CEB15控制器培训资料.doc

Excavator Control CEB-15/16 issue: 11.01.20目录Contents1. 系统总览System summarypage 31.1.CEB-15/16 系统元件System componentspage 3 1.2.电控箱和配线E-Box and wire harnesspage 31.3. 电控箱各管脚功能Functions of E-Box connector pinspage 42. 操作说明Operating description page 52.1.发动机转速测量Engine speed measurementpage 52.2.发动机转速调整Engine speed adjustmentpage 52.3.发动机燃油泵Engine actuatorpage 52.4.发动机转速调节Speed regulator (SR)page 62.5.发动机过载保护Anti stall control (GLR)page 72.6.标定功能Teach-In function page 82.7. 发动机特性自动漂移校正Automatic drift compensation of engine characteristicpage 82.8.发动机自动怠速功能Auto idle functionpage 82.9.精细模式Fine modepage 82.10.低怠速模式Mode function for low idle page 92.11.行走驱动功能Propel functionspage 92.12.暖机功能Warmup function page 102.13. 过热保护功能（发动机和液压油超温时）Overheating protection for engine and hydraulic oilpage 102.14.VD3电流机直流电机位置在没有转速信号时VD3-Current and DC motor position with no speed sensor signalpage 102.15.故障诊断Diagnosis page 112.16.挖掘机型号选择Excavator type selection page 113.系统参数System parameterpage 124. 样机调试Commissioning page 134.1.配线检查Wire harness checkpage 134.2.标定方法Teach-In handlingpage 144.3.标定中的常见问题Teach-In errors page 154.4.标定中断Interruption of Teach-In function page 15 4.5.液压系统设置检查Check of hydraulic settings for modepage 16附件Summary of enclosures (page 17.20)CEB15电控箱外形图Einbauzeichnung Baggersteuerung CEB-14/.,CEB-15/. 695 805 6719直流电机参数、安装图Einbauzeichnung und Kurzspezifikation VDO-Stellglied (2 sheets)408.422/001/014CEB15电控箱电路图Circuit diagram CEB-15/16 695 802 60481. 系统概要1. System summeryCEB15提供如下功能：The excavator control CEB-15/DCM offers the following system functions:-挖掘机作业时的过载保护 - Digital anti stall control for digging and propelling for LS hydraulic pumps.-通过电位计设定发动机转速和精细作业模式- Setting of speed and fine mode via potentiometers. -通过直流电机控制发动机转速- Engine speed control via DC motor (VDO) - 自动怠速功能-Auto idle function-自动测试存储发动机转速特性曲线- Automatic learning of engine speed characteristic (service function)-发动机转速漂移的自动补偿 -Automatic drift compensation of engine speed-暖机功能- Warmup function-过热保护功能- Overheating limitation of hydraulic oil and engine via temperature switches. - 故障诊断功能-Diagnosis via GLR lamp - 最多可存储16种挖掘机的系统参数-16 different parameter sets 1.1.CEB-15/16 系统构成1.1. CEB-15/16 System componentsComponent元件生产厂家supplier/responsible说明specification电控箱 E-box CEB-15/16electronic box CEB-15/16林德LINDE见图695 805 6719EZ 0 695 805 671925针插头由客户自购发动机转速传感器speed sensor 林德或康明斯LINDE or Cummins见图000 978 5000发动机油门驱动部件直流电机engine actuator VDO公司VDO见附件408.422/001/014 P插头由客户自购VD3比例减压阀VD3 valve林德LINDE林德主泵的一部分part of LINDE-pump发动机转速设定电位计speed potentiometer 林德或客户自购LINDE or CUSTOMER CEH-03/00 or equal三针插头由客户自购精细模式电位计mode potentiometer 林德或客户自购LINDE or CUSTOMERCEH-03/00 or equal三针插头由客户自购自动怠速功能启用开关enable switch auto idle客户自购CUSTOMER见图 695 802 6040自动怠速压力继电器pressure switch auto idle客户自购CUSTOMER见图 695 802 6040行走压力继电器pressure switch propel客户自购CUSTOMER见图 695 802 6040温度继电器Temperature switches客户自购CUSTOMER见图 695 802 6040GLR继电器和 GLR指示灯GLR relay and GLR lamp客户自购CUSTOMER见图 695 802 6040标定按钮和标定指示灯Teach-In button and Teach-In lamp客户自购CUSTOMER见图 695 802 60401.2. E-box 及配线1.2. E-Box and wire-harnessLinde挖掘机控制器CEB-15/16 集成在一个工程塑料盒中，通过一个25针插头与整个系统相联（插针具体说明见电路图695 802 6040）The LINDE excavator control CEB-15/16 is integrated into a plastic housing and is connected via a 25-pole automotive connector (see X1 in the circuit diagram 695 802 6040). 