and extra project. Be widely used term "installation ", and “connection”, it comprises both directly and the installation of be connected, connection and be coupled. In addition, "connection " and " coupling " is not limited to physics or mechanical connection, also can comprise being electrically connected to or coupling, no matter be direct or indirect. In addition, electronic communication can use any known mode that comprises direct connection, wireless connections etc. to carry out with being connected.

[00019] Should also be noted that and to use a plurality of devices based on hardware and software and a plurality of different element of construction to implement the present invention. In addition, to should be appreciated that embodiments of the invention can comprise hardware, software and electronic building brick or module, in order discussing, can and to be described as its explanation only implementing with hardware mode as most of assembly. Yet, based on the reading to this manual, those skilled in the art will recognize that at least one embodiment, can implement the present invention is based on by the mode of the executable software of one or more processors (for example, being stored on the computer-readable medium of nonvolatile) aspect of electronics. With regard to this point, should note to use a plurality of devices based on hardware and software and a plurality of different element of construction to implement the present invention. In addition, as described in paragraph subsequently, the concrete mechanical arrangements of explanation is intended to the illustration embodiments of the invention in the accompanying drawings, and other mechanical arrangements that substitute are also possible. For example, " controller " described in manual can comprise the standard processing components, be connected various connections (for example, system bus) with coupling assembling such as one or more processors, one or more computer-readable medium module, one or more input/output interface.

[00020] The features and advantages described in the specification are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and may not have been selected to delineate or circumscribe the inventive subject matter.

OBJECT OF THE INVENTION
[00021] An object of the present invention is to propose a new developed technology integration of open loop positive control hydraulic system with arrangement of CMA Valve & implementation in the Hydraulic Shovel.

[00022] Another object of this invention is to propose an electronic control system in Hydraulic Shovel of 100 Ton Capacity in order to eliminate the pilot control line in Hydraulic shovel which leads to avoid the loss of power in pilot control line & energy saving lead to increase the efficiency of shovel.
Technical Problem:-
[00023] This segment (100 Ton Capacity shovel) large Shovel mostly made of closed loop negative hydraulic system which the hydraulic pilot control has control the main control valve. The number of hydraulic pilot control line is interconnected with operator cabin handle and foot pedal which is lead to leakage during maintenance inside the cabin. And some shovel is this pilot line is controlled by some electronic system which leads complexity in system & maintenance difficulties may occur.

[00024] One or more of these and/or other objects, features, or advantages will become apparent from the specification and claims that follow. No single embodiment of the present invention need exhibit each or any of the objects, features, or advantages and different embodiments may have different objects, features, or advantages.

[00025] The present invention is not to be limited by or to these objects, features, or advantages.

Solutions to the Technical Problem:-
[00026] To propose an electronic control system in Hydraulic Shovel of 100 Ton Capacity in order to eliminate the pilot control line in Hydraulic shovel this leads, to avoid the loss of power in pilot control line & energy saving lead to increase the efficiency of shovel.

[00027] Direct control of main control valves which lead to machine response quickly & utilization of hydraulic affectively. This type of concept valve are having the low flow range valves in order to obtain the maximum flow, stacked no of valve in one unit to meet the flow requirements & to achieve the corresponding function/operation the system runs, even failure of any one metered valve.

BRIEF DESCRIPTION OF DRAWINGS

[00028] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.

[00029] Figure 1. Illustrates a perspective view of a valve station & manifold blocks arrangement in the valve stand.

[00030] Figure 2. Illustrates a valve stand with complete piping assembly.

[00031] Figure 2(a). Illustrates a Boom circuit diagram.

[00032] Figure 3. Illustrates a Hydraulic oil Flow & time response curve in boom cylinder.

[00033] Figure 4. Illustrates a Load cycle for one complete cycle operation of boom in shovel.

[00034] Figure 5. Illustrates a Shovel Hydraulic controller interfacing details.

DETAILED DESCRIPTION
[00035] The present disclosure is best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described embodiments. For example, the teachings presented and the needs of a particular application may yield multiple alternate and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.

