Objectives 目标

• Understand & study 了解及学习

– Hydraulic systems 液压系统
• Open Center Systems 开芯式系统
• Hydraulic Components 液压零件
• Basic Equations 基本公式
• Calculations
• Validate calculation with measurements
on
通过测量对 SEM650 的计算进行验证
• Specific objectives 特定目标
– ??
 Torque Converter
Wheel Loader Power Flow

Fan, Alternator, Air Cleaner, Muffler (MEC, LEC)

T = f (Engine Speed)
Brake pump, Pilot pump, Steering pump, Transmission pump (H&HS)
T = Disp * Pressure/ Efficiency
E4611 AAA IL Torque Converter Data

3.50 1400.0

3.00 1200.0

2.50 1000.0

Primary Torque (ft-lb)

2.00 800.0

Torque Ratio
Torque Ratio
Primary Torque (ft-lb)
1.50 600.0

1.00 400.0

0.50 200.0

0.00 0.0
0.000 0.200 0.400 0.600 0.800 1.000 1.200
Speed Ratio

Converter Data TBU

F
y

Rimpull
F
x
Implement Pump
H&HS
T = Disp * Press / Eff

Gross Engine Lug Curve

MEC & LEC
 Power Flow 动力流动
Rimpull 牵引力
Wheel Speed 轮速
Converter 变矩器

Fuel 燃油
Implement Pumps 工作泵 Lift Force/Speed 举升力 / 速度

Bucket
Tilt Force/Speed 翻转力 / 速度 Force
Cooling Pump 冷却泵 Speed
Engine 发动机 铲斗力 / 速度
Steering Force
Steering Pump 转向泵 Speed 转向力 / 速度

Heat 热能
Brake Charging Pump 刹车辅助泵 Brake Force 刹车力

Implement Pilot Pump 工作先导泵

Transmission Pilot Pump 变速箱先导泵

Air Cleaner, Muffler, Alternator 空滤器，消音器，发电机

 Energy Distribution during
Truckloading 9XX
9XX 装车应用时的能量分配
9XX Energy Distribution 9XX 能量分配
32 sec Truck Loading Cycle
32 秒钟装车周期
Implement Heat 工作热能
6%

Steering Heat 转向热能

1%

Fan Heat 风扇热能

2%
Pilot Heat 先导热能
Work 2%
10% Xmsn Pump Heat 变速箱泵热能
2%

Power Train 传动热能

11%

Brake Heat 刹车热能

2%

Wheel Slip Heat 车轮滑移热能

1%
Eng Stack Heat
38% Alt/AirCln/Muf Heat 空滤器，消音器，发电机热能
发动机排气热能 1%

Eng Cooled Heat 发动机冷却热能

24%
 Focus
Primary users of energy
焦点
能量的主要使用者

• Implement System 工作装置系统

• Powertrain System 传动系统
Hydraulics at Work
Hydraulics at Work
Hydraulics at Work
Hydraulics at Work
 Website with video

http://www.youtube.com/watch?v=HO-wTO7ice8
 Implement System
工作系统
• Open Center Systems 开芯式系统
– Main system 主要系统
– Pilot system 先导系统
– Implement valve function 工作阀功能
– Area curves 面积曲线
– Performance Characteristics 性能特性
– Math Modeling 数学建模
– Problems/Exercises 问题 / 练习
• Closed Center Systems 闭芯式系统
– Variable Implement Pump Controls 可变的工作阀
控制
– Load Sensing Circuits 负载敏感回路
– Problems/Exercises 问题 / 练习
 Terminology
• Industry & Academia – tandem center valve
– Means that in neutral the flow path from
– Pump to Cylinder - closed
– Cylinder to Tank - closed
– Pump to Tank – open

• Caterpillar – most Cat engineers call this an open

center valve

• Industry & Academia – open center valve

– In neutral
– Pump to cylinder to tank all open
 Hydraulic Schematics

Main Flow Lines

Solenoid Actuation
Pilot Lines

Pilot Actuation
Pump

Pump
Variable Pump
Tank

3 Position Directional Control Valve

Head End Rod End

Pressure Relief Valve(safety valve) normally

closed
For more see the following website:
p://www.engineersedge.com/hydraulic/symbols/hydraulic_iso_schematic_symbols
 Tandem Center Valve
(Open Center at Cat)
Pump

Tank

Neutral

Head End Rod End

To Lift
Pump

Tank

Dump

Head End Rod End

To Lift
 Tandem Center Valve
(Open Center at Cat)
Pump

Tank

Neutral

Head End Rod End

To Lift
Pump

Tank

Rack

Head End Rod End

To Lift
 627 G – Implement System
Tandem Center – Interrupted Series

Main Relief

Pump

Bowl

Ejector

Apron
(has float)
 SEM650 示意图
Tandem Center Interrupted Series
 980H Implement Schematic
Tandem Center (open) Interrupted Series

Tank

Main
Pump
 988H Implement Schematic
Tandem (Open) Center Interrupted Series

Tank

Pilot Supply

Main
Pump
 Tandem (Open) Center System

• Work at white board

– What’s wrong with this circuit?
 Tandem (Open) Center Hydraulic
System
开芯式液压系统
泵排放 Pump Displacement = Dp
泵速度 Pump Speed =N
质量 Mass = m
泵容积效率 Pump volumetric eff = Ev
负载 Load = mg
泵力矩效率 Pump torque eff = Tv
阻尼 Damping = c

