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1、LoadersOverviewBasic Concept A loader is a type of construction equipment (engineering vehicle) machinery that is primarily used to load material into another type of machinery (dump truck, conveyor belt, rail-car, etc.).Loaders are used mainly for uploading materials into trucks, laying pipe, clear
2、ing rubble, and digging. A loader is not the most efficient machine for digging as it cannot dig very deep below the level of its wheels, like a backhoe can. Their deep bucket can usually store about 3-6 cubic meters of earth. The front loaders bucket capacity is much bigger than a bucket capacity o
3、f a backhoe loader. Loaders are not classified as earthmoving machinery, as their primary purpose is other than earthmoving.Unlike most bulldozers, most loaders are wheeled and not tracked, although track loaders are common. They are successful where sharp edged materials in construction debris woul
4、d damage rubber wheels, or where the ground is soft and muddy. Wheels provide better mobility and speed and do not damage paved roads as much as tracks but provide less traction.Unlike standard tractors fitted with a front bucket, many large loaders do not use automotive steering mechanisms. Instead
5、, they steer by a hydraulically actuated pivot point set exactly between the front and rear axles. This is referred to as articulated steering and allows the front axle to be solid, allowing it to carry greater weight. Articulated steering provides better maneuverability for a given wheelbase. Since
6、 the front wheels and attachment rotate on the sameaxis, the operator is able to steer his load in an arc after positioning the machine, which can be useful. The loader assembly may be a removable attachment or permanently mounted. Often the bucket can be replaced with other devices or tools-for exa
7、mple, many can mount forks to lift heavy pallets or shipping containers, and a hydraulically-opening clamshell bucket allows a loader to act as a light dozer or scraper.In construction areas loaders are also used to transport building materials - such as bricks, pipe, metal bars, and digging tools -
8、 over short distances. Loaders are also used for snow removal, using their bucket or a snow basket, but usually using a snowplow attachment. They clear snow from streets, highways and parking lots. They sometimes load snow into dump trucks for transport.Front loaders gained popularity during the las
9、t two decades, especially in urban engineering projects and small earthmoving works. Many engineering vehicle manufacturers offer a wide range of loaders, the most notable are those of John Deere, Caterpillar, Case, Volvo, Komatsu and Liebherr.Hydro mechanical Transmission System1.engine；2. torque c
10、onverter；3. power shifting transmission box；4. front axle；5. Caliper disc brake；6. wheel；7. parking brake；8. rear axle；9. gear shift pump；10. steering pump；11. operational pump；12. wheel redactorTransmission System Arrangement1. engine；2. torque converter；3. power shift transmission box；4. rear fram
