PERCUSSION DEVICE AND METHOD FOR CONTROLLING THE SAME

Abstract

A hydraulic percussion device and method of controlling a working cycle of a percussion piston is provided. A rock breaking machine includes a percussion device provided with a reciprocating piston executing a working cycle. The operation is controlled by means of a control unit generating control signals for independently operable feed and discharge valves of a hydraulic system. The position of the piston is detected by a sensing device.

Claims

1. A percussion device comprising: a frame and a piston arranged inside the frame and configured to perform a working cycle including reciprocating longitudinal movement of the piston in an impact direction and a return direction due to pressure of hydraulic fluid fed to first and second working pressure spaces of the percussion device; at least one sensing device arranged for detecting a position of the piston relative to the frame; at least one feed valve arranged for controlling feeding and at least one discharge valve arranged for controlling discharging of the hydraulic fluid of at least one of the first and second pressure spaces; and at least one control unit configured to control the feed valve and the discharge valve for executing the working cycle in response to sensing data received from the at least one sensing device and control parameters input to the control unit, wherein the feed and discharge valves are both controllable to a closed control state and to an open control state, the control unit being provided with at least one control cycle, wherein the mentioned feed and discharge valves are independently controllable, wherein the control cycle includes at least one overlap control feature, wherein the feed and discharge valves are simultaneously in the same control state, and wherein the overlap control feature is steplessly and independently controllable by control signals of the control unit.

2. The percussion device as claimed in claim 1, wherein the overlap control feature comprises: a positive overlap control feature, wherein the feed valve and the discharge valve are simultaneously closed; and a negative overlap control feature, wherein the feed valve and the discharge valve are simultaneously open.

3. The percussion device as claimed in claim 1, wherein the control unit is configured to open the feed valve and the discharge valve simultaneously and to produce a free flow of hydraulic fluid through the at least one of the first and second working pressure spaces, wherein alternating pressure of hydraulic fluid is implemented during the working cycle of the percussion device.

4. The percussion device as claimed in claim 1, wherein the control unit is configured to detect position of the piston at least in the impact direction and is configured to open the feed valve and the discharge valve and to keep them the feed valve and the discharge valve simultaneously open to prevent continuation of the working cycle of the percussion device in response to detection that the piston has exceeded in the impact direction a predetermined distance limit from an impact point designed for the percussion device.

5. The percussion device as claimed in claim 1, wherein the control unit is provided with sensing data on properties of the hydraulic fluid fed from a hydraulic system to the percussion device, wherein the control unit is provided with limit values for at least one property of the hydraulic fluid and wherein the control unit is configured to open the feed valve and the discharge valve and to keep the feed valve and the discharge valve simultaneously open to prevent continuation of the working cycle of the percussion device in response to detection that at least one of the properties of the hydraulic fluid exceeds the input limit values.

6. The percussion device as claimed in claim 1, wherein the control unit is provided with a hydraulic warm-up feature, wherein the control unit is configured to open the feed valve and the discharge valve and to keep the feed valve and the discharge valve simultaneously open to allow free flow of hydraulic fluid through at least one working pressure space to thereby transferring heat energy from the hydraulic fluid flow to the percussion device.

7. The percussion device as claimed in claim 1, wherein the control unit is provided with a blocking feature wherein the control unit is configured to close the feed valve and the discharge valve and to keep the feed valve and the discharge valve simultaneously closed to prevent flow of hydraulic fluid through the at least one controlled working pressure space.

8. The percussion device as claimed in claim 1, wherein the control unit is configured to detect magnitude of rebounds following a strike of the piston to a tool in response to detection data received from the at least one sensing device for detecting position of the piston; and the control unit is configured to adjust magnitude of the overlap control feature.

9. The percussion device as claimed in in claim 1, wherein the control unit includes a hydraulic short-circuit feature, wherein the control unit is configured to open the feed valve and the discharge valve and to keep the feed valve and the discharge valve simultaneously open at or close to a turning point of the working cycle of the piston where the piston movement turns from a return direction movement to an impact direction movement.

10. The percussion device as claimed in claim 1, wherein the control unit comprises a stopping feature wherein the control unit is configured to close the feed valve and the discharge valve and to keep the feed valve and the discharge valve simultaneously closed at or close to a dead point of the working cycle of the piston where the piston movement turns from a return direction movement to an impact direction movement.