体积 Volume = Vp 缸头端压力面积 Pressure area Head End = Phe

压力 Pressure = Pp 体积 Volume = Vhe 缸杆端压力面积 Pressure area Rod End = Pre
压力 Pressure = Phe 冲程 Stroke =S
缸杆全收缩时长度 Collapsed Length = Cl

面积 Area = Apcre

面积 Area = Apt 面积 Area = Actre

面积 Area = Apche
x
体积 Volume = Vre
压力 Pressure = Pre
面积 Area = Acthe

油箱压力 Tank pressure = Pt

Valve Hardware
阀硬件
Tandem (Open) Center
Hydraulic Valve
Operation
开芯式液压阀操作
 工作系统控制阀
动臂保持不动

装载单向阀 阀头端
阀杆端

管路溢流 降低先导控
补油阀 补油阀 制执行器
升起先导控
制执行器

供应通道
举起执行 降低执行器电磁阀
器电磁阀 举升滤芯 至油箱 至油箱 先导通道
至油箱通道 内部通道

主泵系统压力 闭塞油路 激活的零件

先导压力 表面积
吸油 / 回油
 工作控制阀
动臂下降时
装载单向阀
阀杆端 阀头端

升起先导控 补油阀
补油阀
制执行器
降低先导控
制执行器

供应通道
举起执行 至油箱 降低执行
举升滤芯 至油箱 先导通道
器电磁阀 器电磁阀
内部通道
通往下一阀通道
主泵系统压力
吸油 / 回油

激活零件 表面积
先导压力
 988H Tilt Stem Characteristics

988H TILT STEM CHARACTERISTICS (267-9544 CHg LVL 01)

900

800
Pump to tank
700

600
OPEN AREA - mm^2

500

Pump to cylinder HE Pump to cylinder RE

400

300

Cylinder to tank RE Cylinder

200
to tank HE

100

0
-18 -16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18
DUMP STEM DISPLACEMENT - mm RACKBACK

RE, P-C HE, C-T HE, P-C RE, C-T P-T DURING RACKBACK P-T DURING DUMP
 988H Lift Stem Characteristics

988H Lift CHARACTERISTICS 174-0119 CHG LVL 01

900

Pump to tank
800

700
Pump to cylinder RE
Pump to cylinder HE
600
OPEN AREA - mm 2

500

400

300

200

100
Cylinder to tank RE
Cylinder to tank HE
0
-20 -15 -10 -5 0 5 10 15 20
STEM DISPLACEMENT - mm
Lower
P-RE HE-T P-HE RE-T P-T, LOWER
Raise
P-T, RAISE
 Tilt Valve Areas 翻斗阀面积
SEM 650
Pump to cylinder RE Pump to cylinder HE
450
Pump to tank
400
350
300
Area mm ^2

250
200
150
面积 Cylinder to tank HE
100 Cylinder to tank RE
50
0
-20 -15 -10 -5 0 5 10 15 20
Dump Input mm Rack
卸料 收斗
输入
 Boom Valve Areas 举升阀面积
SEM 650
Pump to cylinder RE 450 Pump to cylinder HE
Pump to tank
400
350
300
Area mm^2

250
200
150
面积
Cylinder to tank HE Cylinder to tank RE
100
50
0
-20 -15 -10 -5 0 5 10 15 20
Lower Input mm Raise
下降 举升
输入
Pump Hardware
Gear Pump
Pump Hardware
Vane Pump
 Pump Hardware
Piston Pump

Valve Port Slot Piston

阀口槽 活塞

Outlet Port
出油口
Drive Shaft 传动轴
Inlet Port Swashplate 斜盘
进油口 Cylinder Block
缸体
 WHERE
Are the components located
on your machine?
不同的零件在山工车上的分布？

Next slide shows 992

locations
下一张幻灯片展示的是不同的零件在 992 上的分布
 电子 - 液压工作系统

可变泵 先导溢流阀 工作电子控制组件

电磁阀 先导控制杆组件

主控制阀总成
翻斗缸
先导泵
工作液压泵

翻斗联接位置感应
液压油箱
举升联接位置感应片 举升缸
电子系统 主要液压系统

先导液压系统
两系统通用部分
Examine actual machine
装载机现场调查
Work at Board 白板展示

Speed Control 速度控制

Force Control 力的控制
Feedback to operator
对驾驶员的反馈
 Speed Control
Fill in chart for a light load and a heavy load
速度控制
完成轻载及重载图表

Speed
速度

Input 输入
 Force Control
Fill in chart for a light load and a heavy load
力的控制
完成轻载及重载图表

Max Force
最大力

Input 输入
Basic Hydraulic Equations 基本液压公式

• Continuity
Sum of flows = 0

• Flow Terms
– Pump
– Cyl
– Orifice
– Leakage
– Motor
– Compressibility
• 连续性
流量和 = 0