[00036] References to “one embodiment,” “an embodiment,” “at least one embodiment,” “one example,” “an example,” “for example,” and so on, indicate that the embodiment(s) or example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element or limitation. Furthermore, repeated use of the phrase “in an embodiment” does not necessarily refer to the same embodiment.

[00037] According to the present invention, the machine is powered by an efficient diesel engine of 405 KW which is electronically controlled. Engine Management System (EMS) ensure complete control of all aspects of engine performance and make it respond as per load requirement on the hydraulic side.

[00038] Compact CMA (Controlled Metered Automated) valve is the heart of the Hydraulic System. The CMA200 is an advanced CAN-Enabled (Controller Area Network) electro-hydraulic valve within dependent metering that utilizes pressure and position sensors, on board electronics, and advanced software control algorithms. The CMA offers high performance with sub-micron hysteresis, closed loop control over the spool position, and repeatable performance. CMA valves are controlled by electrical system (Joy sticks and Foot Paddles) communicated through CAN protocol thereby eliminate hydraulic pilot line.

[00039] The work section is comprised of two independent spools that act as a pair working to control double acting services, or alternatively as single spools controlling a single acting service (2 single axis services can be controlled from any work section).Demands to each work section are transmitted over a CAN Bus and power is provided to each work section via a single daisy chain cable arrangement. Each work section has a single pilot valve comprised of on-board electronics, embedded sensors, and two independent 3 positions 4 way pilot spools driven by a low power embedded micro controller. The independent pilot spools control the main-stage spools. Closed loop control of each work section is done locally by leveraging the on-board electronics and sensors. Each main-stage spool has its own position sensor enabling closed loop position control of the main-stage spool.

[00040] Further, a pressure sensor is located in each work port, pressure line and tank line. With the up and downstream pressure information known at any time, flow delivered to the service can be controlled by moving the spools to create the appropriate orifice area for the desired flow rate. In the present circuit, the unloading valve in each cylinder bore side in additional to the main control valve which can handle the high return flow of oil over bore side as well as maintain the operation of each cylinder as per required loads.

[00041] In addition to the main control valve there is a unload valve component with same type of additional CMA valve has been introduce in the cylinder bore line for handling the flow of hydraulic oil at bore end. The unload valve used in cylinder bore end which will use to maintain the machine duty cycle by allowing the oil flow into necessary time.

[00042] The methodology of using the CMA electronic control valve in high capacity hydraulic shovel & complete system include engine and other accessories are fully CAN controlled system. The arrangement of valve based on the flow requirement is the invention. The bunch of valve arranged for particular function of cylinder or motor, even one valve failure in arranged valve the function of particular cylinder or motor will work at low speed & the replacement/repair of the valve is easier, such a way the valves are arranged/circuited accordingly.

[00043] The hydraulic circuit of the hydraulic shovel is having two main variable torque controlled pumps of 400 lpm each being under total power control. The circuit is having two auxiliary pumps, one is for cooling of hydraulic oil & another auxiliary pump is used for low pressure line used for other control of hydraulic oil.

[00044] The high pressure hydraulic oil is generated which is entered pressure relief block & it has been sent to direct electronic main control valve of the shovel. The pressure relief block & main control valves are shown in the below valve stand diagram of Figure.

[00045] In Figure 1, the valve stand is hold by vertical channel (1) of Indian Standard Medium Channel (ISMC) having 100mm size. The channel (1) is welded/bolted with the base structure of the shovel. The channel (1) is connected with plate (4) having main control valves through the spacer channels (2, 3) perpendicular to the channel (1). The plate (4) comprises a quantity of three, is holding the track right & swing control valve (8), track left & swing control valve (9) in top plate. Arm & bucket control valve (10), Boom control Valve (11) and Boom & Bucket unload valve (12) in middle plate (4). Boom control valve (13) is located in the bottom plate (4).

[00046] The main control valve has its own properties of flow control as well as direction controlled; the valve act based on the response of electronic proportional signal received from the controller. Then the main control valve responds according to the signal. The hydraulic oil has directed & controlled flow has been sent to distribution blocks (14, 15, 16, 17, 18, 19 and 20) as shown in Fig. 1.