11、e；5. front frame；6. front axle；7. transmission shaft；8. rear axleTorque Converter1. flywheel；2、4、7、11、17、19. bearing；3. torque converter rotation housing；5. elastic plate；6. first turbine； 8. second turbine；9. stator；10. pump impeller；12. gear；13. stator shaft；14. second turbine shaft；15. first turb
12、ine shaft；16. spacer ring；18. one-way clutch gear；20. one-way clutch rollerPerformance CharacteristicHydro-mechanical Series Drive1. engine；2. piston pump；3. low speed piston motor；4.high peed piston motor；5. transfer caseHastate Power Train System1. Neutral-start parking brake lever；2. Track motors
13、；3. Hastate pumps hoses；4. Hydraulic oil cooler；5. Service brakes；6. hoses；7. Wet, multi-disc parking brakes；8. Double reduction planetary final drives；9. hydraulic filtersStandard Equipment Specifications4. Brakes：Service brakes: Hydraulically-actuated, wet disc brakes actuateon four wheels：Parking
14、 brake: Wet, multi-disc brake on transmission output shaft5. Steering System：Type：Articulated type, full-hydraulic power steering；Steering angle：40 each direction;Minimum turning radius at the center of outside tire 。7. Bucket Controls：The use of a PPC hydraulic control valve offers lighter operatin
15、g effort for the work equipment control levers. The reduction in the lever force and travel makes it easy to operate in the work envy- ornament.Control positions：Boom：Raise, hold, lower, and float；Bucket ：Roll back, hold, and dump8. Hydraulic System：Capacity (discharge flow) engine-rated rpm：Loader
16、pump；Steering pump；Pilot pump(Gear-type pumps)；Relief valve setting；Control valve：2-spool open center type；Hydraulic cylinders：Double-acting, piston；Hydraulic cycle time (rated load in bucket)：Raise，Dump，Lower (empty)，Total cycle time1. The round-back bucket design is stronger with no angled corners
17、. This configuration makes it easier to fill and dump improving productivity.2. The ROPS/FOPS structure protects and shields the operator.4. A safety system locks lift, tilt and drive systems when the operator leaves the seat, raises the seat bar, or turns off the ignition switch. The brakes are wet
18、-type multiple discs that require no maintenance.6. The rugged all-welded unitized frame is constructed of .375-inch gauge steel for years of productivity. Step bushings are placed in all key pivot areas to increase strength and reduce stress.7. A wider wheelbase provides for a smooth ride and more
19、balance for stability with heavier loads. A 9-inch ground clearance allows easy maneuverability through mud and other terrain.8. Hydraulic lines are protected within the loader arm.10. The advanced hydraulic system affords longer service intervals and comes with a sight glass for quick and easy flui
20、d level inspections.New Technology of Wheel LoaderIntroductionKomatsu-integrated design offers the best value, reliability, and versatility. Hydraulics, power train, frame, and all other major components are engineered by Komatsu. You get a machine whose components are designed to work together for