• 流量术语
– 泵
– 油缸
– 节流口
– 泄漏
– 马力
– 可压缩性
 Basic Hydraulic Equations 基本液压公式

• Cylinder Flow •Pump Flow

– Cylinder of piston area Ah with speed of V. •Pump with displacement Dp, volumetric efficiency ,
– 活塞缸面积 Ah ，速度 V speed N.
– Q = (dX/dt)*Ah = V*Ah • 泵的排量 Dp, 容积效率， 速度 N
– •Q = Dp*N*
– Where •
– Q - flow 流量 •Where
– Ah – Area of Head End 缸头端面积 •Q – flow 流量
– V – speed/velocity of cylinder 油缸速度 •Dp – pump displacement 泵排量
– (dX/dt) – cylinder speed. 油缸速度 •N – shaft rotation speed 轴转速
– •Motor Flow
• Orifice Flow •Motor with displacement Dm, volumetric efficiency ,
–
speed N.
Orifice of area A with pressure drop dP.
–
• 马达排量 Dm ，容积效率，速度 N
节流口面积 A ， 压力下降 dP
–
•Q = Dm*N/
Q = A*Cd*sqrt(dP*2/)
– •Where
– Where
•Dm is the motor displacement Dm 为马达排量
– Q – flow though an orifice 通过节流口的流量 •N is the shaft speed N 为轴速
– A – area in mm2 面积 •Leakage Flow
– Cd – orifice coefficient = 0.62 流量系数 •Leakage with leak coefficient K and pressure drop dP.
– dP is the absolute pressure drop cross orifice • 泄漏系数 K 及压力下降 dP
in kPa Dp 是通过节流口时的绝对压力下降，以 kPa 为单位 •Ql = k*dP
– Note: if flow is in l/min, DP is in Kpa, A is in • Commpressibility Flow
mm^2 and 注意：如果流量是以 l/min 为单位， DP 以 kPa 为单位 • Flow need to raise the pressure of a volume V by dP
， A 以 mm2 为单位， over a time
– The fluid is SAE10 then 流度就是 SAE10 • period of dT (compressibility).
– Q = .0582* A*sqrt(dP) • 在一定时间段内，提高一定体积的压力所需的流量
– •Q = (dP/dT)*V/
•
•Where
•
•dP/dT - Pdot = P/T
•V – volume 容积
 - fluid bulk modulus 体积模量 / 系数
 Basic Force Equations 基本的力的计算公式

• Momentum
Sum of forces = 0

• Force/Torque Terms
– Pump & Motor
– Cylinder
• 动量
力的总和 = 0

• 力 / 力矩术语
– 泵 & 马达
– 油缸
 Basic Force Equations for hydraulic components 液压件的基本力的计算公式

• Cylinder of piston area Ah. • Motor 马达

– 活塞缸面积 Ah •
– F = (P)*Ah •T = Disp * dP * 
– •
– Where
•Where
– P = Pressure 压力
•T = Torque to drive motor 驱动泵的力矩
– Ah = Area of Head End 缸头端的面积
–
•dP = pressure across motor 穿过泵的压力
– •  = torque efficiency 力矩效率
•
• Pump 泵
•
– T = Disp * dP / 
–
– Where
– T = Torque to drive pump 驱动泵的力矩
– dP = pressure across pump 穿过泵的压力
–  = torque efficiency 力矩效率
 Summary
• Open Center System Components
– Fixed displacement pumps
– Valves with pump to tank, pump to cylinder, cylinder to tank areas
– Main & line relief valves
– Load Checks
– Make ups & back pressure valves

• Operator control features

– Ability to limit system pressure with the lever
– Tool speed changes with load – operator has a “feel” for load
– Deadband varies with engine speed and load pressure
– Multi-function operation generally is done with interupted series valve
where upstream functions have full priority over downstream functions
Form small teams to work problems
Need to stagger groups to work on machine tests
分成小组解决问题
需要交叉小组进行整车测试
 Fundamentals – Open Center Systems
Exercise

基础知识 - 开芯式系统练习

1. What is the purpose of the following components in an open center system? 以下所列零件
在开芯式系统中有什么用途？

a) Main Relief? 主安全阀？

b) Load check valves? 装载单向阀 ?

d) Line reliefs? 管路溢流阀？

e) Make up valves? 补油阀？

f) Pressure control valve in the tank return line? 油箱回油线路中的压力控制阀？

 Fundamentals – Open Center Systems
基础知识 - 开芯式系统

2. Compute the lift time for your machine assuming the cylinder goes through its full
stroke, a pump efficiency of 90%, a full lift command, and rated engine speed.
假定油缸是在全冲程状况下， 泵抽效率为 90% ， 全举升， 发动机在标准转速下工作，计算整车的举升时间。

3. Compute the lower time for your machine assuming the load is driven and not
overrunning and the operator is asking for full lower. Also assume the cylinder
goes through its full stroke, a pump efficiency of 90%, a full lift command, and
rated engine speed.
假定车是负载但是并不超载， 并且驾驶员要进行全下降时，计算整车的下降时间。仍然是假定油缸是在全冲程状况下， 泵抽效率为 90% ， 全举升， 发动机在标准转速下工
作。
 Fundamentals – Open Center Systems
基础知识 - 开芯式系统

