CAT Loader Hydraulic System Basic Training

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SEM650SEM650
SEM650的计算进行验证
• Specific objectives 特定目标
– ??
爱液压技术论坛 http://bbs.iyeya.cn/
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
2.00 800.0
Primary Torque (ft-lb)

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:

http://www. engineersedge
http://www.engineersedge .com/hydraulic/symbols/hydraulic_
engineersedge.com/hydraulic/symbols/hydraulic_ iso
.com/hydraulic/symbols/hydraulic_iso _schematic_symbols.
iso_schematic_symbols. htm
_schematic_symbols.htm
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 爱液压技术论坛 http://bbs.iyeya.cn/
Tandem Center Valve
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
What’’s wrong with this circuit?
Tandem (Open) Center Hydraulic System
开芯式液压系统
泵排放Pump
Pump Displacement = Dp
泵速度Pump
Pump Speed =N
质量Mass
Mass = m
泵容积效率Pump
Pump volumetric eff = Ev
负载Load
Load = mg
泵力矩效率Pump
Pump torque eff = Tv
阻尼Damping
Damping = c
体积Volume
Volume = Vp 缸头端压力面积Pressure
Pressure area Head End = Phe
压力Pressure
Pressure = Pp 体积Volume
Volume = Vhe 缸杆端压力面积Pressure
Pressure area Rod End = Pre
压力Pressure
Pressure = Phe 冲程Stroke
Stroke =S
缸杆全收缩时长度Collapsed
Collapsed Length = Cl
面积Area
Area = Apcre
面积Area
Area = Apt 面积Area
Area = Actre
面积Area
Area = Apche
x
体积Volume
Volume = Vre
压力Pressure
Pressure = Pre
面积Area
Area = Acthe
油箱压力Tank
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
器电磁阀举升滤芯至油箱先导通道器电磁阀
内部通道
通往下一阀通道
主泵系统压力
吸油 / 回油
表面积
先导压力激活零件
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
2
OPEN AREA - mm
500
400
300
200
Cylinder to tank RE
100
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
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
翻斗联接位置感应片
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

•Pump
– Cylinder of piston area Ah with speed of V. Pump with displacement Dp, volumetric efficiency µ, speed N.
•Pump
– 活塞缸面积 Ah Ah，速度V V • 泵的排量 Dp, 容积效率µ µ，速度N N
– Q = (dX/dt) *Ah = V
(dX/dt)* *Ah
V* •QQ = Dp
Dp**N*µ
– •
– Where Where
•Where
– Q - flow 流量 •QQ – flow 流量
– Ah – Area of Head End 缸头端面积 Dp – pump displacement 泵排量
•Dp
– V – speed/velocity of cylinder 油缸速度 •NN – shaft rotation speed 轴转速
– (dX/dt) – cylinder speed. 油缸速度 Motor Flow
•Motor
– Motor with displacement Dm, volumetric efficiency µ, speed N.
•Motor
• Orifice Flow
Flow • 马达排量Dm Dm
Dm，容积效率µ µ，速度 N
– Orifice of area A with pressure drop dP. •QQ = Dm
Dm* *N/
N/µ
µ
– 节流口面积 A，压力下降 dP Where
•Where
– Q = AA**Cd*sqrt(dP
Cd* *2/
sqrt(dP* 2/ρ
ρ) Dm is the motor displacement Dm
•Dm Dm为马达排量
– •NN is the shaft speed N N为轴速
– Where Leakage Flow
•Leakage
– Q – flow though an orifice 通过节流口的流量 Leakage with leak coefficient K and pressure drop dP.
•Leakage
– A – area in mm2 面积 • 泄漏系数 K及压力下降dP dP
– Cd – orifice coefficient = 0.62 流量系数 Ql = k
•Ql *dP
k*
– dP is the absolute pressure drop cross orifice in kPa • Commpressibility Flow
Dp
Dp是通过节流口时的绝对压力下降，以kPa kPa
kPa为单位 • Flow need to raise the pressure of a volume V by dP over a
– Note: if flow is in l/min, DP is in Kpa, A is in mm^2 time
and 注意：如果流量是以l/min l/min
l/min为单位， DP kPa
DP以kPa
kPa为单位 • period of dT (compressibility).
，AA以mmmm2 为单位，
• 在一定时间段内，提高一定体积的压力所需的流量
– The fluid is SAE10 then 流度就是SAE10 SAE10
•QQ = (dP/dT)
(dP/dT)**V/
V/ββ
– Q = .0582
.0582** A *sqrt(dP)
A*
•
–
Where
•Where
•
dP/dT - Pdot = ∆P/
•dP/dT P/∆
∆T
•VV – volume 容积
•ββ - 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 Ah •
– F = (P)*Ah •T = Disp * dP * µ
– •
– 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
– • µ = torque efficiency力矩效率
•
• Pump 泵
•
– T = Disp * dP / µ
–
– Where
– T = Torque to drive pump 驱动泵的力矩
– dP = pressure across pump 穿过泵的压力
– µ = 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 “feelfeel”” 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？
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% 90%，全举升，发动机在标准转速下工作，计算整车的举升时间
90%
。
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% 90%，全举升，发动机在标准转速下工作。
90%
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4000 4000 Kpa，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
Kpa
4000Kpa
道你的机器的支撑载荷时的压力，使用此压力而不要用14000 14000 Kpa
Kpa的压力。 Chinese needs edited
14000Kpa
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4000 4000 Kpa
4000Kpa
Kpa（或是你已知的压力）时，要达到3 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% 90%
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% 90%
90%时，举升缸在降落的方向所能产生的最大的力是多少？
8. What is meant by the term “hydraulic modulation

