Typically, off-road construction machines are not equipped with suspensions at the wheel axles. This has led to alternative concepts that uses the working implement to mitigate the vibration transmitted to the cabin. The most common solutions are based on passive ride control (PRC) methods. A PRC usually requires a hydraulic accumulator and dissipating valves properly connected to the working hydraulics. In this way, the PRC is able to dissipate the fluid energy and damp the oscillations of the pressure inside the hydraulic actuators, with clear benefits on the machine vibration. This paper focuses instead on an active ride control (ARC) methodology, which controls the working hydraulic motion to counter-reach the machine vibrations, avoiding the use of an accumulator. The paper addresses the main challenge of designing the controller for the ARC for the reference case of a wheel loader. A high pass pressure filter control with pressure feedback is proposed for this application. The controller is first studied in a simulation model and then validated through experiments on a stock machine. The bandwidth limitation of the standard hydraulic system does not permit to achieve the same performance of a state-of-art PRC system considered as baseline. Notwithstanding, the experimental results on the proposed ARC shows significant improvements with respect to a case where no controller is used. Moreover, the proposed method could be applied with more effectiveness in hydraulic systems with higher dynamic response.

One of the most significant goals of earthmoving equipment is to maximize productivity during loading cycles. A real-time knowledge of the forces exchanged between the machine implement and the surrounding, that is, while digging, can be used in different ways to increase productivity. It can be used to determine the amount of material moved by the machine; or to find the optimal bucket trajectory; moreover, as input to traction control systems. This article presents an online force estimation algorithm able to predict vertical and horizontal forces exchanged between the front-loader and the surrounding environment, as well as the reaction forces through the implement itself. Taking the case of a 14-ton wheel loader as reference, this article illustrates the development of a simulation model for the analysis of the machine digging system, along with the instrumentation and testing of the proposed estimation algorithm. The model is divided into two sections describing, respectively, system kinematic and system dynamics. The kinematic model of the front-loader is compared against measurements, and results show an average error lower than 1%. The dynamic model predicts both hydraulic and dynamic features of the machine implement, achieving an accuracy on the payload mass within 2%–3%, even during dynamic conditions. The estimated pushing force reflects the expected behavior when tested for various pushing efforts and in different ground conditions. Eventually, the algorithm was tested on a complete loading cycle and the results show good consistency considering the measured front-loader trajectory and vehicle speed. The proposed model overcomes some drawbacks of the currently used technologies. For example, it allows for an online estimation of the bucket forces for any position of the implement. Although the results discussed in this article pertain to a specific reference machine, the proposed method can be extended to most wheel loaders equipped with standard digging equipment.

Cabin vibration in construction machines is a known issue affecting both comfort and safety of the operators, and it also induces losses in machine productivity. The solution offered in commercial machines, known as the passive ride control, has the drawbacks of limited performance on a wide range of operating conditions and component costs, which has motivated research toward “active” alternatives that utilize electro-hydraulic systems without additional components. Nonetheless, the nonlinearities and the dynamic response of these systems constraint the performance of such alternatives, when compared to the commercial solution and therefore, their diffusion on the market. To address the challenges mentioned above, this article proposes an alternative hydraulic system layout to perform the ride control function based on connecting the boom lift actuators of the front-end loader in differential mode. This article describes the development of two active control strategies for this new ride control system that utilizes pressure and acceleration information to suppress cabin oscillations and presents the experimental tests on a full-size wheel loader. The results show a similar capability for reducing the oscillations achieved by the commercial solution and the one proposed in this research. In certain scenarios, the proposed formulation offers up to 10% of further improvement in terms of cabin oscillation reduction.

This paper presents the formulation of a variable load sense control strategy suitable to achieve power savings in hydraulic systems using post-compensated load sensing (LS) hydraulic control architectures. Such architecture is typical in off-road construction machinery. The paper also describes the application of the proposed control strategy referred to as variable load sensing margin (VLM) on a full-size wheel loader. The paper first presents the rationale for the proposed strategy, showing how the state-of-the art LS architecture present in commercial machines has margin for lowering the throttling losses present at the control valves. A feedforward controller, derived from an empirical study on a reference vehicle, is used to control the flow to the front-end loader functions. Test results show improvements of the hydraulic power consumption up to 45%, based on the commanded speed of each front-end loader actuator. The paper also describes a gain scheduling pressure feedback control strategy which is used to allow controlling also functions that include priority. For the case of off-road vehicles this is typically the steering function. The experimental results show how good performances with an error in controlled velocity below 5%, is achieved when the front-end loader functions are used concurrently with the steering.