4. Compute the lower time for your machine assuming the load is overrunning, the head end pressure
is 4000 Kpa, and the cylinder to tank area is at its maximum. If you know the pressure to hold the
load on your machine use that pressure rather than 4000 Kpa. Note that on loaders the pressure
varies significantly with linkage position.
假设车是超载的， 杆头压力是 4000Kpa ， 油缸到油箱的面积最大时，计算整机的下降时间。计算时，忽略掉快速下降阀。如果知道你的机器的支撑载荷时的压力， 使用此压力而不要用
14000Kpa 的压力。 Chinese needs edited

5. What must the cylinder to tank area be in order to have a lower time of 3 seconds assuming an
overrunning load and still assuming the head end pressure is 4000 Kpa (or your known pressure)?
假定在超载情况下并且杆头压力仍然是 4000Kpa （或是你已知的压力）时，要达到 3 秒钟的下降时间， 油缸到邮箱的面积必须是多少？

6. What is the max force that can be generated by the lift cylinders in the raise direction if the cylinder
efficiency is 90%?
油缸效率为 90% 时，举升缸在举升方向所能产生的最大的力是多少？

7. What is the max force that can be generated by the lift cylinders in the lower direction if the cylinder
efficiency is 90%?
油缸效率为 90% 时，举升缸在降落的方向所能产生的最大的力是多少？
 Fundamentals – Open Center Systems
基础知识 - 开芯式系统

8. What is meant by the term “hydraulic modulation”?

什么是“液压调制”？

9. Can an operator use engine speed to gain hydraulic modulation with an open center
system? Explain your answer.
驾驶员可以利用发动机转速在开芯式系统中来获取液压调制吗？解释一下你的答案。

10. How does the gain of cylinder motion to tool motion impact hydraulic modulation?
油缸的机械运动到工作装置机械运动的增加 / 获取是怎么来影响液压调制的 ?
 Fundamentals – Open Center Systems
基础知识 - 开芯式系统

11. What determines the valve spool deadband for an open center circuit with a resistive load? If your
machine has an open center circuit how much is the deadband for one of the circuits? Compare your
estimate to measured data from PPG or to data from a Dynasty model or both.
什么决定了带有阻力载荷的开中位回路的阀芯死区 ? 如果你们的车有一个开中位回路 , 那么其中一个回路的死区是多少 ? 比较一下你的估计数字和从 PPG 里或者从
Dynasty 模型或者同时从两者中测得的数字

12. What determines the valve spool deadband for an overrunning load condition? How much is the
deadband for one of the circuits on your machine? Compare your estimate to measured data from
PPG or to data from a Dynasty model or both.
在超载条件下 , 是什么决定了阀芯的死区 ? 其中一个回路的死区是多少 ? 比较一下你的估计数字和从 PPG 里或者从 Dynasty 模型或者同时从两者中测得的数字
 Fundamentals – Open Center Systems
基础知识 - 开芯式系统

13. If you had a conventional open center hydraulic system and desired the
operator to see no variation in deadband at the lever when moving resistive
loads what variables would your control algorithm need to compensate for?
如果你有一个常规的开芯式系统而且想在移动阻力载荷的时候，驾驶员在控制杆处不会看见任何的死区的变动，你的控制运算法则需要什么变量来补偿？

14. What is a simple test you can do to determine if a cylinder is voiding during a
gravity driven function? How can you compute the amount of the void? How
can you compute the time needed to fill the void? Perform these calculations
and run the simple test on your machine. Compare your calculated times to the
measured ones.
什么样的简单试验可以确定在重力驱动功能期间，油缸是否有空隙？你怎么来计算空隙的数量？你怎么来计算填充空隙所需要的时间？进行计算并且在你的机器上进行此简单实验
。将你计算出的时间和所测的时间进行比较
 Fundamentals – Open Center Systems
基础知识 - 开芯式系统

15. Most conventional wheel loader open center systems use interrupted series valves. What does this
mean? If the operator pulls the tilt lever and the lift lever to their full displacements what are the
resulting motions?
大多数常规装载机的开芯式系统使用中断式系列阀 . 这代表什么意思呢 ? 如果驾驶员把摇臂及动臂拉到全位移时 , 产生的机械运动是多少 ?
Machine Tests
整车测试
 Machine Tests 整车测试

1. Observe the modulation characteristics of your machine.. How much deadband is

there in the lever? Does it change with engine speed? Does it change with load
(note – if you can’t get a load compare deadband with the linkage low versus high –
the lift pressure will be higher when the linkage is raised). Dump the bucket so
you can clearly see the cutting edge. What is the minimum distance you can move
the bucket?

2. For your machine: 对于你的车

a) Calculate the lift time with the engine at HI. 计算一下举升时间 , 当发动机处于高速运转时
b) Measure the lift time for your machine. 测量一下举升时间
c) Compare the values from a and b. How different are they? What factors might
contribute to the
differences? 比较一下 a 和 b 的值 . 它们有多大的区别 ? 什么因素导致此诧异的产生 ?

