By optimizing the hydraulic system of mobile machinery through sensor technology, heavy construction machinery manufacturers and their suppliers can more effectively solve some key problems on the construction site, such as operator fatigue and skills, work safety and accuracy, and equipment Requirements for wear, downtime, reduced emissions and higher fuel efficiency.
In the past few years, construction machinery, agriculture and other mobile machinery have become increasingly demanding in terms of capacity, efficiency, reliability and safety. Most of these machines use hydraulic pressure to achieve operation functions such as propulsion, steering, and lifting. The requirements for power, efficiency, and maneuverability are directly reflected in the hydraulic components and systems.
As part of the hydraulic system, understanding the status and position of hydraulic components such as pumps, motors, cylinders, valves, and the temperature and pressure of the oil in the tank has become an important part of mobile machinery control. A new generation of sensing technology applied to mobile machinery emerged at the historic moment to provide various information of hydraulic components for the control system.
Honeywell is a global supplier of sensors and related components. The company has developed a standard platform for the mobile machinery market, which can customize various hydraulic sensors.
The wheel loader is a good example. In order to make the machine work more stably and efficiently, more and more various sensors are used on the wheel loader, including temperature, speed, angle, position and pressure sensors.
The temperature sensor is used to monitor the temperature of the hydraulic oil in the hydraulic system. During operation, the hydraulic oil pump pumps oil out of the oil tank and pumps it into the hydraulic cylinder at a certain pressure, and the hydraulic cylinder is directly connected to the load. In the working cycle, the reciprocating movement of the cylinder will generate heat in the hydraulic oil, which may cause the temperature to exceed the maximum working range of the system. When the hydraulic oil reaches a predetermined temperature, the temperature sensor sends a control signal to turn on the cooling fan of the hydraulic oil cooler to keep the temperature below the set range, thereby preventing overheating or system failure.
For a variety of applications, Honeywell provides customizable sensor platforms designed to provide construction machinery manufacturers and corresponding motor, pump, and hydraulic cylinder suppliers with the ability to retrofit temperature sensors. The modular design of the sensor platform can provide different probe lengths, thread specifications, materials, connectors, housings and output types. Honeywell said that this design can use component methods to ensure that the sensors can be commercially mass-produced.
Honeywell said that the sensor platform can also be used in places with limited space, severe size and weight, ensuring that the equipment developed is compact, rugged, and can reduce the size of the entire system without sacrificing performance. In addition, the sensor can specify a variety of housing materials to ensure compatibility with various types of hydraulic oil.
Honeywell's RTY rotary position sensor uses the Hall effect (Hall-effect), installed in an IP67 sealed housing, can measure the angle of the swash plate in the hydraulic motor in harsh transportation environments.
In addition to the temperature sensor, the sensor is also used to measure the position of the liquid level in the hydraulic tank. Before the liquid level monitoring, the mechanical float switch was usually used. Honeywell said that currently non-contact infrared (IR) sensors are more and more widely used in liquid level monitoring. Infrared sensors have more advantages, mainly with higher accuracy and longer service life.
The speed sensor is the most widely used sensing element in mobile machinery. Speed ​​sensors are often used to monitor the working speed of hydraulic pumps. When a hydraulic hub motor is used to drive the machine, the speed sensor is usually used to detect the wheel speed and the direction of the wheel.
With limited space for installing sensors on hydraulic pumps, Honeywell can provide customized integrated speed and temperature sensors for monitoring pump speed and hydraulic oil temperature. The device can also provide fault diagnosis information such as short circuit and other wiring, improving the safety and working efficiency of the equipment.
In hydraulic hub motor applications, sensors are used to monitor wheel speed and direction. The solution proposed by Honeywell is to use a Hall-effect magnetic induction sensor to integrate the two functions of detecting speed and direction to prevent the "jitter" caused by false signals or false pulses that may be generated when the wheel motor is idling.
For example, if the wheel loader is positioned at a certain angle and then starts to move forward or backward, the electronic control system must be able to detect the angle of the machine and maintain its stability. In this case, the sensor must be able to determine whether the wheel is moving and the direction of the movement, and then transmit the data to the electronic control module to provide feedback to the hydraulic system to compensate for jitter.
In various types of mobile machinery, angle sensors are used to monitor the position of the swash plate in the hydraulic motor. The swash plate can control the hydraulic oil flow of the motor, thereby controlling the speed of the hub motor. According to different applications, designers can choose non-contact magnetic sensors (MR) or Hall effect sensors.
Different types of hydraulic systems are used on the wheel loader. In order to make the vehicle safer and more efficient, several types of sensors are needed, including temperature, speed, angle, position and pressure.
Under normal circumstances, Hall-effect sensors have lower cost and can provide good performance, but non-contact MR sensors have longer life, higher accuracy, and can withstand higher temperatures, vibrations and harsh environmental conditions, but the price Both are more expensive than Hall effect sensors. The choice of sensor type should consider the technical and cost requirements of the vehicle.
Position sensors are extremely important on certain construction machines, such as backhoe loaders, wheeled excavators, and mobile truck cranes. These machines use hydraulically operated legs to keep the machine stable and prevent it from tipping or tipping. Measuring the angle of the outrigger cylinder is critical to ensure safe operation.
Honeywell's intelligent position sensor uses non-contact magnetoresistive technology, which can be used in oily and harsh transportation places. It can be used in machinery such as backhoe loaders to maintain vehicle stability and ensure the safety of operators.
For applications in these situations, Honeywell combines MR technology with special integrated circuits to develop smart sensors that can provide a full range of 0 ~ 360 ° position measurement.
Honeywell said that smart sensors can not only ensure the safety of the outriggers, but also improve the digging accuracy. For example, accurately measuring the position of the loader or backhoe bucket can help the operator dig more accurately, eliminating multiple inspections and repeating the digging work. This can help less skilled operators improve efficiency, reduce machine wear, and thus complete work faster and reduce engine emissions.
In addition, smart sensors can be used in automatic excavation systems to increase productivity and make machine operation easier.
Honeywell said that when applying position sensors in cylinder control, several key technical parameters should be paid attention to, including sensor accuracy, sealing performance, and output type. In addition, the angle range to be measured should also be considered. For example, if the boom rotation angle range is 90 °, then a 180 ° measurement sensor is not required. The output range of the sensor is static, and an increase in the measurement angle range will cause a reduction in measurement resolution and accuracy.
Manufacturers can also consider using non-contact sensors to eliminate failures caused by mechanical connections and reduce downtime for replacing parts in the field. Although non-contact sensors are relatively expensive, they can reduce the overall installation cost and shorten the assembly time.
Another type of sensor used in mobile machinery is a pressure sensor. The pressure sensor can be used to indirectly measure the position of the oil in the fuel tank to ensure that there is sufficient lubricating oil, fuel and hydraulic oil to ensure safe operation. For example, when used in a hydraulic accumulator, a pressure sensor or pressure switch detects the pressure in the pipeline to determine whether there is a leak. In the cylinder control, the pressure sensor is combined with the intelligent position sensor by measuring the pressure in the cylinder to ensure that the vehicle is more stable and efficient.
Honeywell said that by optimizing the hydraulic system of mobile machinery through sensor technology, heavy construction machinery manufacturers and their suppliers can more effectively solve some key problems on the construction site, such as operator fatigue and skills, work safety and Requirements for accuracy, wear of equipment, downtime, reduced emissions and higher fuel efficiency.
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