Article(id=1207658079492088614, tenantId=1146029695717560320, journalId=1205116883411038211, issueId=1207658076900008717, articleNumber=null, orderNo=null, doi=null, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=null, receivedDateStr=null, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1765857723353, onlineDateStr=2025-12-16, pubDate=null, pubDateStr=null, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1765857723353, onlineIssueDateStr=2025-12-16, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1765857723353, creator=13701087609, updateTime=1765857723353, updator=13701087609, issue=Issue{id=1207658076900008717, tenantId=1146029695717560320, journalId=1205116883411038211, year='2025', volume='23', issue='2', pageStart='189', pageEnd='376', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1765857722735, creator=13701087609, updateTime=1765862348176, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1207677477451833566, tenantId=1146029695717560320, journalId=1205116883411038211, issueId=1207658076900008717, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1207677477451833567, tenantId=1146029695717560320, journalId=1205116883411038211, issueId=1207658076900008717, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=288, endPage=291, ext={EN=ArticleExt(id=1207658079836021550, articleId=1207658079492088614, tenantId=1146029695717560320, journalId=1205116883411038211, language=EN, title=Design and performance test of load sensing system for excavator pump drive valve control, columnId=1207658079282373410, journalTitle=Chinese Journal of Construction Machinery, columnName=Design Manufacture and Quality Control, runingTitle=null, highlight=null, articleAbstract=

In order to improve the operating efficiency of excavator hydraulic system, a pump-driven valve-controlled load sensing system was designed. Pressure sensors are installed at the inlet and outlet of the multi-way valve respectively to perform real-time pressure feedback instead of the pressure compensation valve of the load sensitive system to achieve pressure compensation, and dynamically adjust the position of the main valve core and the swash plate swing angle of the electro-hydraulic proportional pump to drive the action of the hydraulic cylinder. The valve-controlled cylinder system in the pump drive valve control system is analyzed theoretically and the mathematical model is established. The experimental platform is designed with proportional valve test bench, BODAS controller and other electronic control and acquisition components, and the principle test of pump drive valve control is carried out, which verifies the correctness of the simulation model and pump drive valve control principle. The results show that when the system is in the pump drive valve control program, the output flow rate changes abruptly with the load change of step rise under different pressure differences. With the continuous increase of load pressure, the flow mutation becomes larger and larger, and the error between the output flow and the set flow also increases.

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为了提高挖掘机液压系统运行效率,设计一种泵驱阀控负载敏感系统。在多路阀进出口分别安装压力传感器,进行实时压力反馈代替负载敏感系统的压力补偿阀实现压力补偿,动态调整主阀芯的位置以及电液比例泵的斜盘摆角,驱动液压缸的动作。对泵驱阀控控制系统中的阀控缸系统进行理论分析以及建立控制模型。利用比例阀试验台、BODAS控制器等电控及采集元件进行试验平台设计,进行泵驱阀控原理验证,验证仿真模型以及泵驱阀控控制原理的正确性。研究结果表明:在系统处于泵驱阀控程序时,在不同压差的情况下输出流量随着阶梯上升的负载变化而发生突变。随着负载压力的不断提高,流量突变也变得越来越大,输出流量与设定流量之间的误差也随之增大。

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徐国玉(1972—),男,高级工程师。E-mail:

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徐国玉(1972—),男,高级工程师。E-mail:

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徐国玉(1972—),男,高级工程师。E-mail:

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挖掘机泵驱阀控负载敏感系统设计及性能测试
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徐国玉 1 , 李强 2
中国工程机械学报 | 设计制造与质量控制 2025,23(2): 288-291
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中国工程机械学报 | 设计制造与质量控制 2025, 23(2): 288-291
挖掘机泵驱阀控负载敏感系统设计及性能测试
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徐国玉1 , 李强2
作者信息
  • 1.中铁十一局集团有限公司,湖北 十堰 442000
  • 2.武汉理工大学 建筑工程学院,湖北 武汉 430070
  • 徐国玉(1972—),男,高级工程师。E-mail:

