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Electro-Hydraulic Two-Axle Steering System For City Crane
Electro-Hydraulic Two-Axle Steering System For City Crane
Electro-Hydraulic Two-Axle Steering System For City Crane
Crane
Koichi SHIMOMURA*1, Takashi MORITA*2
*1
Engineering & Development Div. System & Component Development Dept., KOBELCO CRANES CO., LTD.
*2
Electronics Research Laboratory, Technical Development Group
Lock pin
Steering
cylinder
wheel
Proportional
valvess
valves
Steering Steering
cylinders cylinders
Angle sensor
Angle Angle Check
Sensor Check Sensor valve
valves
Vehicle
speed
Vehicle speed
Operating
panel
CAN
_bus
Steering
Crane
controller
controller
2.5
All-wheel
↑
Signal A
main signal
0.2
Range of error
−45 −35 0 35 45
Steering angle (deg)
Crab
Fig. 7 Signal of steering angle sensor
signals are used not only for the steering control, but
also for other controls. In a conventional machine,
two sensors are provided, i.e., a main sensor on the
rear axle and a sub-sensor on the front axle. The
steering controller receives input via dual channels,
Manual
i.e., a direct input of pulse signals from the rear axle
Fig. 6 Steering system in off-road mode
and an indirect input via a Controller Area Network
(CAN) from the front axle, in which the signal passes
angle has been devised with special care and taken through other controllers. Unlike ordinary anomaly
to a higher level than that of the state detection in detection, the signals from the dual channels are
the conventional domestic model. As a natural compared and an anomaly is judged to exist when
procedure, a duplexed system is employed for signal the difference exceeds a predetermined value. The
detection in a manner similar to that of other critical signals are not used by the control and are shifted
state detections, such as the detection of accelerator over to a failure procedure.
operation. The duplexed signals, however, may both
be distorted in the same manner by a disturbing 2.3.2 Steering operation
factor. Redundancy by cross-sensing is adapted to
prevent this problem from happening and to further Even if the above described state detection
improve reliability (Fig.7). There is a risk that one returns a normal result, a steering operation that is
or both of the duplexed signals may not reflect the totally unmatched with the driver's steering actions
actual value even when the signals are in the normal may occur when there is an anomaly in the electrical
range (or in a range that is beyond the upper or lower output from the steering controller or in the
limit of the sensor voltage, but does not reach the hydraulic actuators receiving the electrical output.
failure range). This happens when, for example, Therefore, special care has been taken to devise
something causes the supply voltage for the sensor duplex channels, not only for the electrical system,
and/or the electrical potential level of the grounding but also for the hydraulic system (Fig.4).
to deviate from the normal range. This problem The system is configured around the basic concept
happens also when unintended powering or a that the rear axle must never act on its own when in
ground fault occurs on the signal line. The above highway mode. (In particular, it must remain in
configuration makes it possible to judge anomalies neutral in the high-speed range.) This basic concept
even when such problems occur. In the newly takes precedence over everything else. For each of
developed system, one of the duplexed signals is the rear axles, i.e., the second and third axles, the
taken as a base. An anomaly is judged to have taken steering operation is determined by the strokes of
place when the other signal is converted into an angle two cylinders whose movement is governed by the
that exceeds ±10% of the range of the base value. If output from the steering control valve (proportional
this happens, the values are not used for the control, valve), which is actuated on the basis of commands
and the system is shifted to a failure procedure. from the steering controller. The proportional valves
Vehicle speed signals from the speed detection are disposed facing each other on both sides of each
sensors are also critical because they are used for control valve and are constructed so as to maintain
calculating the steering angle and mode switching the steering state unless there is an electrical output.
conditions when in highway mode. Vehicle speed In other words, when the outputs from the
down the circuit in order to maintain the state of the Axle3 level2 ○ ○
Axle3 level3 ○ ○
steering cylinders. These check valves themselves are
configured to open the hydraulic circuit and to make
the steering cylinders operable when an electrical thereafter, is held in neutral. In Level 2, only the axle
signal is output. It should be noted that a check affected by the anomaly is forcibly steered into the
valve is provided for each steering cylinder of the neutral state and, thereafter, held in neutral. In Level
third axle so that the steering cylinders are not 3, the axle affected by the anomaly is immediately
actuated if one of the check valves fails to operate. shifted to a hold state, while the axles that are not
For the second axle, only one check valve, common directly affected are steered by the driver until they
to both of the steering cylinders, is provided. Instead, enter the neutral state and, thereafter, are held in
to ensure a neutral state when in highway mode, a neutral.
mechanical locking mechanism (including lock pins)
conventionally used in the domestic model is 2.3.4 Verification of safety
provided, in addition to the hydraulic holding
mechanism. A pneumatic lock cylinder actuates a pin Just as in the case of conventional development,
to lock the steering cylinder. the new control system was established after the
As for the electrical aspect, the feedback from the verification of control specifications by testing on
proportional valve output is monitored as in the case bench and actual machines, as well as by a thorough
of the domestic model, and the operation shifts to a confirmation of their behavior under each failure
failure procedure as soon as an anomaly is detected. mode as defined by Failure Mode and Effects
The electrical output to each check valve is configured Analysis (FMEA). The typical verification items are
such that the outputs of both the high side (power as follows.
supply side) and the low side (grounding side) come The steering mode performance for the operation
from the steering controller. As a result, there is only of a normal system is verified. Above all, straight-line
a negligibly small possibility of a check valve's failing stability is regarded as an important factor. The
to hold the steering cylinder due to an electrical specifications require that the rear axle in the neutral
problem. state must be aligned within +/- 0.3 degree. Testing
on an actual machine under various conditions has
2.3.3 Fail-safe procedure proved that the actual alignment falls within +/- 0.15
degree.
A fail-safe procedure has been devised to prevent It is most critical to verify the behavior under
an unsafe event from happening in the event that failure. Verification based on FMEA, including the
an anomaly should occur in the state detection, effective use of accumulated data, was performed
steering controller, or output system. Anomalies with the cooperation of a steering system
are categorized in four levels, according to their manufacturer.
importance, from Level 0 (minor) to Level 3 (major). For the sake of safety and for compliance with
The steering controls on the second and third axles European regulations, a swing-out test is a
are limited in certain ways, depending on the level, to particularly important part of the verification
prevent major unsafe events, while, as far as possible, process. The test includes checking the amount of
keeping the steering function effective (Table 1). swing-out when the rear part of the vehicle body
In Level 0, the normal control is continued. In sways from side to side due to an abrupt change in
Level 1, an axle affected by an anomaly is steered by the steering angle of the third axle. This behavior of
the driver until the axle goes into neutral and, the third axle is regarded as the worst case in the