3. Repeat step 1 with the engine at a lower speed – perhaps half throttle. 重复第一项的操作当发动
机低速运转时 ?- 可使用半油门
 Machine Tests 整车测试
4. For your machine: 对于你的车
Calculate the lower time assuming a pumped load and repeat assuming an
overrunning load. 假设是泵载荷且超载时，计算下降时间
What is the actual lower time on the machine? 实际的下降时间是多少 ?
From this time and your previous calculations can you determine if it is
overrunning or pumped? If your machine has a quick drop valve, how does
it influence this time? 通过以上两个时间信息，你能决定是超载荷还是泵载荷吗？ 如果你的车上装有快速下降阀的话， 它是怎么影响这个
时间的？

5. What is a simple test you can do to determine if a cylinder is voiding during a

gravity driven function? How can you compute the amount of the void? Run the
simple test on your machine and perform these calculations. 什么样的简单试验可以确定在重力驱动功
能期间，油缸是否有空隙？你怎么来计算空隙的数量？你怎么来计算填充空隙所需要的时间？进行计算并且在你的机器上进行此简单实验。将你计算出的时间和所测的时间进
行比较 (Chinese needs edited)
 Machine Tests 整车测试

6. Repeat step 4 with the engine at a lower speed – perhaps half throttle.
重复第四项的操作当发动机低速运转时 - 可使用半油门
Load Sensing 加载敏感的

Variable Pump System

变量泵系统
 Efficiency 效率
Power Wasted in
Fixed Displacement
Pump System 固定活塞泵系统中功率的损耗
Flow During modulation
流量 Cylinder or 调制期间
Output Power
缸或输出功率

Pressure 压力
Relief 溢流

Flow Power Wasted in During stall 失速期间

流量 Fixed Displacement
Pump System
Cylinder or 固定活塞泵系统中功率的损
Output Power
=0
缸或输出功率 = 0
Pressure 压力
 Modifications to go from
Open Center Hydraulic System to
Closed Center Hydraulic System
开芯式系统到闭芯式系统的变更

泵排量 Pump Displacement = Dp max

泵速度 Pump Speed =N
泵容积效率 Pump volumetric eff = Ev
泵力矩效率 Pump torque eff = Tv
质量 Mass = m
负载 Load = mg
阻尼 Damping = c

体积 Volume = Vp
压力 Pressure = Pp 体积 olume = Vhe
压力 Pressure = Phe
缸头端压力面积 Pressure area Head En
缸杆端压力面积 Pressure area Rod End
冲程 Stroke =S
Collapsed Length = Cl
面积 Area = Apcre

Area = Apt 面积 Area = Actre

面积 Area = Apche
x
体积 Volume = Vre
压力 Pressure = Pre
面积 Area = Acthe

油箱压力 Tank pressure = Pt

Also need to add pump controls

Either electronic or hydromechanical
同样需要增加泵控制 - 电子的或者液压机械的
 Variable Displacement Piston Pump 可变活塞泵

Valve Port Slot Piston

阀口槽 活塞

Outlet Port
出油口
Drive Shaft 传动轴
Inlet Port Swashplate 斜盘
进油口 Cylinder Block
缸体

Click to play movie

Pump Controls – High Pressure Cut Off
泵控制 - 高压截止

Flow 流量

Pressure 压力

Pump controls sense pump discharge pressure 泵控制感应泵释放压力

and destroke pump at high pressure
 High Pressure Cut Off 高压截止

Command to achieve flow 完成流动命令

Pressure 压力

Flow 流量

Pressure 压力

面积 Area = Apcre

面积 Area = Actre
面积 Area = Apche

面积 Area = Acthe
 Pump Controls – Load Sensing
泵控制 – 负载敏感的

Main valve is modified to send

tank pressure to pump control when valve is in
neutral
Flow and
流量 cylinder pressure to pump control when function
is in use. 当阀处于零位时，主阀被更改用来将油箱压力发送到泵控制 ; 当功能在使用时 , 将油缸
压力发送到泵控制 .

Margin Pressure The pump control adjusts swashplate

极限压力 angle to maintain a pressure drop from pump
to pressure signal.
泵控制调整斜盘角度来维持泵到压力信号的压力的下降。
This means that when the function is in use margin
pressure is held constant
across the pump to cylinder area.
这就意味着当功能在使用时 , 边缘压力在泵到油缸区保持为常量
 Load Sensing Control 载荷敏感控制

Command to achieve flow 完成流动命令

Pressure 压力

- Flow 流量

Delta Pressure
Delta 压力

面积 Area = Apcre

面积 Area = Actre

If Op Cmd = 0 面积 Area = Apche

Pressure 压力
P = P tank 油箱
If Op Cmd is non zero
P = P cylinder 油缸 Pressure
from working
面积 Area = Acthe
Function 来自工作功能的压力

Operator Command 驾驶员命令

 Physical Locations of Controls
• Load sensing control and high pressure cut off on
the pump
• Signal network in the implement valve
• Signal line sends signal from valve to pump

Load sensing control

High pressure cut off Implement
Signal to pump Valve Cylinder
Lines

Pump
Pump to valve

Suctio Return to tank Cylinder

n

Case drain
Tank
 Sample System
In the next several slides we will examine a single circuit
in neutral, actuated, and at high pressure cut off. We will
examine the pump control action for each situation.