[00047] The ISA angle (7) is connected with another manifold stand channel of ISMC 100 (6). The ISMC 100 (6) is welded with ISMC 150 (5) manifold holding channels at top & bottom. The two ISMC 150 (5) is used, where top is having/ bolting, bucket bore end manifold (19) and Swing block manifold (20). In bottom is having/bolting Bucket rod end manifold (14), Arm rod end manifold (15), Arm bore end manifold (16), Boom bore end manifold (17) & Boom rod end manifold (18). The manifolds are called as distribution blocks for distributing the hydraulic oil to the receivers such as cylinders & motors.

[00048] According to an embodiment of the present invention, the arrangement of valve is based on the flow requirement. The bunch of valve arranged for particular function of cylinder or motor, even one valve failure in arranged valve the function of particular cylinder or motor will work at low speed & the replacement/repair of the valve is easier, such a way the valves are arranged/circuited accordingly. The figure 2. shows the valve stand diagram with complete piping of the valve station according to the meet the flow requirements.

[00049] Fig. 2 (a) illustrates Hydraulic system along with automation circuit, creating the model/design of the circuit, drawing & circuit checking is shown in Fig. 3 for Boom Cylinder operation.

[00050] The hydraulic circuit of boom shown in figure 2(a) is divided in two parts that consists of A, B, C1 and C2. Where the B, C1 & C2 are under CMA valve unit. A is under receiver unit.

[00051] The work section is comprised of two independent spools that act as a pair working to control double acting services, or alternatively as single spools controlling a single acting service (2 single axis services can be controlled from any work section).Demands to each work section are transmitted over a CAN Bus and power is provided to each work section via a single daisy chain cable arrangement. Each work section has a single pilot valve comprised of on-board electronics, embedded sensors, and two independent 3 positions 4 way pilot spools driven by a low power embedded micro controller. The independent pilot spools control the main-stage spools. Closed loop control of each work section is done locally by leveraging the on-board electronics and sensors. Each main-stage spool has its own position sensor enabling closed loop position control of the main-stage spool.

[00052] Further, a pressure sensor is located in each work port, pressure line and tank line. With the up and downstream pressure information known at any time, flow delivered to the service can be controlled by moving the spools to create the appropriate orifice area for the desired flow rate. In the present circuit, the unloading valve in each cylinder bore side in additional to the main control valve which can handle the high return flow of oil over bore side as well as maintain the operation of each cylinder as per required loads.

[00053] In addition to the main control valve there is a unload valve component with same type of additional CMA valve has been introduce in the cylinder bore line for handling the flow of hydraulic oil at bore end. The unload valve used in cylinder bore end which will use to maintain the machine duty cycle by allowing the oil flow into necessary time. The variation of the flow supplied to the two boom cylinders with respect to time as per the duty cycle is shown in figure 3.

[00054] It may be noted that the negative values of the flow indicates the fluid that comes out either from rod end or the piston end of the cylinder. Also, due to the difference in areas of the piston end and rod ends of the cylinders, the flow supplied to them differs.

[00055] The variation of pressure in the piston end and the rod end sides of the boom cylinders with respect to the load cycle for one complete cycle operation of the excavator is shown in figure 4.

[00056] Due to closure of the CMA valves (as no flow is supplied to either to piston end or to the rod end of cylinders), the pressure at the piston and rod sides of the cylinders are locked and found to be constant at 170 bar and 5 bar, respectively.

[00057] As soon as the flow is initiated at 11 s to the piston side of the cylinder, the pressure rises to around 240 bar till 12 s. similar variation of pressures during flow and no-flow conditions are observed during remaining period of the duty cycle. It may be noted that, with respect to above figure, when no flow is supplied (CMA valves are closed), the pressure in both sides of the cylinders are locked and remain fixed. With the initiation of the flow (opening of the CMA valves), the pressure varies with the stroke length.

[00058] Similarly the all function of other cylinders and motors are designed & circuited in a loop.