21、higher production, greater reliability, and more versatility. Komatsus highly productive, innovative technology, environmentally friendly machines built for the 21st century.Dual-Speed Hydraulic SystemKomatsus automatic dual-speed hydraulic system increases operational efficiency and productivity by
22、 matching the hydraulic demands to the work conditions.（1） Digging OperationsEngine power used to operate the switch pump is transferred to the transmission to provide increased rim pull when digging.（2） Lifting Operations The switch pump assists the loader pump to provide increased lifting speed an
23、d power when lifting and loading.Increased Reliability 1. Komatsu Components Komatsu manufactures the engine, torque converter, transmission, hydraulic units, and electrical parts on this wheel loader. Komatsu loaders are manufactured with an integrated production system under a strict quality contr
24、ol system.2. Flat Face-to-Face O-Ring Seals Flat face-to-face O-ring seals are used to securely seal all hydraulic hose connections and prevent oil leakage.3.Cylinder Buffer Rings Buffer rings are installed to the head-side of the all-hydraulic cylinders to lower the load on the rod seals, prolong c
25、ylinder life by 30% and maximize overall reliability.4. Wet multi-disc brakes and fully hydraulic braking system The wet disc service and parking brakes are fully sealed and adjustment-free to reduce contamination, wear and maintenance. Added reliability is designed into the braking system by the us
26、e of two independent hydraulic circuits providing hydraulic backup should one of the circuits fail. If the brake oil pressure drops, a warning lamp flashes and an alarm sounds intermittently. If the brake pressure continues to drop, the parking brake is automatically applied providing a double safet
27、y system.5. High-Rigidity Frames The front and rear frames along with the loader linkage have high rigidity to withstand repeated twisting and bending loads to the loader body and linkage. Both the upper and lower center pivot bearings use tapered roller bearings for increased durability.1.Kim G W,
28、Wang K W. Enhanced control performance of a piezo- electric-hydraulic pump actuator for automotive transmission shift control. Proc Inst Mech Eng Part D-J Automob Eng, 2010, 224(2): 161-174 2Yang H Y, Zhang B, Xu B. Development of axial piston pump/motor technology. Chin J Mech Eng, 2008, 44(10): 1-
29、8 3.Liu Y S, Wu D F, Long L, et al. Research on the port valve of a water hydraulic axial pump. Proc Inst Mech Eng Part E-J Process Mech Eng, 2009, 223(3): 155-166 4. Kim J H, Ahn H J, Kim K Y. High-efficiency design of a mixed-flow pump. Sci China Tech Sci, 2010, 53(1): 24-27 5.Lei T J. New Compila
30、tion of Hydraulic Engineering Manual. Beijing: Beijing Institute of Technology Press, 1998. 313-318 6.Lu Y X. Technical Handbook for Hydraulics and Pneumatics. Beijing: China Machine Press, 2002. 470-572 7.Wen D S, Gao J, Wang Z L, et al. Output torque of double-acting multi-pump and multi-motor. Ch
