Multi-parameter monitoring and intelligent early warning system and method for dry disc brake device of mine car

Abstract

The invention discloses a multi-parameter monitoring and intelligent early warning system and method for a mine car dry disc braking device. The system comprises a data processing module, and a high-temperature fiber grating sensor, a laser displacement sensor, a piezoelectric vibration sensor, an industrial camera and an early warning execution module which are in signal connection with the data processing module. The data processing module corrects and processes the acquired temperature signal, thickness signal, vibration frequency signal and surface image signal, judges the wear state of the current brake device according to the signal processing result, and judges whether to send an early warning signal to the early warning execution module or not according to the wear state; and the early warning execution module implements corresponding early warning action according to the early warning signal. According to the method, the problem of misjudgment caused by single parameter monitoring is effectively solved, and the fault recognition accuracy is remarkably improved through multi-dimensional data cross validation. Seamless connection from state monitoring to safety protection is achieved through a closed-loop control system. And the multi-sensor cooperative working mode can effectively ensure the detection precision.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle braking system monitoring, and in particular to a multi-parameter monitoring and intelligent warning system and method for a dry disc braking device of a mining truck. Background Art

[0002] In the heavy-load downhill working condition of a mining dump truck, the brake friction pads and brake discs bear huge loads, resulting in a fast wear rate and being prone to defects such as cracks and spalling due to high temperature or mechanical shock. The traditional manual detection method has problems such as low efficiency and inability to monitor in real time, and it is difficult to timely detect potential faults in the braking system. Most of the existing technologies adopt a single thickness monitoring method, lacking comprehensive consideration of temperature changes, vibration characteristics and surface defects, resulting in insufficient accuracy of fault judgment. Especially in high-temperature working conditions, the traditional measurement method is easily affected by thermal expansion, causing thickness measurement errors; at the same time, it is difficult to identify early micro-cracks on the brake disc by single-parameter monitoring, posing a safety hazard. In addition, the existing warning system lacks a hierarchical response mechanism and cannot take differential disposal measures according to the severity of the fault. These problems seriously affect the reliability and safety of the braking system of mining vehicles, and there is an urgent need to develop a solution that can realize multi-parameter collaborative monitoring, intelligent diagnosis and hierarchical warning. Summary of the Invention

[0003] In view of this, the present invention provides a multi-parameter monitoring and intelligent warning system for a dry disc braking device of a mining truck, which has the advantages of realizing multi-parameter collaborative monitoring, intelligent diagnosis and hierarchical warning, and improving the reliability and safety of the braking system.

[0004] To achieve the above object, the present invention provides the following technical solutions: A multi-parameter monitoring and intelligent warning system for a dry disc braking device of a mining truck, comprising: a data processing module and a high-temperature fiber Bragg grating sensor, a laser displacement sensor, a piezoelectric vibration sensor, an industrial camera and a warning execution module that are signal-connected thereto.

[0005] Among them, the high-temperature fiber Bragg grating sensor collects the surface temperature of the brake disc in real time, the laser displacement sensor measures the remaining thickness of the brake friction pad in real time, the piezoelectric vibration sensor collects the vibration frequency of the braking device in real time, the industrial camera collects the surface image of the brake disc, the data processing module corrects and processes the obtained temperature signal, thickness signal, vibration frequency signal and surface image signal, and judges the wear state of the current braking device according to the signal processing result, and at the same time judges whether to send a warning signal to the warning execution module according to the wear state, and the warning execution module performs corresponding warning actions according to the warning signal.

[0006] Preferably, the data processing module calculates the current vibration energy of the braking device based on the acquired vibration frequency signal. When the vibration energy of the braking device exceeds the vibration energy threshold preset inside the data processing module, the data processing module controls the industrial camera to turn on, enabling it to collect the surface image of the brake disc. The data processing module detects the surface cracks and defects of the current brake disc based on the acquired surface image information.

[0007] Preferably, when the ratio of the calculated vibration energy of the braking device to the vibration energy threshold is greater than or equal to 150%, the data processing module controls the industrial camera to turn on.

[0008] Preferably, the industrial camera uses a circularly polarized light source and combines with the YOLOv5 model to realize crack and defect recognition, with a detection sensitivity of 0.1 mm / pixel and a false alarm rate < 2%.

[0009] Preferably, a wear-temperature coupling prediction algorithm is integrated in the data processing module. The remaining life of the brake friction lining is calculated based on the real-time temperature, and the recommended maintenance time is displayed on the cab instrument interface. The calculation formula of the wear-temperature coupling prediction algorithm is: , where, t - remaining time; t - remaining time, h 当前 - current brake friction lining thickness, h 临界 - critical value of brake friction lining thickness, Δh / Δt - wear rate of brake friction lining.

[0010] Preferably, the laser displacement sensor measures a spot diameter ≤ 0.5 mm, and eliminates the thermal expansion error through the temperature-thickness expansion model. The calculation formula of the temperature-thickness expansion model is: , where, h 校正 - brake friction lining thickness after data correction, h 实测 - actually measured brake friction lining thickness, T - actually measured temperature, α - thermal expansion coefficient of friction lining material, T0 - reference temperature.