建议安装在驾驶室内，安装尺寸见图: 695 805 6719。防护等级：IP6K6K。We recommend to install the E-Box inside the drivers cab. Installing position and dimensions see EZ 695 805 6719. Protection class: IP6K6K, with plugged connector. 联接线必须有可靠的防护套以免被结构件磨损。插头、接线点必须保证联接可靠,采用有效的密封手段，避免潮湿和灰尘侵害接头部位和系统元件。请参照电路图695 802 6040中的相关说明。插头的相关资料和数量在电路图中亦有说明。The wire harness must be protected against chafing at the chassis. Good electrical connections for plugs and contacts must be secured. Penetration of moisture and dirt into connectors and system components are to be avoided. If necessary sealing is to be realised by customer. Please realise the EMC-Notes in the circuit diagram 695 802 6040. Information and order-numbers for the wire harness plugs are given in the circuit diagram. 1.3. CEB15/16各插针的功能（电路图中X1）1.3. Functions of E Box connector pins (X1)Pin No.系统功能System function电信号说明功能Electrical function注释Remarks1 电源正极+ UBattsupply input2030V，0.1A，没有PWM输出信号20.30V / 0,1A, without PWM output signals2过热温度开关over temp. switch开关量输入1)digital input 1)触点闭合 正常温度contact closed = normal temperature3标定按钮Teach-In button 开关量输入1)digital input 1) 闭合 开始标定，详情见4.2contact closed = active, more s. 4.24接收数据口RXD/ for service外部分析仪逻辑信号输入input ser. interface逻辑信号，与外部分析仪通讯。用于整机诊断维护TTL signal for service5挖掘机型号代码type coding开关量输入digital input 与电源正极间串有10k电阻，已装在E-box内10 kW pullup resistor at +UBatt, inside E Box6挖掘机型号代码type coding开关量输入digital input 与电源正极间串有10k电阻，已装在E-box内10 kW pullup resistor at +UBatt, inside E Box7挖掘机型号代码type coding开关量输入digital input 与电源正极间串有10k电阻，已装在E-box内10 kW pullup resistor at +UBatt, inside E Box8暖机功能开关warmup temp. switch开关量输入1)digital input 1)与电源正极间串有10k电阻，已装在E-box内10 kW pullup resistor at +UBatt, inside E Box9自动怠速功能启用开关autoidle enableswitch 开关量输入1)digital input闭合 启用自动怠速功能contact closed = enabledE-box 内部装有自恢复保险丝，本开关可以使用银触点。PTC Pullup at +UBatt inside E Box, compatibel with silver plated contacts, 10行走压力继电器pressure switch propel开关量输入1)digital input 1)闭合 挖掘机处于行走状态contact closed = propelling 11VD3比例电磁铁输入电源负极VD3 solenoid - 脉宽调制信号输出PWM output用于测量输入到VD3的电流Input for current measurement12 电源负极- UBatt,逻辑地analog ground13电源负极- UBatt, 电源地power ground14转速传感器speed sensor 频率信号输入frequency input测量范围：7007000Hz，最小电压幅度1V（有效值）frequency = 700.7000Hz, min. amplitude 1Veff15 自动怠速压力继电器pressure switch auto idle开关量输入1)digital input 1)闭合 挖掘机正在作业contact closed = working16 VD3比例电磁铁输入电源正极VD3 solenoid + 脉宽调制信号输出PWM output 短路保护熔断器不得大于0.75Amax. 0,75A / short circuit proof17直流电机角度电位计position poti模拟量输出analog input05V0.5 V18 转速电位计speed poti模拟量输出analog input05V0.5 V19标定指示灯Teach-In lamp开关量输出digital output灯亮 接地短路保护熔断器不得大于0.1AActive = closed to Ground max. 0,1A / short circuit proof20各电位计供电poti supply提供电压到各电位计supply output5 V / 10 mA21发送数据口TXD/ for service输出到外部分析仪output ser. interface逻辑信号，与外部分析仪通讯。用于整机诊断维护TXD: TTL signal for service22 精细模式电位计fine mode poti模拟量输入analog input05V0.5 V23 直流电机电源正极DC motor +PWM信号输出PWM output 短路保护熔断器不得大于1.5Amax. 1,5A / short circuit proof24 直流电机电源负极DC motor - PWM信号输出PWM output 短路保护熔断器不得大于1.5Amax. 1,5A / short circuit proof25故障指示灯GLR error output开关量输出digital output闭合到地 （灯不亮） 没有故障短路保护熔断器不得大于0.1Aclosed to Ground = no errormax. 