Design and performance test of load sensing system for excavator pump drive valve control
Guoyu XU1 , Qiang LI2
Affiliations
  • 1. China Railway 11th Bureau Group Co., Ltd., Shiyan 442000, Hubei, China
  • 2. School of Civil Engineering and Architecture, Wuhan University of Technology, Wuhan 430070, Hubei, China
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为了提高挖掘机液压系统运行效率,设计一种泵驱阀控负载敏感系统。在多路阀进出口分别安装压力传感器,进行实时压力反馈代替负载敏感系统的压力补偿阀实现压力补偿,动态调整主阀芯的位置以及电液比例泵的斜盘摆角,驱动液压缸的动作。对泵驱阀控控制系统中的阀控缸系统进行理论分析以及建立控制模型。利用比例阀试验台、BODAS控制器等电控及采集元件进行试验平台设计,进行泵驱阀控原理验证,验证仿真模型以及泵驱阀控控制原理的正确性。研究结果表明:在系统处于泵驱阀控程序时,在不同压差的情况下输出流量随着阶梯上升的负载变化而发生突变。随着负载压力的不断提高,流量突变也变得越来越大,输出流量与设定流量之间的误差也随之增大。

负载敏感系统  /  泵驱阀控  /  挖掘机  /  输出流量

In order to improve the operating efficiency of excavator hydraulic system, a pump-driven valve-controlled load sensing system was designed. Pressure sensors are installed at the inlet and outlet of the multi-way valve respectively to perform real-time pressure feedback instead of the pressure compensation valve of the load sensitive system to achieve pressure compensation, and dynamically adjust the position of the main valve core and the swash plate swing angle of the electro-hydraulic proportional pump to drive the action of the hydraulic cylinder. The valve-controlled cylinder system in the pump drive valve control system is analyzed theoretically and the mathematical model is established. The experimental platform is designed with proportional valve test bench, BODAS controller and other electronic control and acquisition components, and the principle test of pump drive valve control is carried out, which verifies the correctness of the simulation model and pump drive valve control principle. The results show that when the system is in the pump drive valve control program, the output flow rate changes abruptly with the load change of step rise under different pressure differences. With the continuous increase of load pressure, the flow mutation becomes larger and larger, and the error between the output flow and the set flow also increases.