Load sensing control

High pressure cut off Implement
Signal to pump Valve Cylinder
Lines

Pump
Pump to valve

Suctio Return to tank Cylinder

n

Case drain
Tank
 System in Neutral

• Signal pressure = tank pressure

• Pump controls assure pump pressure = margin

Load sensing control

High pressure cut off Implement
Signal to pump Valve Cylinder
Lines

Pump
Pump to valve

Suctio Return to tank Cylinder

n

Case drain
Tank
 Variable Pump – Neutral Mode
Load Sensing Spool Meters
Load Sense Pump near 0 – has sufficient flow to
Control High Pressure compensate for leakage and
Signal = Tank Cut off
Control
maintain output = margin
 System Actuated

• Signal pressure = cylinder pressure

• Pump controls assure pump pressure = margin plus cylinder

Load sensing control

High pressure cut off Implement
Signal to pump Valve Cylinder
Lines

Pump
Pump to valve

Suctio Return to tank Cylinder

n

Case drain
Tank
 Variable Pump – Actuated Mode
Load Sense
Control Load Sensing Spool Meters
High Pressure Pump at displacement needed to provide sufficient flow to
Signal = Cylinder
Cut off
Control
maintain pressure drop from pump to signal (cylinder)
output pressure = margin plus cylinder
 System at High Pressure Cut
• Function stalled – cylinder not moving
• Cylinder pressure = pump pressure (no flow across valve)
• Signal pressure = pump pressure
• Pump controls assure pump pressure = high pressure cut off setting

Load sensing control

High pressure cut off Implement
Signal to pump Valve Cylinder
Lines

Pump
Pump to valve

Suctio Return to tank Cylinder

n

Case drain
Tank
 Variable Pump – Pressure Limit Mode
Pressure Cut off Spool Meters
Load Sense High Pressure Pump near 0 – has sufficient flow to
Control Cut off
Control
compensate for leakage and
Signal = pump
maintain output = high pressure cut pressure
 Pump Controls
627H Tier 4 Interim

Compensator

High Pressure Cut off

 Pump Controls – 980H Interim
Pump Discharge sent to control
piston
 Pump Controls – 988H
Electronic Pump Control – no signal
pressure
Pilot Pressure sent to control spool
Hydrac Valve
Solenoid actuated

Pump Controlled Pressure

Pilot Supply

Tank
How do we generate the load
sensing signal?
 Signal Generation 信号的产生
Additional passages are added to the spool to create 额外的通道被增加到阀芯中
signals to send to the pump controls. In multi-function 产生信号，并将其发送到
applications like wheel loaders that have tilt and lift the 泵控制。在像装载机这种
signals are resolved and the highest is sent to the pump. 具有举升及翻斗的多功能
应用中，信号被分解，最
1A 1B 2A 2B 高的信号被发送到泵中

Signal

Neutral Neutral
 Signal Generation 信号的产生
In neutral signal is connected to tank, 额外的通道被增加到阀芯中
产生信号，并将其发送到
when shifted signal is connected to cylinder 泵控制。在像装载机这种
具有举升及翻斗的多功能
应用中，信号被分解，最
1A 1B 2A 2B 高的信号被发送到泵中

Signal
Actuated

Neutral
 Work at White Board
• Show circuit
• Discuss performance characteristics
– Neutral
– Deadband
– Velocity vs Lever
627 Tier 4H Interim
 980 Closed Center Valve
Parallel Circuit

Tank

Pump
 Summary
• Variable pumps are used to gain efficiency
– Especially during modulation or when pressure reaches relief
– Excess flow is controlled by destroking the pump rather than sending
oil over the pump to tank area or the relief valve
– Savings of ~ 3 – 10 % can be realized in a truck loading cycle
• Operator loses two control features
– Ability to limit system pressure with the lever
– Tool speed doesn’t change with load – operator loses “feel” for load
• Pump Controls
– Two controls are needed – load sensing & high pressure cutoff
• Signal relief is also used in place of high pressure cutoff
– Controls can be hydromechanical or electronic
• Valve/Electronic Modifications
– Signaling network needs to be added for hydromechanical controls
– Solenoids and software need to be added for electronic controls
 Fundamentals – Closed Center Systems
基础知识 - 闭芯式系统
1. What are the sources of inefficiency in an open center hydraulic system? For your
machine estimate the amount of energy used to raise a load from bottom to top at full
speed and the amount of energy lost in each source of inefficiency. Repeat if you are
raising at half speed. Repeat again if a cylinder is stalled when reaching the top for 5
seconds. Compute the overall system efficiency for all three cases.
在开芯式液压系统里面 , 无效率的来源是什么 ? 估算一下你的车在全速时 , 将载荷从底部举升到顶部时所使用的能量的量以及在每一个无效率来源中 , 能量损失的数量 . 重复以上的估算
, 当车在半速行驶时 . 估算一下；当油缸到达顶部停止 5 秒钟后 . 油缸处于失速状态时，再次估算一下；计算这三种情况的总系统效率 .