31、ina Mech Eng, 2010, 21(23): 2836-2838 装载机概述基本概念 装载机是一种主要用于向另一种机械（自卸车、输送皮带、铁路运输车辆等）“装载”物料的建设机械（工程车辆）设备。装载机主要用于向卡车装载物料，以及铺设管道、清理碎石和挖土等工作。作为挖土作业装载机不是最有效的机械，与挖掘机不同，装载机不适用于轮胎支承面以下较深处的挖掘作业。装载机的深底铲斗一般可装载36立方米的土壤。铲斗前置装载机的斗容量远大于挖掘装载机的斗容量。装载机不属于铲土运输机械，因其主要用途并非土方运输。尽管履带式装载机是普遍的，但与大多数推土机不同，大多数装载机是轮式的而并非履带式。履带式装
32、载机适用于棱角锐利的建筑材料会破坏橡胶轮胎的场合，或者在松软泥泞道路上的作业。轮式装载机具有良好的机动性和较高的工作速度，并且不像履带那样破坏铺装路面，但其所能提供的牵引力较小。与安装前置铲斗的标准拖拉机不同，许多大型装载机不使用汽车转向机构。取而代之，它们通过液压驱动的安装于前、后桥之间的转向铰接装置转向。这种转向称为“铰接转向”，它可使前桥固定，并使其承受更大的重量。对于一定的轴距铰接转向提供了较好的机动性。由于前轮与工作装置绕同一车轴旋转，驾驶员在使机械定位后可使铲斗沿弧线“转向”，这一点是实用的。装载机的工作装置可以是更换式的或者是固定安装。铲斗常常可用其它装置或工具更换，例如，许多装
33、载机可以安装叉车工装提升重型货物或者装运集装箱，装备液压开启式“蛤壳”型铲斗可以使装载机像推土机或铲运机一样作业。在各种建筑工地上装载机也经常用来近距离转运建筑材料，例如砖块、管材、钢筋、各种挖掘工具等。借助铲斗或除雪铲，装载机也用于除雪作业，但通常使用除雪装置。它们用来清除街道、公路和停车场上的积雪。有时用装载机将积雪装载到自卸车上进行运输。近20年来，特别是在城市建设工程和小型土方运输工程中，装载机获得了普遍的应用。许多工程车辆制造商可生产多种类型的装载机，其中最知名的有约翰迪尔、卡特彼勒、凯斯、沃尔沃、小松和利勃海尔等品牌。 液力机械传动系统1.发动机；2.液力变矩器；3.动力换档变速箱
34、；4. 前桥；5. 钳盘式制动器；6. 车轮；7.驻车制动器；8.后桥；9. 变速油泵；10. 转向油泵；11. 工作油泵；12.轮边减速器 传动系统布置1.发动机；2.液力变矩器；3. 动力换档变速箱；4.后机架；5.前机架；6.前桥；7.传动轴；8. 后桥 液力变矩器1.飞轮；2、4、7、11、17、19.轴承；3. 变矩器旋转壳体；5. 弹性板；6. 第一涡轮； 8. 第二涡轮；9.导轮；10. 泵轮；12. 齿轮；13. 导轮轴；14. 第二涡轮轴；15.s第一涡轮轴；16. 隔离环；18. 单向离合器齿轮；20. 单向离合器滚柱工作特性液压机械组合传动1.发动机；2. 柱塞液压泵；3
35、.低速柱塞马达；4.高速柱塞马达；5.分动箱静液传动系统1.空档启动停车制动手柄；2.履带驱动马达；3. 液压泵；4. 液压油冷却器；5.行车制动器；6. 液压软管；7. 湿式、多片停车制动器；8. 双级行星减速最终驱动装置；9.液压滤清器标准装置规格类型与性能参数 1.制动器：行车制动器：液压驱动，四车轮湿式盘式制动；驻车制动器：变速箱输出轴湿式多片制动 2.转向系:铰接式，全液压动力转向；3. 铲斗控制：应用液压程序控制阀使工作装置操纵杆操作轻便。操纵杆作用力和行程的减小使工作装置的操作变得容易。4.液压系统：发动机额定转速容量（流量）：装载机液压泵；转向泵； 引导泵（齿轮泵）；安全阀设定
36、压力；控制阀：双阀芯开式中心型；液压缸：双作用，活塞；液压循环时间：提升时间，倾卸时间，下降时间，总循环时间尺寸规格1. 圆弧底铲斗设计更加坚固，没有死角。这种结构使铲斗更加容易装载和倾卸物料，从而提高了生产率。2. 防倾翻/防落物驾驶室结构保护了驾驶员的安全。3. 当驾驶员离开座椅、提起座椅横杆或者关闭启动开关时，安全系统将锁定提升、倾翻和驱动系统。4. 全焊接整体车架由0.375英寸工具钢建造，坚固耐用，满足长期生产能力要求。重要枢轴均采用阶梯衬套，以便增加强度和减小应力。5.较宽的轴距保证了平稳行驶，重载作业更加稳定。6.液压管路设置于装载机动臂内部受到保护。7.先进的液压系统可提供较长
37、的工作时间，并配置了玻璃液面计，以便于检查液压油面高度。轮式装载机新技术简介小松集成设计可获得最大的价值、最高的可靠性与多功能性。液压系统、传动装置、机架等主要部件均由小松制造。机械部件通过设计使其共同协调工作，以获得更大的生产能力、更高的可靠性和更多的功能。小松的高生产率、技术创新与环境友好型机械产品为21世纪而制造。双速液压系统 小松自动双速液压系统通过使液压需求与工况相匹配提高了作业效率和生产率。（1） 铲装作业 铲装作业时，用来驱动转换泵的发动机功率输入变速箱以增加铲掘力。（2） 提升作业提升装载作业时，转换泵辅助装载机主泵以增加提升速度和功率。提高可靠性1. 小松部件该轮式装载机上小
38、松制造了发动机、变矩器、液压装置和电器元件。小松装载机制造采用了严格质量控制下的集成生产系统。2. 扁平面对面O型圈密封 对所有液压软管连接采用扁平面对面O型圈进行安全密封，以防液压油泄露。3. 液压缸缓冲密封圈缓冲密封圈安装在全液压油缸的头部以降低推杆密封载荷，可延长液压缸寿命30%并使总可靠性最大。4. 湿式多片制动器与全液压制动系统行车与停车湿式盘式制动器完全密封并无需调节，从而减少了污染、磨损和维护。在制动系统中采用两个独立液压回路，作为当某一液压回路发生故障时的贮备，从而增加了系统的可靠性。当制动压力降低时，报警灯闪烁，报警器间歇鸣叫。如果制动压力持续降低，停车制动器将自动启动，形成
39、双安全系统。5. 大刚度车架前、后车架及装载机铰接机构具有较大的刚度，以抵抗重复扭转与弯曲载荷对装载机机身和铰接机构的作用。上、下中心枢轴轴承均采用圆锥滚子轴承以提高寿命。1。 金姆G W,王建民KW加强控制性能的压电式电液泵致动器的自动变速器换挡控制。 Proc瞬时D-J Automob Mech Eng部分Eng,2010(2):161 - 1742杨H Y,张B,徐B .发展轴向柱塞泵/电机技术。 下巴J Mech Eng,2008,26(10):1 - 83。 刘Y年代,吴D F,长L,王佛松。研究在该端口阀门的水液压轴泵。 Proc瞬时E-J Mech Eng部分过程Mech Eng,2009(3):155 - 1664。 金姆J H,Ahn H J,金K y高效混流泵的设计。 Sci中国科技Sci,2010年,53(1):24 - 27日5。 Lei T j .新编译的液压工程手册。 北京:北京理工大学出版社,1998年。 313 - 3186。 Lu Y x为液压与气动技术手册。 北京:中国机器出版社,2002年。 470 - 5727。 温家宝D年代,高J,王建民Z L,王佛松。输出转矩的双multi-pump及多机。 中国制造Eng,2010,21(3):2836 - 2838