load sensing system  /  pump drive valve control  /  excavator  /  output flow
徐国玉, 李强. 挖掘机泵驱阀控负载敏感系统设计及性能测试. 中国工程机械学报, 2025 , 23 (2) : 288 -291 .
Guoyu XU, Qiang LI. Design and performance test of load sensing system for excavator pump drive valve control[J]. Chinese Journal of Construction Machinery, 2025 , 23 (2) : 288 -291 .
以挖掘机和起重机为主的工程机械,当前主要向着节能化、智能化的方向发展,对于其动力系统、负载敏感系统、液压零部件进行节能研究以及优化设计大概可以分为2个方向:减小动力系统能量消耗和减小液压系统内部的能量损耗[1-2]。针对减小液压系统的能量损耗,主要研究目标是开发功能更加完善的负载敏感系统、抗流量饱和负载敏感系统、负流量控制系统以及正流量控制系统[3]
电液比例控制技术是负载敏感系统中的重要技术,通过传感器、控制器等电子设备实时对液压系统的压力、流量等参数进行检测,并且快速地计算反馈,可以在不使用压力补偿阀的条件下实现液压系统的压力补偿功能,减小了压力补偿阀带来的压力损失。使用传感器结合控制器对泵阀的电信号控制取代了系统中的负载敏感油路,避免了油路带来的沿程压力损失,使响应更加准确与快速[4-5]。Min等[6]提出一种通过流量/压力切换控制的电液负载敏感系统,实现流量和压力的较小输出控制。实际流量需求由流量前馈控制器计算,压力余量由压力反馈控制器保持为期望值。杨华勇等[7]利用挖掘机样机对比了负载敏感系统与电液流量匹配控制系统的特性,结果表明,在明显降低泵与负载之间的压力裕度提高能效的同时,弥补了负载敏感系统的流量饱和问题。程敏等[8]提出一种基于流量前馈与压力反馈复合控制的电液负载敏感系统。该系统通过实时检测负载所需流量以及压差反馈来控制变量泵的斜盘对排量进行调节。研究结果表明,与现有单纯依靠压力反馈的负载敏感系统相比,所提出的流量压力复合控制系统,通过压力闭环来实现流量匹配,减小了冲击和压力损失,并且在减小系统压力裕度的同时,具有较高的响应速度和阻尼性能。
采用电液比例控制技术的泵驱阀控液压控制系统,使用压力传感器检测多路阀前后压差,通过控制器计算流量控制泵的排量与阀的开度,在实现压差恒定的同时,提高了系统的控制精度和稳定性并且减小了机械结构带来的压力损失[9-10]。本文提出一种新的压差检测方式作为泵驱阀控负载敏感系统的压差输入信号,意在减小压力高频波动时输入控制器的压差信号可能导致的阀芯振荡以及系统不稳定的问题;对泵阀协同负载敏感系统原理进行理论分析,建立各子系统的控制模型,搭建实验台对模型以及泵驱阀控液压控制原理进行验证。
泵驱阀控负载敏感系统的原理如图1所示。与传统抗流量饱和负载敏感系统不同,泵驱阀控负载敏感系统采用电子压力补偿的控制方法[11]。在多路阀进出口处,分别安装压力传感器来进行实时压力反馈代替负载敏感系统的压力补偿阀实现压力补偿;利用电液比例泵代替负载敏感泵,通过压力传感器实时检测多路阀进出口压差变化,结合手柄的流量信号,经过控制器的计算流量反馈;然后分别向电液比例泵的电磁换向阀和控制液控换向阀的三通比例减压阀发出控制信号;随后动态调整主阀芯的位置以及电液比例泵的斜盘摆角,使通过多路阀的流量在不随负载压变化而变化的同时达到手柄给定流量,来驱动液压缸的动作。
泵驱阀控负载敏感系统的结构特点为:将压力补偿阀设置于主阀节流口后,通过梭阀取出多路阀的最大负载压力,一支通过流道送至各联压力补偿阀的负载敏感腔,一支通过管路与负载敏感泵的负载敏感腔连接,从而实现节流阀口前后的压差为定值,并且压差值可通过负载敏感泵进行调节。通过阀口开度控制阀口的流量,不受负载的影响,实现比例分流的功能,消除了因系统所需流量超过泵的输出流量带来的多执行机构不能同步工作的问题,使其在大流量情况下仍然可以保持多执行机构的协同工作。泵驱阀控负载敏感系统以其节能高效、精准可靠等优点,在工程机械中得以大量的使用。
泵驱阀控负载敏感系统控制器原理如图2所示。在泵驱阀控液压系统中使用的控制器中输入信号为多路阀的阀前压力、阀后压力以及手柄流量信号;输出信号为对电液比例泵与多路换向阀的信号。可知在控制器中需要同时对电液比例泵与多路换向阀进行控制。在阀控环节中主要利用流量补偿控制原理,通过安装在多路换向阀前后的压力传感器采集到主阀的进出口的压力,之后利用减法器得到主阀的进出口压差,将压差值进行开方处理,然后将压差开方值与设定的流量值共同输入插值控制器中,经过二次插值之后输出对多路换向阀开度的控制信号[12]。在泵控环节中,为使多路阀前后的压差维持一个定值,将压力传感器采集到的阀口前后压差输入控制器中的泵控环节程序中,经过压力闭环处理得到设定压差所对应的输出信号;之后输入电液比例泵中,通过控制泵的摆角来改变泵的输出流量来达到需要的压差;最后通过阀控环节得到不同压差-流量-阀口开度的对应关系,结合泵控环节维持的固定压差,实现设定流量与负载无关,与阀口开度呈线性关系。