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? ?
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
PPG Dynasty
PPG里或者从Dynasty
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
PPG
PPG里或
者从Dynasty
Dynasty
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
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
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 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
4. For your machine: 对于你的车
Calculate the lower time assuming a pumped load and repeat assuming an overrunning load.
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?
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 Chinese needs edited)
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
Pump Displacement = Dp max
泵速度Pump
Pump Speed =N
泵容积效率Pump
Pump volumetric eff = Ev
泵力矩效率Pump
Pump torque eff = Tv
质量Mass
Mass = m
负载Load
Load = mg
阻尼Damping
Damping = c
体积Volume
Volume = Vp
压力Pressure
Pressure = Pp 体积olume
olume = Vhe
压力Pressure
Pressure = Phe
缸头端压力面积PressurePressure area Head End = Phe
缸杆端压力面积PressurePressure area Rod End = Pre
冲程Stroke
Stroke =S
Collapsed Length = Cl
面积Area
Area = Apcre
Area = Apt 面积Area

Area = Actre
面积Area
Area = Apche
x
体积Volume
Volume = Vre
压力Pressure
Pressure = Pre
面积Area
Area = Acthe
油箱压力Tank
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
Area = Apcre
面积Area
Area = Actre
面积Area
Area = Apche
面积Area
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
and
Flow cylinder pressure to pump control when function
流量 is in use.
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..
The pump control adjusts swashplate

Margin Pressure angle to maintain a pressure drop from pump
极限压力 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
Area = Apcre
面积Area
Area = Actre
If Op Cmd = 0 面积Area
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
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
Suction Return to tank Cylinder
Case drain
Tank 爱液压技术论坛 http://bbs.iyeya.cn/
Vickers Load Sensing Compensator and Pressure Limiter
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.

Lines
Pump
Pump to valve
Case drain
Tank
System in Neutral
• Signal pressure = tank pressure

• Pump controls assure pump pressure = margin

Lines
Pump
Pump to valve
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
maintain output = margin
Control
System Actuated
• Signal pressure = cylinder pressure

• Pump controls assure pump pressure = margin plus cylinder

Lines
Pump
Pump to valve
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

Lines
Pump
Pump to valve
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
compensate for leakage and
Signal = pump Control
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
doesn’’t change with load – operator loses “feel
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 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 1500 Kpa.
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
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 PPG Dynasty
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 PPG Dynasty
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
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? 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
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
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

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

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

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

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

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

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

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

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

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

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
Pressure Compensation
What is Pressure Compensation and
What are the Advantages?
Method to maintain a constant pressure drop across the
meter – in spool regardless of valve inlet to work port
pressure drop
Provides same flow force across stem regardless of load

Do not have uncommanded changes in flow
Provides same lever efforts
Only a portion of pressure drop taken across main stem

further reduces lever efforts and flow forces
Proportional Priority Pressure Compensation
or Post Pressure Compensation
Pressure Compensation: Flow to an implement is not
affected by P-C pressure drop
Proportional Priority: if there is higher flow demand than

what the pump can deliver, the valve automatically
proportions the available flow so all actuated implements
continue to move at a proportionately reduced rate
PPPC and Post Main Spool pressure compensation are the

same thing
Closed Center LS - Post Compensation
1A 1B 2A 2B
Closed Center LS - Post Compensation
1A 1B 2A 2B
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
Pump
Tank
Neutral
Cyl A Cyl B
To Lift
Pump
Tank
Dump
Cyl A Cyl B
To Lift

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Objectives 目标

• Understand & study 了解及学习

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

Primary Torque (ft-lb)

Converter Data TBU

Gross Engine Lug Curve

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

Fan Heat 风扇热能

Wheel Slip Heat 车轮滑移热能

Eng Cooled Heat 发动机冷却热能

• Implement System 工作装置系统

• Caterpillar – most Cat engineers call this an open center valve

• Industry & Academia – open center valve

Main Flow Lines

3 Position Directional Control Valve

Head End Rod End

Pressure Relief Valve(safety valve) normally closed

For more see the following website:

Head End Rod End

Head End Rod End

Head End Rod End

Head End Rod End

• Work at white board

主泵系统压力 闭塞油路 激活的零件

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

Pump to cylinder HE Pump to cylinder RE

Cylinder to tank RE Cylinder

988H Lift CHARACTERISTICS 174-0119 CHG LVL 01

Valve Port Slot Piston

Next slide shows 992 locations

可变泵 先导溢流阀 工作电子控制组件

Speed Control 速度控制

• Cylinder Flow Pump Flow

• Cylinder of piston area Ah. • Motor 马达

• Operator control features

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？

8. What is meant by the term “hydraulic modulation

2. For your machine: 对于你的车

Variable Pump System

Flow Power Wasted in During stall 失速期间

Area = Apt 面积Area

Also need to add pump controls

Valve Port Slot Piston

Click to play movie

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

Command to achieve flow 完成流动命令

Main valve is modified to send

The pump control adjusts swashplate

Command to achieve flow 完成流动命令

Operator Command 驾驶员命令

Load sensing control

Suction Return to tank Cylinder

Load sensing control

Suction Return to tank Cylinder

• Signal pressure = tank pressure

Load sensing control

主泵系统压力闭塞油路激活的零件

可变泵先导溢流阀工作电子控制组件