2. What sources of inefficiency described in one above are corrected by a closed center
load sensing system with a high pressure cut off control? What are the main operating
conditions where the improved efficiencies are most beneficial? Repeat exercise 1 for a
closed center load sensing system with a margin pressure of 1500 Kpa.
以上所描述的无效率来源中 , 哪一种可以被带有高压截止控制的闭芯式载荷感应系统来校正 ? 在什么主要的操作条件下 , 改进后的效率是最有益的 ? 重复练习一 : 用带有 1500
Kpa. 边缘压力的闭芯式载荷感应系统

3. What variable can an operator control with an open center system that he cannot
control with a closed center system? Name one application where this is important.
什么变量在开芯式系统中 , 驾驶员可以控制但是在闭芯式系统中不能控制 ? 列举一个应用实例
 Fundamentals – Closed Center Systems
基础知识 - 闭芯式系统

4. What determines the valve spool deadband for a closed center circuit with a resistive load? If your
machine has a closed center circuit how much is the deadband for one of the circuits? Compare
your estimate to measured data from PPG or to data from a Dynasty model or both.
什么决定了带有阻力载荷的中位封闭回路的阀芯死区 ? 如果你们的车有一个中位封闭回路 , 那么其中一个回路的死区是多少 ? 比较一下你的估计数字和从 PPG 里或者从 Dynasty 模型或者同时从两
者中测得的数字

5. What determines the valve spool deadband for an overrunning load condition for a closed center
circuit? How much is the deadband for one of the circuits on your machine? Compare your
estimate to measured data from PPG or to data from a Dynasty model or both.
对于一个中位封闭的回路 , 在超载条件下 , 是什么决定了阀芯的死区 ? 其中一个回路的死区是多少 ? 比较一下你的估计数字和从 PPG 里或者从 Dynasty 模型或者同时从两者中测得的数字
 Fundamentals – Closed Center Systems
基础知识 - 闭芯式系统

6. What feedback does an operator lose when going from an open center system
to a closed center system? Name one application where this is important.
从开芯式系统到闭芯式系统 , 驾驶员失去的是什么反馈 ? 列举一个应用实例

7. Can an operator use engine speed to gain hydraulic modulation with a closed
center system? Explain your answer.
在闭芯式系统里面 , 驾驶员能否利用发动机转速获取液压调制 ? 解释一下你的答案
 Fundamentals – Closed Center Systems
基础知识 - 闭芯式系统

8. What are the key differences between a closed center hydromechancical load
sensing system and a conventional open center system? Consider efficiency,
controllability, feedback to the operator regarding load, force capability, etc.
闭芯式液压机械载荷感应系统与常规的开芯式系统有什么主要的区别 1? 考虑有效率 , 可控制性 , 载荷及力能等的对驾驶员的反馈

9. The 980H Interim machine has a high pressure cut off control on the pump. The
system also has a load sensing relief. Why can’t we eliminate the relief and rely
on the high pressure cut off to control the pump displacement when a function
is at relief pressure?
Pressure Compensation
980H Interim Closed Center LS - Post Compensation
Valves in Neutral
980H Interim Closed Center LS - Post Compensation
Shifted Valves
 If we have a parallel supply and no compensation we get a lot of flow to the low 如果我们有个平行的供应且没有补偿的话，在低压回路中我们
pressure circuit and very little flow to the high pressure circuit. For example, 获取了很多流量但是在高压回路中获取的就很少。比如说，假设
assume circuit 1 has a 1000 Kpa load, circuit 2 has a 19000 Kpa load, and pump 回路 1 有 1000Kpa 的载荷，回路 2 有 19000Kpa 的载荷，泵边界是 1400 。
margin is 2300. The pump pressure will be 21300. If both valves are shifted 那么泵压是 20400 。如果两个泵进行相同量的换档，那么在回路 1 中
wide open all flow will go to circuit 2. 的穿过 P-C 的压力下降为 19400 ，在回路 2 中仅为 1400 。 所以大多数的
流动将会进入到回路 1 中。 THIS NEEDS EDITED

19000 Kpa
19000 Kpa 1000 Kpa

0 Flow Full Flow

Goal
19000 Kpa + 2300Kpa
21300 Kpa
Actual < 21300

19000 Kpa 1000 Kpa

MG Closed Center LS - Post Compensation
Valves in Neutral
MG Closed Center LS - Post Compensation
Valve Shifted
 Load Cases
1. Resistive A & B ports A = 19000 Kpa, B = 1000 Kpa
Pump capability = 300 lpm Demand A = 100 lpm B = 100 lpm

2. Resistive A & B ports A = 19000 Kpa, B = 1000 Kpa

Pump capability = 300 lpm Demand A = 200 lpm B = 200 lpm

3. Resistive A port, Overrunning B port A = 19000 Kpa, B = vacuum

Pump capability = 300 lpm Demand A = 100 lpm B = 100 lpm

4. Resistive A port, Overrunning B port A = 19000 Kpa, B = vacuum

Pump capability = 300 lpm Demand A = 200 lpm B = 200 lpm

5. Stall A port, Resistive B port A = 35000 Kpa B = 1000 Kpa

Pump capability = 300 lpm Demand A = 100 lpm B = 100 lpm

6. Stall A port, Overrunning B port A = 35000 Kpa B = vacuum

Pump capability = 300 lpm Demand A = 100 lpm B = 100 lpm
 980H Interim Closed Center LS - Post Compensation
Case 1 Demand 100 lpm in both circuits
19000 Kpa

19000 Kpa
1000 Kpa
19000 Kpa 19000 Kpa
19500 Kpa 19500 Kpa

100 lpm
100 lpm
19000 Kpa + 2300Kpa
21300 Kpa

19000 Kpa 1000 Kpa

 980H Interim Closed Center LS - Post Compensation
Case 2 Demand 200 lpm in both circuits
19000 Kpa

