Energy-saving Control Method for Aerial Work Platforms Based on Variable Speed and Variable Displacement Electro-hydraulic System under Different Working Conditions

doi:10.3969/j.issn.1004-132X.2026.05.017

Abstract

Abstract:

To address the issues of significant throttling losses at the main valves of the load-sensing system in electric aerial work platforms， a collaborative energy-saving control method for pumps and valves was proposed based on variable speed and variable displacement electro-hydraulic system under different operating conditions. This method combined electro-hydraulic system optimization with a new energy-saving control strategy to reduce throttling losses in the main valve assembly. In terms of electro-hydraulic system optimization， a dual-variable electro-hydraulic system with variable speed-variable displacement was designed， an electro-hydraulic proportional pump was adopted to replace the load-sensing pump， and the pressure compensating valve in the original load-sensing system was removed. In terms of control strategy， under single-action operating conditions， an underflow control strategy was adopted to further reduce throttling losses at the main valves. Under composite action conditions， based on the load mathematical model， a valve port pressure difference feedforward compensation algorithm was proposed， which achieved precise flow distribution for each action while ensuring the system operates at minimum throttling loss. Simulation and experimental results show that compared to the original load-sensing system， the proposed new system and energy-saving control method reduce throttling losses by 59%~85% under single-action conditions and by 10.7% under composite-action conditions， while keeping the flow coupling error in composite actions within 5%.

Key words: aerial work platform, dual-variable, pump-valve coordination, throttling loss

摘要：

针对电动高空作业平台负载敏感系统主阀处节流损失大的问题，提出了一种基于变转速变排量电液系统的分工况泵阀协同节能控制方法。该方法综合采用电液系统优化和新型节能控制策略以达到降低主阀组节流损失的目的。在电液系统优化方面，设计了一种变转速-变排量的双变量电液系统，采用电液比例泵取代负载敏感泵，并移除原负载敏感系统中的压力补偿阀。在控制策略方面，在单动作工况下采用欠流量控制策略以进一步降低主阀的节流损失；在复合动作工况下基于负载数学模型提出了阀口压差前馈补偿算法，在实现各动作流量精准分配的同时使系统在最小节流损失状态下工作。仿真和实验结果表明：相较于原负载敏感系统，采用所提出的新系统和节能控制方法时，单动作工况下系统的节流损失降低了59%~85%，复合动作工况下系统的节流损失降低了10.7%，且复合动作的流量耦合误差控制在5%以内。

关键词: 高空作业平台, 双变量, 泵阀协同, 节流损失

CLC Number:

TH137.51

LIU Yuchao, XI Yi, DAI Juchuan, SUN Yifan, ZHANG Yuxiao. Energy-saving Control Method for Aerial Work Platforms Based on Variable Speed and Variable Displacement Electro-hydraulic System under Different Working Conditions[J]. China Mechanical Engineering, 2026, 37(5): 1170-1182.

刘宇超, 习毅, 戴巨川, 孙依凡, 张宇效. 基于变转速变排量电液系统的高空作业平台分工况节能控制方法[J]. 中国机械工程, 2026, 37(5): 1170-1182.

Figures/Tables 26

Fig.1 Schematic of original load-sensing system

Fig.2 Architecture of dual-variable electro-hydraulic system

Fig.3 Workflow of condition-specific pump-valve coordinated control strategy

Fig.4 Graph showing the relationship between handle control current， valve opening and flow rate

Fig.5 Comparison chart of expected pump flow rate and valve flow rate curves

Fig.6 Mechanism sketch of aerial working platform

Fig.7 Thrust curve of main boom cylinder under different loads and different luffing angles

Fig. 8 Comparison diagram of calculated curves from load model and experimental curves for the main boom cylinder thrust

Fig.9 Hydraulic cylinder pressure test diagram

Fig.10 Schematic of jib arm mechanism

Fig.11 Comparison diagram of calculated curves from load model and experimental curves for the jib arm cylinder thrust

Fig.12 Load sensing system simulation model

Fig.13 Dual-variable system simulation model

Tab.1 Main simulation parameter table

仿真参数名称	数值
主臂变幅油缸缸径/mm	180
主臂变幅油缸杆径/mm	120
主臂变幅油缸行程/mm	2030
飞臂变幅油缸缸径/mm	63
飞臂变幅油缸杆径/mm	45
飞臂变幅油缸行程/mm	654
电机转速/（r·min $- 1$ ）	0~3600
负载敏感泵理论排量/（mL·r $- 1$ ）	28
电液比例泵理论排量/（mL·r $- 1$ ）	28

Tab.1 Main simulation parameter table

仿真参数名称	数值
主臂变幅油缸缸径/mm	180
主臂变幅油缸杆径/mm	120
主臂变幅油缸行程/mm	2030
飞臂变幅油缸缸径/mm	63
飞臂变幅油缸杆径/mm	45
飞臂变幅油缸行程/mm	654
电机转速/（r·min $- 1$ ）	0~3600
负载敏感泵理论排量/（mL·r $- 1$ ）	28
电液比例泵理论排量/（mL·r $- 1$ ）	28

Fig.14 Comparison diagram of simulation and experimental curves of pump outlet flow and pressure

Fig.15 Simulation curves of pump outlet flow and pressure

Fig.16 Simulation curves of pressure differential before and after main valve group and associated power loss

Fig.17 Schematic diagram of compound motion of main boom luffing-up and jib arm luffing-up

Fig. 18 Simulation data of compound motion of main boom luffing-up and jib arm luffing-up

Fig.19 Physical testing platform for the new system

Tab.2 Sensor model and performance parameters

名称

型号

输出信号

类型

测量范围

测量

精度

压力

传感器

流量

传感器

HTF/3403-15-C3.37

模拟电流

信号

0~40 MPa

±0.5%

Fig.20 Experimental data of jib arm luffing

Fig.21 Experimental data of workbar swing motion

Fig.22 Experimental data of main boom luffing

Fig.23 Experimental data of compound motion

Fig.24 Comparison diagram of throttling losses for each typical motion

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