0,1A / short circuit proof1) 针对金触点开关设计。E-Box内部在电源正极和该插针间串接了一个3.3k电阻。如改用银触点开关，建议增加一个额外的负载（如在电源正极和该插针之间加一个50mA的指示灯）1) this switching inputs are designed for switches with gold plated contacts. (Pull up resistor 3,3kW at +UBatt , inside the E Box). If switches with silver plated contacts are used an external load (e.g. lamp 50mA between +UBatt and the input pin) is recommended. 2. 性能描述 2. Operating description2.1.发动机转速测量2.1. Engine speed measurement 发动机转速测量建议使用电感式传感器，安装在发动机飞轮壳上。For engine speed measurement we suggest an inductive sensor mounted at the enginie flywheel.E-box适用的测量范围为7007000HzThe E Box can count pulses from 700 Hz.7000 Hz. 转速频率（Hz） 发动机转速 （ rpm ） x 飞轮齿数频率信号幅度 （ 接通E-box后）的有效值不得小于1 VSpeed frequency (Hz) = engine speed (1/min) * teeth of flywheel / 60Sensor amplitude: min. 1Veff (with plugged E Box)2.2. 发动机转速调整2.2. Engine speed adjustment可通过设定转速电位计调整发动机工作转速The engine idle speed can be adjusted with the speed potentiometer. 转速电位计0对应于发动机实际工作最低怠速，100对应于发动机实际工作最高怠速 0% = Min. regulated idle speed, 100% = Max. regulated idle speed.发动机最低怠速允许范围和最高怠速允许范围存储在电控箱中（系统参数），其值见第三节。在标定起始阶段需调整转速电位计0与100位置时对应的发动机怠速，使其分别落在允许范围内Min. and max. regulated idle speed are stored system parameters, values s. 3. 转速电位计对应的输出电压决定发动机的工作点。The poti voltage generates the setpoint for the engine speed regulator (SR), s. 2.4 and the anti stall control (GLR), s. 2.5.2.3. 发动机油门执行机构2.3. Engine actuator 直流电机（VDO公司生产）驱动燃油泵油门拉杆。直流电机的转角通过其内部的电位计反馈到CEB15/16，使电控箱得以控制其转角进而控制发动机的转速。直流电机的详细资料见附件408.422/001/014 PThe DC motor (VDO) actuates the injection pump lever. The DC motor angle is sensed by a potentiometer inside the DC motor housing. This poti gives a position feedback and enables the E Box to regulate the DC motor angle and also the idle speed. For detail information on the DC motor see VDO drawing 408.422/001/014 P. 直流电机与燃油泵油门拉杆间的机械联接结构必须是可调的，以保证直流电机的旋转角度(87,53)可完全应用到调整油门拉杆的摆角。建议在油门拉杆上安装一个弹簧以消除联接机构和直流电机减速箱的机械间隙。The mechanical linkage at injection pump lever must have the possibility to adjust the active DC motor angle (87,53) to the injection pump angle. We recommend to use a spring at the injektion pump lever tocompensate slack in the linkage and DC motor gear box. 直流电机与燃油泵油门拉杆间的连接机构及调整装置Linkage and adjustment between DC motor and injection pump20953010152535405060708090100位置（%)高怠速范围实际最大工作速度实际最小工作速度低怠速最大值低怠速最小值最小工作速度0,71200,2370,4751,1874,750,95 1,4251,6621,92,1372,3752,6122,853,0873,3253,5623,84,0374,2754,512电压 (V)允许最小斜率反馈电压范围低怠速范围反馈电压范围高怠速最大值高怠速最小值允许最大斜率最大工作速度标定速度线实际工作速度线857565554550直流电机和角度传感器（电位计）工作范围：Range definitions for DC motor and position poti:直流电机最大转角：1035DC motor max. angle range: 1035为防止直流电机终点限位装置损坏，限定其工作范围为87,55。同时限定其最大工作电流To prevent the DC motor stops from damage, a working angel range of 87,55 is used and the max.motor current is limited. 直流电机工作角度087,5对应于角度传感器（电位计）的位置信号为397%.The working angle 0.87,5 gives a position signal from 3.97%.87,50直流电机最大转角 DC motor angle range0直流电机工作转角DC motor working angle range103角度传感器信号 Pos. poti signal95%97%98% 100%5%0% 2% 角度传感器信号错误pos. Signal error角度传感器信号错误pos. signal error3%发动机实际可调整的转速范围 Speed range对应转速电位计 0 100燃油泵高怠速限位Injection pumpHigh idle stop燃油泵低怠速位置Injection pumpLow idle pos.