11. The percussion device as claimed in claim 1, wherein the control unit is configured to direct substantially constant hydraulic fluid pressure to a first working pressure space for moving the piston in the return direction and is configured to feed and discharge hydraulic fluid pressure to and from the second working pressure space and to thereby control reciprocating movement of the piston during the work cycle.

12. The percussion device as claimed in claim 1, wherein the feed valve WO and the discharge valve are both directly electrically controlled and operable on/off valves.

13. The percussion device as claimed in claim 1, wherein the feed valve includes a main feed valve which is controlled by means of pressure signals received from a pilot feed valve, the discharge valve including a main discharge valve which is controlled by means of pressure signals received from a pilot discharge valve, and wherein the pilot feed valve and pilot discharge valve are controlled independently by the control unit.

14. A breaking hammer comprising a hydraulic percussion device in accordance with claim 1.

15. A rock drilling machine comprising a hydraulic percussion device in accordance with claim 1.

16. A method of controlling operation of a hydraulic percussion device, the method comprising: detecting position of the piston by means of at least one sensing device and providing at least one control unit with sensing data gathered by the sensing device; controlling at least one feed valve and at least one discharge valve under control of the control unit and controlling feeding and discharging of hydraulic fluid of at least one of a first and second pressure spaces of a percussion device for executing a working cycle of a piston in response to the received sensing data and control parameters input to the control unit, wherein the feed and discharge valves are both controlled to a closed control state and to an open control state during the work cycle; controlling the feed valve and the discharge valve independently relative to each other under control of the control unit during the work cycle; implementing in a control cycle of the mentioned valves at least one overlap control feature, wherein the feed and discharge valves are simultaneously in the same control state; and generating control signals in the control unit for controlling the feed and discharge valves steplessly and independently relative to each other in accordance with the overlap control feature.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0040] Some embodiments are described in more detail in the accompanying drawings, in which

[0041] FIG. 1 is a schematic side view of an excavator, which is provided with a breaking hammer;

[0042] FIG. 2 is a schematic view of a diagram showing some issues relating to the disclosed percussion device and its control features;

[0043] FIG. 3 is a schematic and sectional side view of a hydraulically operated percussion device of a rock breaking machine;

[0044] FIG. 4 is a schematic side view of part of a percussion piston and a sensing device configured to monitor its movements;

[0045] FIG. 5 is a schematic view of some features relating to a control system and control unit of a hydraulic rock breaking machine;

[0046] FIG. 6 is a schematic view of a diagram showing some control modes utilizing overlap control features;

[0047] FIG. 7 is a schematic view of a hydraulic percussion device provided with a pilot controlled valve system; and

[0048] FIG. 8 is a schematic view of a hydraulic rock drilling machine provided with a percussion device which is in accordance with the disclosed solution.

[0049] For the sake of clarity, the Figures show some embodiments of the disclosed solution in a simplified manner. In the Figures, like reference numerals identify like elements.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

[0050] FIG. 1 shows a breaking hammer 1 arranged on a free end of a boom 2 of a working machine 3, such as an excavator. Alternatively, the boom 2 may be arranged on any movable carriage or on a fixed platform of a crushing apparatus, for example. The breaking hammer 1, which is one type of a rock breaking machine, comprises a percussion device 4 for generating impact pulses. The breaking hammer 1 may be pressed by means of the boom 2 against material 5 to be broken and impacts may be simultaneously generated with the percussion device 4 to a tool 6 connected to the breaking hammer 1. The tool 6 transmits the impact pulses to the material 5 to be broken. The percussion device 4 is hydraulic, whereby it is connected to a hydraulic system of the working machine 2. The impact pulses are generated in the percussion device 4 by means of a percussion piston, that is moved back and forth in the impact direction A and return direction B under the influence of hydraulic fluid. Further, the breaking hammer 1 may comprise a protective casing 7, inside which the percussion device 4 may be located. The percussion device 4 may be in accordance with the solution disclosed in this document.