19000 Kpa
1000 Kpa
19000 Kpa
19000 Kpa
19500 Kpa 19500 Kpa

Goal
150 lpm 19000 Kpa + 2300Kpa
150 lpm
21300 Kpa
Actual
P < 21300

19000 Kpa 1000 Kpa

 980H Interim Closed Center LS - Post Compensation
Case 3 Demand 100 lpm in both circuits
19000 Kpa

19000 Kpa
0 Kpa
19000 Kpa 19000 Kpa
19500 Kpa 19500 Kpa

100 lpm
100 lpm
19000 Kpa + 2300Kpa
21300 Kpa

19000 Kpa 0 Kpa

 980H Interim Closed Center LS - Post Compensation
Case 4 Demand 200 lpm in both circuits
19000 Kpa

19000 Kpa
0 Kpa
19000 Kpa 19000 Kpa
19500 Kpa 19500 Kpa

Goal
150 lpm 19000 Kpa + 2300Kpa
150 lpm
21300 Kpa
Actual
P < 21300

19000 Kpa 0 Kpa

 980H Interim Closed Center LS - Post Compensation
Case 5 Demand 100 lpm in both circuits, one circuit stalled, one resistive
35000 Kpa

Pressure keeps increasing

1000 Kpa
until relief blows
35000 Kpa
< 37300 Kpa 35500 Kpa
Due to stall

0 lpm Small flow to

signal relief
100 lpm
35000 Kpa + 2300Kpa
37300 Kpa

37300 Kpa 1000 Kpa

 980H Interim Closed Center LS - Post Compensation
Case 6 Demand 100 lpm in both circuits, one circuit stalled, one overrunning
35000 Kpa

Pressure keeps increasing

0 Kpa
until relief blows
35000 Kpa
< 37300 Kpa 35500 Kpa
Due to stall

0 lpm Small flow to

signal relief
100 lpm
35000 Kpa + 2300Kpa
37300 Kpa

37300 Kpa 0 Kpa

 Cylinder
Signal

Tank

Pump
 LS Signal

Compensator
Spring
From Cyl

To Cyl

Check
Spring

Pump
To Tank
 Summary

• With parallel valves flow sharing is dependent on load

pressures and lever commands
– For equal valve commands low pressure circuits get more flow than
high pressure circuits

• Compensators are used to add restriction to the low pressure

circuits to get equal flow sharing regardless of load pressures
– The pressure setting of the load compensator is less than the
pump margin pressure
– Pump margin is now the sum of the pressure drop across the pump
to cylinder area and the compensator area
Motorgrader Valve
 Fundamentals – Pressure Compensation
基础知识 - 闭芯式系统 Needs edited

9. If your system has post compensation with each compensator is set to the same
value and the operator pulls the tilt and lift levers to their maximum displacements
what are the resulting motions? How is this different than a conventional
interrupted series system? How can you change the compensator settings so that
the system behaves more like a conventional system?
如果你的系统具有后补偿，每一个补偿器都设置了同样的值并且驾驶员将摇臂及动臂拉到最大位移处，这种情况下，所产生的机械运动是多少？这和常规的阻断系列系统有什
么区别？你怎样来更改补偿器设置使得这个系统运转起来更像一个常规系统？
 Ride Control System
• Basic idea – vibration absorber
• Use accumulator and orifice to provide
spring and damper
• Connect Head end of lift to accumulator
• Connect Rod end of lift to tank
• Need ability to “turn off” ride control
 Simplest Ride Control
• When closed
– Rod End to tank closed completely
– Small orifice from accumulator to HE
– This allows accumulator pressure to stay = HE but prevented
a lot of motion during digging
– If no orifice the load could drop when ride control is turned on
• When on
– HE open to accumulator
– RE open to tank
 Additional valving for ride control

• Use pump oil to keep accumulator pressure = lift HE

• This prevents “mushy” linkage

• Current version on H series

– Two solenoids control the flow paths
– This allows for electronic controls
• Normal ON
• Machine speed > value which is configurable
• The system should not be on during normal truckloading
• Off – off all the time
• Service mode
– Turns on ride control regardless of speed when the ride control button is held
down
– This allows one to open the main spool to drain the accumulator
Accumulators
 Equations
• PV^n = constant
• Precharge * Volume^n = Pressure * Volume^n
• n = 1 for
• n = 1.4 for
 Fundamentals – Ride Control

1. For your machine create a plot of the force at the lift cylinder as a
function of the displacement of the lift cylinder. Assume the oil is
incompressible.

2. Now assume there is no accumulator and the oil has a bulk modulus
of 50000 psi. Create a plot of the force at the lift cylinder as a
function of the displacement of the lift cylinder.

3. What would happen if you dumped the bucket and the bucket hit the
dump stops and the ride control system was on or had the
accumulator connected to the lift HE via an orifice? What would
happen when you released the tilt lever?
 Tandem Center Valve
(Open Center at Cat)
Pump

Tank

Neutral

Cyl A Cyl B
To Lift
Pump

Tank

Dump

Cyl A Cyl B
To Lift