在 标定过程中生成两个对应于发动机低怠速和高怠速的直流电机转动角度The Teach-In function generates two fix angle positions for low and high idle adjustment.低怠速调整： 5% 直流电机的最大转角 = 发动机调整低怠速 （对应0转速电位计位置）low idle adjustment: 5% of max. DC motor angle = low idle speed, 高怠速调整： 95% 直流电机的最大转角 = 燃油泵高怠速限位转速（对应100转速电位计位置）high idle adjustment: 95% of max. DC motor angle = injection pump stop for high idle 如果没有直流电机位置反馈（位置反馈信号失效），直流电机带动油门拉杆运转到其高怠速限位位置，E-box将限制直流电机的最大输入电流（约400mA），以避免损坏燃油泵或直流电机。In a case of no position feedback (position poti signal failted) the DC motor goes to the high idle stop of injection pump. The LINDE Box limits the DC motor current at the max. value (ca. 400mA) to avoid damage for the injection pump or DC motor stops. 如果E-box得到的角度电位计反馈信号 98 %（表明直流电机实际使用角度范围不当，过于偏向某一侧）,GLR指示灯将闪烁，见2.15。If the E Box gets a position signal 98 %, the GLR lamp blinks an error code, s. 2.15.直流电机输出角度与发动机转速间的关系在标定过程中将被自动记录在存储器中。见4.2。The characteristic between DC motor position and engine speed will be recorded automatically by the Teach-In function, s. 4.2.2.4. 发动机转速调节机构（SR）2.4. Speed regulator (SR)转速调节机构（SR）的工作点由转速电位计设定（见2.2）The setpoint for the speed regulator (SR) is generated by the speed poti (s. 2.2). 发动机实际转速由转速传感器测量The actual engine speed is measured by the speed sensor.- 在怠速状态（无负载），SR调节发动机转速到转速电位计设定点-In idle (unloaded) state the SR controls the idle speed to the poti selected setpoint. -当发动机带载时，若载荷过大使发动机转速无法维持在设定的工作点，SR指示直流电机转过一个固定的角度（由调节幅度中的SR部分确定），增大燃油泵供油量；其余的调节部分由过载保护功能GLR（见2.5）承担。*考虑到SR响应速度的问题，目前多数LSC系统仅单独使用GLR完成过载保护功能。-with the engine under load, the SR tries in vain the selected idle value. In this case the SR increases the fuel flow of the injection pump via DC motor to an fixed angle which is defined by the SR-part of p-grad. The rest of p-grad (GLR-part of p-grad) is the droop (s.2.5). 调节幅度 （设定怠速额定转速）/额定转速 x 100 p-grad = (idle speed - rated speed) / rated speed * 100% 在整个工作转速中调节幅度的大小需由系统参数来设定 （ 如8）The p-grad values for all workings speeds are necessary to define by the system parameter. 在带载情况下，SR和过载保护功能GLR（见2.5）共同作用，但SR作用稍后。整个调节过程需13秒，取决于系统稳定性。Under load conditions the SR and GLR (s. 2.5) are working together, but the SR is the slower one. The time for full reaction is 1.3s, depending of system stability. 根据柴油发动机工作原理，需首先降低载荷由GLR完成，因为载荷降低后发动机转速有所恢复，此时由SR承担的调节部分将减少The reason for this algorithm is to reduce the droop, because the speed increasment by SR will bereduced after unloading. 如果转速设定电位计在100位置，直流电机驱动燃油泵到最高怠速限位位置，以得到发动机最大输出功率。If speed poti = 100% the DC-motor goes to high idle stop of injection pump to get max. engine power.2.5. 过载保护功能（GLR）2.5. Anti stall control (GLR) 过载保护控制功能是CEB15/16的基本功能。它通过改变系统的Dp来避免发动机超负荷工作。GLR的设定工作点由选择的发动机工作怠速（见2.2）和系统参数“设定工作怠速GLR设定点GLR调节幅度(例如 50rpm) 计算得出。The anti stall control is the basic function of CEB-15/16. It should avoid overstraining of Engine engine by influencing the Dp. The GLR setpoint will be calculated from the selected idle speed (s. 2.2) and the system parameter difference between GLR setpoint and idle speed“ = GLR-part of p-grad (e.g. 50 rpm). 如果发动机实际工作转速低于GLR设定点，E-box将增加VD3的输入电流，降低系统Dp，进而降低液压系统功率消耗（主泵排量减小），减少发动机负荷。If the actual engine speed drops below the GLR setpoint the E-Box increase the current of the VD3-soleniod, this reduces the Dp of the hydraulic load sensing regulator and thus the hydraulic power consumption. By destroking the hydraulic pump the engine is relieved. VD3电比例减压阀特性曲线Characteristic of VD3-Valve 2.6. 