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PC300/350-7,8 CLSS system

This sub-materials is edited and changed for Latin


America Hands-on Training from the text of the training
center in Japan by E.Hama on Aug.28,2011.
Power Train

Note:
PC350-8 PC350-7 and -8 have
basically same power
train.
Self Pressure
Reducing valve is
mounted on the front
line.

2
What’s CLSS
C ・・・・Closed Center Spool is closed when neutral

L ・・・・Load LS pressure
, load pressure to move
S ・・・・Sensing actuators

S ・・・・System
(1)Pump swash plate angle control Saving energy

(2)Pressure compensation control Simultaneous operation

CLSS is the basic hydraulic control which is adopted from PC200-6 in 1993 for the first time in the
world. Now CLSS is widely employed not only on excavators but also bulldozers and wheel 3
loaders. Large excavators are equipped with OLSS, so called Open center type.
CLSS structure
Actuators Color rule for hydraulic pressures
Front pump : red
Rear pump : pink
LS circuit : green
Control valve servo input : orange

Merge-divider valve
(1)variable piston pump
Front and rear pumps in tandem
which discharge amount is controlled
by swash plate angle.
(2) servo piston
Swash plate angle is controlled by
the servo piston ,whose input
PC valve PC valve pressure is generated by PC and LS
valve reduced from Pump pressure.
(3)servo piston control

LS valve LS valve
1. PC valve(Power Constant)
Pump discharge amount is
controlled by Pump pressure and to
prevent engine stall.
2. LS valve(Load Sensing)
Pump discharge amount is
Servo
Front Rear controlled proportionally to lever
4
pump Servo pump
piston piston stroke
CLSS Pump Control Principle
Unload valve: when spools in neutral,
Pump oil flow drains to tank. And when
lever moves, the load pressure (PLS)
closes the unload valve with PLS.
Servo piston stays balanced with
pressures 5:3 because piston areas 3:5
( Red : Orange ).
LS valve : PP = PLS + spring force , or
ΔPLS differential pressure = PP – PLS
Pump flow is controlled to keep this
ΔPLS constant, or proportional oil flow to
lever stroke.
PC valve: Two springs make hydraulic
power control to prevent engine stall
decreasing pump flow when pressure
increased.
LS-EPC and PC-EPC decrease pump
flow rate when the current increases
from the controller.
5
Unload & Main relief valve function

Pump pressure and Load When cylinder rod hits the


When lever is free and spool is in
pressure (PLS) are different. stroke end, Pump pressure
neutral, Pump flow is blocked due
to CLOSED CENTER. Pump flow is When lever is operated and spool is and PLS are increasing till
drained through Unload vale at set moved. Pump oil flows into hydraulic Main relief pressure. Unload
pressure ( equivalent to the spring cylinder and start to move cylinder rod pressure is always kept with
force) so called “ Unload with the load pressure. The load Pump pressure + set
pressure” which depends on pressure, PLS is fed back to the pressure, so relieved oil is
models as listed in below table. spring side of Unload valve and it drained through Main relief
Meanwhile LS pressure is zero. closes with PLS + set pressure. valve.

6
LS valve principle
Pump flow controlled proportionally to lever stroke

LS valve controls Pump flow to keep ( PP – PLS ) constant such as 1.8MPa in case
of PC200-8. When ΔPLS is low, Pump flow is increased and when high, is
decreased. The spring force is equivalent to the LS differential setting pressure, or
which is generated by the spring force. (Setting pressure depends on models as below table.)
PC200, 300 and 400 series are equipped with LS-EPC valve. When the controller
increases current to LS-EPC valve, LS-EPC pressure is increased to decrease
ΔPLS setting pressure, or decrease Pump discharge.
(LS-EPC current is usually supplied about 0mA except all levers in neutral ,traveling Lo & Mi operation and
L mode selection)

7
LS valve Principle
Lever stroke = Pump flow

So as to keep ΔPLS= setting pressure constant, LS valve 8


controls Pump discharge amount.
PC valve Principle

When Pump pressure, PP is increased, PC vale decreases Pump flow


rate moving to RH against the two springs, 1 and 2.

In addition to the above mechanical control, when the current is


increased to PC-EPC, PC-EPC output pressure pushes the PC valve to
RH against the springs to decrease Pump flow.
This function enables 100% absorption of the engine power and
prevents engine stall. No current makes engine stalled due to 9
excessive load than the engine horsepower.
Pump-Engine control = Working modes
The red hyperbola curve shows the diesel
engine maximum horsepower setting to be
used in hydraulic system, or P X Q =
Cut-OFF constant =engine horsepower.