综合非对称阀控非对称缸、电液比例泵以及控制器的模型,建立泵驱阀控负载敏感系统的总体模型,其控制模型如图3所示,其中A为主阀芯截面积,V1为输入速度,V2为输出速度,Q1为输入流量,Q2为输出流量。
图3中,先导腔控制压力pcij与主阀芯位移xv的传递函数如下:
式中:m1为主阀芯位移;BP1为主阀芯黏性阻尼系数;Ka为先导压力腔压缩弹簧刚度;K1为压力传感器的增益;s为自变量。
先导泵提供驱动多路阀阀芯运动的先导油液,试验多路阀在进行试验时只做单向运动,多路阀的PA连通,驱动多路阀阀芯将先导油通入对应的先导腔。控制器利用采集到的多路阀前后压差数据,结合手柄输入的设定流量,经过控制器内部流量补偿器的解算后输出控制多路阀阀芯的三通比例减压阀的控制信号;结合电液比例泵的控制算法,输出对泵的斜盘控制信号,通过改变输出排量保证多路阀前后压差保持不变。
根据泵驱阀控液压试验平台原理,将电液比例泵、试验多路阀、控制器以及三通比例减压阀通过液压管路连接起来。三通接头将先导压力油通入试验多路阀的合流阀,以保证在试验过程中液压油只在多路阀的一端流动,不流入多路阀的另一端,避免影响系统试验结果。将压力传感器安装于泵的测压口以及多路阀的压力补偿阀所在位置进行压力检测。
根据试验要求,利用搭建的泵驱阀控液压试验平台以及依据泵驱阀控原理编写的控制算法进行试验。初始条件设定电液比例泵的转速为1 500 r/min,手动调节先导液压泵的输出工作压力为4 MPa。在控制器算法的压力闭环程序中,首先提前设定控制器中输出到三通比例减压阀的信号,使先导压力腔的压力可以令试验定制多路阀块的主阀芯具有固定开度,设定多路阀前后目标压差,此时压力闭环程序结束。在泵驱阀控程序中,设定压差为目标压差的同时,设定阀的目标输出流量,此时在泵驱阀控程序中输出阀芯的开度控制信号与电液比例泵的排量控制信号,从而达到预定的目标流量。
保持初始条件不变,压差闭环程序中设定主阀芯阀口开度为5 mm,将目标压差设定为2 MPa,目标流量设定为60 L/min,进行不同负载条件下的泵驱阀控原理试验。图4为不同负载相同目标流量相同压差条件下的泵驱阀控特性曲线。
保持初始条件不变,压差闭环程序中设定主阀芯阀口开度为5 mm,将目标压差设定为1.5 MPa,目标流量分别设定为50、60、70 L/min,进行多次试验。由于验台的负载加载是由溢流阀来完成的,并且只能通过手动调节输入溢流阀的电信号来改变负载,因此对于负载的加载时间间隔以及不同流量不同负载相同压差下的泵驱阀控流量特性曲线如图5所示。
保持初始条件不变,压差闭环程序中设定主阀芯阀口开度为5 mm,将目标压差分别设定为2.0、1.8、1.5 MPa,目标流量设定为60 L/min,负载设置为当液压控制系统进入泵驱阀控程序时,稳定一定时间后逐渐稳步增大负载压力。根据要求进行多次试验,图6为不同压差下的泵驱阀控流量特性曲线。
图4~图6可知,在系统处于压差闭环程序时,由于设置的试验阀主阀芯开度固定,且具有相同的负载压力,因此输出的流量会决定于压差的大小,随着压差的变大输出流量也变大。在系统处于泵驱阀控程序时,在不同压差的情况下输出流量随着阶梯上升的负载变化而发生突变。在负载压力突变的区间,系统控制器会提高泵的排量来维持设定的压差,从而调控输出流量回到设定流量。并且,随着负载压力的不断提高,流量突变也变得越来越大,输出流量与设定流量之间的误差也随之增大。
本文开展挖掘机泵驱阀控负载敏感系统设计及性能测试分析,得到如下结论。
(1)在系统处于泵驱阀控程序时,在不同压差的情况下,输出流量随着阶梯上升的负载变化而发生突变。
(2)随着负载压力的不断提高,流量突变也变得越来越大,输出流量与设定流量之间的误差也随之增大。
  • 河南省高等学校重点科研基金资助项目(22A470005)
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河南省高等学校重点科研基金资助项目(22A470005)
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    1.中铁十一局集团有限公司,湖北 十堰 442000
    2.武汉理工大学 建筑工程学院,湖北 武汉 430070
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