标定功能2.6. Teach-In function标定功能记录了直流电机的转角（信号来自其内部的角度传感器）与发动机转速间的实际关系。The Teach-In function records the real relation between DC motor position and idle speed.在整机装配完成后，初次起动时或因维护保养发动机后造成其特性变化时必须进行标定。在标定开始时，需要人工调整发动机在直流电机指定工作范围内（87,55）的最高和最低怠速，使其落在系统参数允许的范围内。同时注意直流电机的实际使用角度范围是否均衡（2% 98%）。其余工作由系统自动完成。The function must be activated for start up and for service. At the begin of Teach-In there are two steps for checking and adjusting the engine speed at high or low idle. The rest of Teach-In function works automatically.按下标定按钮，标定开始。标定步骤和标定过程中出现的错误由标定指示灯指示。标定详细方法见4.2。The Teach-In function is initiated by pressing the Teach-In button. The Teach-In steps and -errors areindicated by the Teach-In lamp. Teach-In handling see 4.2.如果没有标定或标定不成功，GLR按照标准特性曲线工作。改变挖掘机型号代码将删除现有的特性曲线同时转用标准特性曲线。If Teach-In has not been initiated yet or has not been successful the GLR works at a standard characteristicwith higher droop. A change of excavator type coding deletes the recorded Teach-In characteristic and switches to the standard characteristic. 2.7. 发动机特性曲线漂移的自动补偿2.7. Automatic drift compensation of engine characteristic如果自动怠速压力继电器断开超过3秒（怠速状态），现有的特性曲线将被转速调节机构修正，目的是消除由于一些因素，如机械联接间隙以及和发动机老化和温度漂移带来的影响。修正过的特性曲线将被系统采用直到发动机关闭（下次发动机起动时仍用原先存储的特性曲线）。If the auto idle switch is open for more than 3s (idle state) the stored DC motor/speed charateristic will be corrected from the SR output signal. The correction will be stored in the E-Box till the next power down.Reasons for correcting the stored actuator characteristic are e.g. ageing and/or temperature drift in mechanical linkage and engine.2.8. 自动怠速功能2.8. Auto idle function闭合自动怠速功能启用开关，自动怠速功能将被启用。For auto idle function on the auto idle enable switch must be closed.此时如果自动怠速压力继电器断开（怠速状态）5秒钟（系统设定参数），发动机转速将被自动降低到设定值（系统设定参数）。在行驶工况下（行走压力继电器闭合），发动机转速将保持在转速电位计设定的转速值。If the auto idle pressure switch is open (idle state) the engine speed is reduced automatically after a rest time of 5s (system parameter). In propel condition (pressure switch propel = closed) the speed will stay or change to the poti selected speed value.2.9精细模式2.9. Fine Mode精细模式用于挖掘机需要较慢和准确动作的场合The Fine-Mode function is used for slow and accurate excavator movments. 精细模式的设定由精细模式电位计来完成The Fine Mode setting is made with the fine mode potentiometer. Dp Dp max = 26 bar Dp min= 8 bar精细模式电位计Fine-Mode Poti 90.100 % 0.10 % 标准的精细模式电位计设定： 0 最大Dp., 100% = 最小 DpStandard definition for Fine Mode: 0% poti = Max. Dp., 100% poti = Min. Dp也可通过对调电位计的插针设定成相反状态：0 最小Dp., 100% = 最大 Dp ，此时，标定过程中参数表中精细模式电位计的0和100也相反。For reverse definition (0% = Min. Dp, 100% = Max. Dp), reverse the poti supply pins.2.10. 低怠速模式2.10. Mode function for low idle这一功能用于挖掘机在低怠速下的简单动作，此时发动机运转平稳。This function is used for simple excavator movements at low idle, while the engine is running smoothly. Dp Dp max= 26 bar Dp low idle= 8 bar低怠速模式终点1000rpm1200rpm高怠速 high idle低怠速low idle 发动机转速 Engine Speed 如果转速电位计设定的转速低于低怠速模式起点（上图1200rpm，系统参数），系统将以低怠速模式运行，Dp被减小，与转速间的关系见上图。在低怠速模式终点（如1000rpm，系统参数），Dp最低降至Dp低怠速 。如果Dp已被精细模式电位计设定成较低值，在低怠速模式下系统自动选取两者中的较小值。This mode function starts Dp reduction if an idle speed below low spee