[0051] FIG. 2 discloses that a percussion piston 9 of a percussion device 4 of a hydraulic breaking device 1 is reciprocated in the impact direction A and return direction B in accordance with a working cycle WC. Movement and position of the piston 9 is detected by means of one or more sensing devices S or sensors. The working cycle WC is controlled by a control unit CU, which is configured to control one or more feed valves FV and one or more discharge valves DV. The feed valve and the discharge valve both comprise two control states: an open control state and a closed control state. The valves can be directly electrically operable valves, or alternatively, they may be pilot controlled valves, as will be disclosed later in FIGS. 3 and 7.

[0052] The control unit CU comprises one or more control cycles CC for controlling the valves FV and DV, and for generating needed control signals to change the control states of the valves. Since the valves FV and DV are controlled by the control unit CU and since their control is not restricted by physical limitations or connections, the valves FV and DV are independently controllable to any of their control state. Further, at least one of the control cycles CC of the control unit CU comprises at least one overlap control feature OC. The overlap control OC means that the valves FV and DV are in the same control states: FV open+DV open=negative overlap; and FV closed+DV closed=positive overlap. The control unit CU can select the desired overlap feature OC and can adjust in response to detected sensing data and input control principles.

[0053] The features disclosed in FIG. 2 can be implemented in different type of rock drilling machines as well.

[0054] FIG. 3 discloses a basic structure of a percussion device 4 of a rock breaking machine, such as a rock breaking hammer or a rock drilling machine. The percussion device 4 comprises a frame 8 inside which is a percussion piston 9 arranged to be moved in an impact direction A and return direction B. The piston 9 comprises a working collar 10 at its middle section. At the impact direction A side of the collar 10 there is a first working pressure space 11 and at a return direction B side there is a second working pressure space 12 inside which pressure of hydraulic fluid is controlled by means of a control unit CU. The working pressure spaces 11, 12 are separated from each other by means of a collar sealing element 13. A clearance 14 or annular gap surrounds the working collar 10 and this clearance 14 is sealed by the collar sealing element 13.

[0055] The piston 9 comprises a first working pressure surface 15 for moving the piston 9 in the return direction B, a second working pressure surface 16 for moving the piston 9 in the impact direction A. The control unit CU may alternate pressure in the second working pressure space 12 by connecting the second pressure space to a tank T or to a pressure source PS. The control unit CU may connect the first working pressure space 11 to the pressure source for the duration of the working cycle. Since effective area of the second working pressure surface 16 is larger than the one of the first working pressure surface 15, the piston moves in the impact direction A when high pressure is fed to the second working pressure space 12. Let it be mentioned that the control of the pressure flows, and the effective areas of the working pressure surfaces may be arranged and dimensioned also in other ways, as it is already mentioned above in this document.

[0056] The percussion piston 9 is supported to the frame 8 by means of a first piston bearing 17 and a second piston bearing 18. The first and second piston bearings 17, 18 are separate sleeve-like piston bearing elements 19, 20 which can be mounted axially inside a central through opening 21 of the frame 8. The first piston bearing element 19 provides support for the piston 9 at a lower end portion of the percussion device 4, and the second piston bearing element 20 provides support at the upper end portion. The piston bearing elements 19, 20 or bushings are provided with one or more hydraulic seals 22, 23 for sealing an inner opening diameter of the piston bearings elements 19, 20 to outer diameters of the piston 9. In addition to these seals and a sealing section, the piston bearing elements 19, 20 comprise bearing portions 24, 25 for providing slide bearing for the opposite end portions of the piston 9. The piston bearing elements 19, 20 may also comprise end cushion spaces 26, 27 forming closed pressure spaces with the working pressure surfaces 15, 16 if the piston exceeds its normal stroke lengths in the impact direction A and return direction B. As can be seen, the second working pressure space 12 may be defined between the piston 9 and the second piston bearing element 20. The bearing portion 25 of the second bearing element 20 may be provided with a dedicated lubrication channel 28 for providing lubrication from a lubrication source L for the slide bearing surfaces. Both piston bearing elements 19, 20 may comprise dedicated tank channels 29, 30 provided with throttling devices 31 and connected to the tank T.

[0057] The percussion piston 9 comprises an impact surface 32 facing towards the impact direction A and configured to strike a tool. A rear surface 33 of the piston 9 is facing towards the return direction B and is configured to move inside a gas space 34 of a direct acting pressure accumulator 35. At an end portion of a sealing section of the second piston element 20 there is a gas sealing element 36 for separating the bearing portion 25 and the gas space 34 fluid tightly from each other.