Command currents from Controller to PC-EPC


and LS-EPC reduce hydraulic absorption
horsepower and maximum pump flow rate. The
larger current, the less pump flow rate.
PC-EPC
Current The settings of engine speed and hydraulic
absorption horsepower are lowered at the same
time by Controller when working mode is
switched to E, B and L. LS-EPC controls simply
to reduce max. pump flow rate when L mode is
selected by increasing the command current.
Cut-OFF is made by PC-EPC when pressure
sensor detects high pressure near the max.
LS-EPC pressure setting increasing the command current.
Current

10
LS valve movement (1)
Min. direction as neutral or small lever stroke

The yellow piston (6) is pushed to LH side by PP,. The PP flows into the large end of 11
Servo.
LS valve movement (2)
Max. direction as Full lever

The smaller ΔPLS than 1.8MPa ( in case of PC200-8) and the spring (4) force pushes
the piston to RH side. The pressure in the large end of the Servo is drained to tank 12
through the PC valve. Then pump discharge amount increases.
LS valve movement (3)
Balanced

The piston(6) moves LH( to min. ) or RH( to max. ) whichever and pump flow changes.
When ΔPLS becomes the value, 1.8MPa in case of PC200-8, piston(6) returns to 13
Balanced position after Servo stays in certain position .
PC valve movement (1)
Max. direction when PP is low, large end to drain

14
PC valve movement (2)
Min. direction, when PP is high

When load becomes heavy


and pump pressure ( both of
front and rear ) is rising, spool
(3) is pushed to LH, port B
and C are connected.
PC valve output pressure to
the large end pushes Servo
piston until balanced position .
It’s value becomes 3/5 of
Pump pressure because area
ratio (Large end to Small
end ) is 5:3.
15
Main pump hydraulic pressure
pickup ports PC200-8

LS-EPC output pressure PC-EPC(F) output pressure

PC valve output pressure PC-EPC(R) output pressure


( Servo piston inlet pressure)
for Rear pump

LS pressure
for Front pump
Front pump pressure
LS pressure Rear pump pressure 16
for Rear pump
Control valve top side
PC350-8
LS Bypass valve
Unload valve Main relief valve for rear pump
for rear pump

LS slow return valves

17
Pressure Compensation
control Principle
Pressure compensation
valve is installed in the
outlet port, or after the
spool.
The higher LS pressure
(green) is introduced in
all pressure
compensation valves. In
lighter load (yellow) side,
this pressure chalks the
passage until ΔP
becoming same on both
sides.
These same ΔPs enable
proportional flow rate to
lever strokes free from
different loads and
assure simultaneous 18
movements.
Pressure Compensation valve
If not available

CLSS is of Parallel circuit, so


oil flows into lighter load side
more than heavier load side.
Simultaneous movements of
compound operation is very
difficult.

19
Pressure Compensation valve
starts to work

PLS of the heavier load side pushes LS Shuttle vale and flows into LS line. The LS pressure
(green) starts to chalk the lighter load side Pressure Compensation valve until same PLS in
the lighter load side to be balanced with the heavier one.
Finally ΔPs become same in the both sides, so oil flow rates can be controlled by the spool 20
strokes free from the different loads.
Pressure compensation –
lower than other line

When load pressure is


lower than other working
equipments, highest PLS
comes into Spring
chamber E and pushes
Piston(4) to RH until
passage B reaches same
PLS with the highest one.
So all moved spool have
same PP and PLS to
enable simultaneous and
compound operation.
Before

After 21
Pressure compensation –
inside shuttle valve

When holding pressure,


Port A is higher than the
spring chamber B
pressure.
The shuttle valve(3)
separates chamber A
and PLS line. Port A
pressure flows into the
spring chamber B to
prevent separation of
valve (2) and piston (4).
And valve(2) is closed
as a load check valve.

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Pressure compensation
–for Travel ,How to distinguish
Almost all pressure compensation valves
are not interchangeable except travel ones
or swing ones.
How to distinguish each others
Numbers of notches & grooves are
different

3 notches &
2 grooves for
bucket dump

4 notches &
2 grooves for
travel

Travel ports have no holding load pressure, the shuttle valve


23
is not adopted. Valve and piston are one piece from PC200-7.
Pressure compensation –
Area ratio A2/A1
Ratio=1.0
area by area
Ratio is over than 1.0 ;
less flow to actuator
Ratio is less than 1.0 ;
more flow to actuator

24
LS select valve

When compound operation of Boom Raise and Swing, starting up


pressure of swing is very high that makes Boom very slow. To prevent
from this, LS Select valve blocks the Swing LS pressure by Boom
Raise PPC pressure. 25
LS select valve & Hoses

From PPC
valve

LS Shuttle
valves

LS select valve

Boom raise
PPC Hose
26
Pressure compensation –
adjustable valve for attachment

Balance on Poppet

(1) Before opening the poppet(4) or when PP is low, the


(1) PP - Cp < F
pressure balance is as shown above formula. The Poppet is closed.
valve(1) is open slightly.
(2) PP - Cp > F
(2) When the poppet(4) is open, PP flows into a, g, c and Cp.
It makes bigger pressure difference on the valve (1) and
Poppet is open.
the valve(1) opens widely.
Adjusting the spring force by screw(6), compensation ratio for 27
attachment can be changed.
Merge-Divider valve OFF
PC200-8

The spool(3) is
pushed to RH side
by the spring(4) and
the spool(1) is
pushed to RH by the
spring(2).