[00059] This is new concept of main control valve introducing arrangement of metering valve concept to control & adapt the flow or load control architecture according to the requirement of the system functional operation. The built in flow sharing type of metering valve arrangement provides precise, coordinated motion control between services. These types of new technology with have monitor capabilities of pressure, load, flow, speed of the hydraulic system which is deviated from the traditional hydraulic system in Shovel of higher bucket capacity. The figure 5 shown hydraulic controller is used for interfacing with all inputs & outputs.

[00060] The controller will collect the all input data from engine, hydraulics, motors, radiator, cabin, cabin seat & response accordingly to the machine requirements. The controller monitors the machine health condition before starting & running the shovel. It will give the alarm before any fault as well as if need the system advice to stop. The hydraulic interface will be programmed using computer & may also controlled/operated through computer. Hence remote operation of shovel is also possible which leads to Industry 4.0.

RESULTS AND ADVANTAGES:

[00061] The arrangement made in CMA valve accordingly to the flow requirement of the each actuation which lead to precise control maintained for all load conditions. The communication with the valve is easier which leads improved reliability and productivity. In general other are using the normal valve which is single valve for one actuation, if in case of one valve failure the total machine function is need to stop until the problem/ spare replace.

This technology integration leads to the future development of Industry 4.0.
The machine has been manufactured and the performance testing on the machine by providing the required flows as per the actuations and below are the test results:

Hydraulics Requirement:

Actuation Total Max Flow requirements Software flow setting CMA max pr setting* Remarks
Boom 557 lpm 400 lpm Bore: 250 bar
Rod: 200 bar Meets the requirement
Arm 350lpm 370 lpm Bore: 250 bar
Rod: 100 bar Meets the requirement
Bucket 400 lpm 400 lpm Bore: 250 bar
Rod: 200 bar Meets the requirement
Bucket Open 150 lpm 150 lpm Bore: 200 bar
Rod: 250 bar Meets the requirement
Swing Drive 250 lpm 250 lpm 275 bar Meets the requirement
Travel (Left) 300 lpm 200 lpm 250 bar Meets the requirement
Travel (Right) 300 lpm 200 lpm 250 bar Meets the requirement

[00062] The pressure settings through software and there can be +50 bar spike, so it’s recommended to have mechanical relief valve.

Machine Requirements:

Actuation Actual Speed Achieved
Boom Boom up: 11 Secs.
Boom Down: 5.20 Secs
Arm Arm-out: 6.7 Secs.
Arm-in: 4.5 Secs
Bucket Bucket-in: 9.1 Secs
Bucket-out: 9.5 Secs
Bucket Open Bucket open: 2 Secs
Bucket close: 1.5 Secs
Swing Swing rpm ~ 4.5 rpm
90 deg swing: 5 Secs (?90 Deg rotation)
Travel (Turtle Mode) 3 revolutions in 1.29 mins
Travel (Rabbit Mode) 3 revolutions in 1.01 mins

[00063] Although a few implementations have been described in detail above, other modifications are possible. Moreover, other mechanisms for performing the systems and methods described in this document may be used. In addition, the logic flows depicted in the figures may not require the particular order shown, or sequential order, to achieve desirable results. Other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Accordingly, other implementations are within the scope of the present invention.
,CLAIMS:WE CLAIM

1. An open loop hydraulic system, the system comprises:
- a Hydraulic Controller interface to send a command signal by a user;
- a Controller to receive a signal from the Hydraulic Controller interface and checking the hydraulic system parameters;
- the Controller to forward the signal to an integrated electronic proportional valve/CMA;
- the integrated electronic proportional valve/CMA to executes the instructions from Engine Management System (EMS) and hydraulic control system.
2. The system as claimed in claim 1, wherein the controller is communicated with other systems through CAN (Controlled Area Network) Bus on J1939 Protocol.
3. The system as claimed in claim 1, wherein the Controller is electrically connected with the Hydraulic Controller interface.
4. The system as claimed in claim 1, wherein the hydraulic system parameters are hydraulic engine, fuel, battery etc.
5. The system as claimed in claim 1, wherein the integrated electronic proportional valve/CMA to execute the instructions when the hydraulic system parameters are in order and the integrated electronic proportional valve/CMA does not execute the instructions when the hydraulic system parameters are not in order.