[0058] Position of the percussion piston 9 can be detected by means of a sensing device S. Gathered sensing data is transmitted to the control unit CU. The control unit CU may also receive sensing data from one or more detecting devices D which may be configured to detect properties of the hydraulic fluid, for example. An operator OP may communicate with the control unit CU via a user interface UI and may thereby input control parameters, control commands and updated computer programs to the control unit CU. The control unit CU is arranged to produce control commands for one or more feed valves FV and one or more discharge valves DV connected to the hydraulic system HS. In FIG. 3 the valves FV and DV are electrically operable control valves and are under direct control of the control unit CU. The valves FV and DV may be simple on/off-type valves. Since large volume flows of hydraulic fluid is typically controlled during the working cycle, it is possible to arrange two or more parallel feed valves FV and two or more parallel discharge valves DV for ensuring fast control measures.

[0059] FIG. 4 discloses a sensing device S which may comprise two sensing units S1 and S2. A first sensing unit S1 may be arranged to monitor a lower dead centre of a piston 9 and may comprise two sensing switches Sa and Sb, whereas a second sensing unit S2 may be arranged to monitor an upper dead centre of the piston and may comprise two sensing switches Sc and Sd. Alternatively, needed timing measures of the control cycle may be calculated in a control unit in response to sensing data received from lower switches Sa, Sb and upper switches Sc, Sd. Use of the simple sensing switches Sa-Sd is advantageous because of their small size, durability and low price, for example.

[0060] The piston 9 may be provided with a dedicated sensing collar 37 position of which is detected by means of the sensing device S.

[0061] FIG. 5 discloses some features relating to the disclosed control system. A control unit CU comprises one or more processors P, one or more memory devices M and one or more input and output devices 38. One or more control programs CP can be loaded to the control unit CU. The control program CP can be stored to the memory device M and can be processed in the processor P. The control unit CU can receive sensing data SD from the position sensing devices S and the detection devices D. Control parameters PA and different limit values LV can be also be input to the control unit CU.

[0062] FIG. 6 discloses a diagram wherein some possible use cases of the disclosed overlap control feature is listed. These control situations and use cases are already discussed above in this document.

[0063] FIG. 7 is a simplified presentation of an alternative to the direct controlled feed and discharge valve system presented in FIG. 3. In this embodiment a hydraulic system HS comprises a main feed valve MFV controlled by a pilot feed valve PFV, and correspondingly a main discharge valve MDV controlled by a pilot discharge valve PDV. The control unit CU generates electrical control for the pilot control valves PFV and PDV, which then provide hydraulic control signals for the main control valves MFV and MDV.

[0064] It may also be possible to combine the direct control system disclosed in FIG. 3 and the pilot control system disclosed in FIG. 7 and to thereby provide one valve with direct control and one valve with pilot control, in case it is desired for some reason.

[0065] FIG. 8 discloses a rock drilling unit 40 comprising a rock drilling machine 41 arranged movably on a feed beam 42. The rock drilling machine 41 comprises a hydraulic percussion device 4 for generating impact pulses which are transmitted by means of tool 6 to a rock surface. The tool 6 may comprises one or more drilling tubes or rods and a drill bit 43 at its distal end. A rotation device 44 is arranged to turn the tool 6 around its longitudinal axis. At a front end of a body 45 of the rock drilling machine 41 there may be a flushing housing 46 for feeding flushing fluid via the tool 6 to a drilled hole for removing drilling cuttings. The percussion device 4 is connected to a hydraulic system HS comprising control features and components disclosed in this document, and being controlled under control of at least one control unit CU. The control unit CU may communicate with a user interface UI, sensors S and detectors D, and provides required electrical control signals for control valves of the hydraulic system HS in a manner disclosed in this document.

[0066] Let it be mentioned that in FIG. 8 a top hammer type drilling machine is disclosed. However, the solution may be implemented also in DTH-type rock drilling machines wherein a percussion device is located at a drill bit side end of a tool.

[0067] The drawings and the related description are only intended to illustrate the idea of the invention. In its details, the invention may vary within the scope of the claims.