Normally the Merge-


Divider valve is OFF and
main pumps flows, P1 and
P2 and all PLS are merged.

In case of PC200-7 merge-


divider valve , both spool (1) for
Main and spool (3) for LS are
switched together by one
ON/OFF solenoid valve . 28
Merge-Divider valve ON
PC200-8

When the Merge-Divider


solenoid valves are ON,
pilot pressure flows into
the spring chambers. The
both spools are pushed
to LH and all pressures
are divided except (A)
and (C), or 5 and 8 Front
pump LS lines.

29
Merge/Divide algorithm

Controlled by two
EPC valves.
Refer the text
“ PC200-8 saving
fuel consumption
30 “ in
detail.
Swing control function
PC200-8

※Note) When not only


Swing but also one or more
of Swing, Boom, Arm and
Bucket are operated, the
brake is released.

Swing lock switch

When 5 seconds after all levers return to neutral position or Controller receives OFF signal from all PPC
Pressure switches or sensors of Boom, Arm, Bucket and Swing, the swing parking brake is turned ON. Once
one or multiple levers are operated, Controller sends current to Swing Brake solenoid to release the parking
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brake. The algorithm PC200-8 is same as PC200-7 except the six PPC pressure sensors on PC200-8.
Swing Parking Brake ON/OFF
ON OFF

When the swing brake solenoid is turned OFF, the brake is engaged because pressure in Chamber(a) is drained
from Port (B)and Spring (1) pushes down Piston(7), Discs (5) and Plates(6) are engaged.
When the swing brake solenoid is turned ON, the brake is released because pressure from Self Pressure 32
Reducing valve is introduced to Chamber(a) and pushes up Spring (1). Discs (5) are separated from Plates(6).
Swing motor braking system
Swinging Braking

Braking system of Swing motor consists of 4 check valves and one relief valve. When swinging normally, oil
flows MA, high pressure to MB, low pressure opening and closing the check valve s as shown. When spool
is returned to Neutral, MB port pressure is raised because Motor is still turning with the inertia. The relief
valve is open with high pressure and MA port pressure is lowered due to lack of oil. The check ( Suction) 33
valve supplies oil from the drain line. This braking function makes Swing stopping.
Travel Junction valve ON/OFF
PC200-8
OFF ON

OFF: When traveling straightly, or STEERING signal is OFF, Travel Junction valve is OFF so as to connect LS
lines of LH and RH travel to assure straight travel, or no travel deviation.
ON: When steered, or STEERING signal is ON, Travel Junction valve is ON. Pilot pressure pushes Travel34
Junction spool to disconnect LH and RH travel LS lines. It assures good and sharp steering.
Travel Junction – STEERING signal ON/OFF
When straight travel When steered to LH

Straight travel gives same PPC pressure on both side of the spool (J) and it stays center without oil flow to the pressure
switch of STEERING signal. When one lever is stroked more than another one, PPC pressures become different, in this
case, RH Travel PPC pressure is higher than LH. The spool (J) is pushed to LH side and STEERING signal pressure 35
switch is turned ON. Travel junction / steering system algorithm is same for PC200-7 and 8.
Travel motor – min. angle

When Pump controller


sends current to
Travel speed solenoid,
Control pressure
applies to the spool
(9). Main pump oil
flows into the Piston
(15) to change the
swash plate angle to
Minimum.

In order to realize Hi-Mi-Lo speeds of traveling,


combination of Pump and Motor capacities is
changed. Minimum swash plate angle of Motor
36
is for Hi speed.
Boom hydraulic drift prevention(1)

The difference of diameters, d1 and d2 or the doughnut area (A) receives Load pressure, PLS and
it pushes Poppet (5) to LH. Oil flows into Boom cylinder and PLS loses some pressure due to the
passage resistance and the difference keeps Poppet open. 37
Boom hydraulic drift prevention(3)
When Boom lever is in LOWER position.

Boom LOWER PPC pressure pushes Pilot piston (2) and oil in the chamber (b) drains to tank
through Orifice (c) and it makes the pressure of chamber (b) lower than B. The pressure
difference opens Poppet (4) and Boom starts to lower by the oil flow from B , A and then to
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Tank.
PC200,300 and 400 -8

Arm Quick Return valve


Quick Return valve
is not open when
neutral or PPC
pressure below 13
Kg/cm2.

Quick Return valve


is open when PPC
pressure is higher
than 13 Kg/cm2, or
lever is moved
largely. Arm bottom
oil returns directly to
tank to make Arm
dumping much
faster than oil
returns fully through
Arm DUMP PPC pressure pushes the spool (1) to
spool.
drain oil of the spring chamber (b) and it makes 39
oil flow and pressure difference.
Arm Quick Return valve PC200-8

Arm Quick Return valve


Return hose
40

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