[0011] Preferably, two-level early warning plans are set in the early warning execution module. Among them, the first-level early warning plan is to send a maintenance reminder, and the second-level early warning plan is to lock the current braking system function and start the standby electric braking unit to decelerate and brake the whole vehicle until it stops completely.

[0012] Preferably, when the data processing module determines that any of the following conditions is met, it sends a first-level warning signal to the warning execution module: the thickness of the current brake friction pad is less than or equal to 30% of the original thickness, the temperature of the brake disc and the brake friction pad is greater than or equal to 280 °C, the crack length on the brake disc is greater than or equal to 3 mm, and the ratio of the vibration energy of the braking device to the vibration energy threshold is greater than or equal to 150%; when the data processing module determines that any of the following conditions is met, it sends a second-level warning signal to the warning execution module: the thickness of the current brake friction pad is less than or equal to 50% of the original thickness, the temperature of the brake disc and the brake friction pad is greater than or equal to 320 °C, the crack length on the brake disc is greater than or equal to 5 mm, and the ratio of the vibration energy of the braking device to the vibration energy threshold is greater than or equal to 300%.

[0013] The present invention also provides a multi-parameter monitoring and intelligent warning method for a dry disc braking device of a mine car, which is applied to the multi-parameter monitoring and intelligent warning system of the dry disc braking device of a mine car in the above embodiment, and includes: S1, synchronously collecting thickness, temperature, vibration and image data; S2, compensating for temperature drift of the thickness and performing wavelet denoising on the vibration signal; S3, if the vibration energy exceeds the limit, starting image review and calculating the damaged area; S4, generating a combined fault code according to the multi-parameter priority weight and executing the corresponding warning strategy.

[0014] Preferably, in step S4, the priority weight is temperature > damage > thickness. When any one of the parameters exceeds the first-level warning threshold, a second-level warning braking protection is triggered.

[0015] The beneficial effects of the present invention are as follows: Compared with the prior art, the present application effectively solves the problem of misjudgment caused by single-parameter monitoring, and significantly improves the fault recognition accuracy through multi-dimensional data cross-verification. The closed-loop control system realizes seamless connection from state monitoring to safety protection, avoiding the risk of complete failure of the braking system. The multi-sensor collaborative working mode can effectively ensure the detection accuracy while reducing the system power consumption through the trigger-based image acquisition strategy.

[0016] Additional aspects and advantages of the present invention will be given in part in the following description, become apparent in part from the following description, or be learned through the practice of the present invention. Description of the Drawings

[0017] Figure 1 is the layout diagram of the key components of the present invention; Figure 2 is the threshold judgment logic diagram of the present invention. Detailed Embodiments

[0018] Embodiments of the present invention will be described in detail below. Examples of the embodiments are shown in the accompanying drawings, where the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below by referring to the accompanying drawings are exemplary and are intended to explain the present invention, but should not be construed as limiting the present invention.

[0019] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, "a plurality of" means two or more unless otherwise specifically defined.

[0020] Reference will be made below Figure 1 and Figure 2 to describe the multi-parameter monitoring and intelligent warning system for the dry disc braking device of a mine car in the embodiments of the present invention.

[0021] A multi-parameter monitoring and intelligent warning system for the dry disc braking device of a mine car is disclosed in the embodiments of the present application, including: a data processing module and a high-temperature fiber Bragg grating sensor, a laser displacement sensor, a piezoelectric vibration sensor, an industrial camera, and a warning execution module that are signal-connected thereto.

[0022] Among them, the high-temperature fiber Bragg grating sensor collects the surface temperature of the brake disc in real time. During braking, the temperature of the brake disc is the same as that of the brake friction pad. Therefore, the temperature data collected by the high-temperature fiber Bragg grating sensor can synchronously reflect the temperature of the brake friction pad. The laser displacement sensor measures the remaining thickness of the brake friction pad in real time. The piezoelectric vibration sensor collects the vibration frequency of the braking device in real time. The industrial camera collects the surface image of the brake disc. The data processing module corrects and processes the obtained temperature signal, thickness signal, vibration frequency signal, and surface image signal, and judges the wear state of the current braking device according to the signal processing result. At the same time, it judges whether to send a warning signal to the warning execution module according to the wear state. The warning execution module performs corresponding warning actions according to the warning signal.

[0023] Among them, the high-temperature fiber Bragg grating sensor is a temperature detection device based on the fiber Bragg grating principle, whose temperature resistance performance can adapt to the instantaneous high-temperature working conditions of the brake disc, and accurate temperature data can be obtained through wavelength demodulation technology. The laser displacement sensor is a non-contact ranging device based on the laser triangulation method. The piezoelectric vibration sensor is a vibration detection device used to capture high-frequency mechanical impact signals during braking. The industrial camera is a vision detection device with high-speed image acquisition capabilities, which can be specifically implemented by using a global shutter CMOS sensor and a ring light source to ensure clear surface images can still be obtained under moving conditions. The data processing module is an operation unit integrating multi-source data fusion algorithms, which can complete the spatio-temporal alignment and feature extraction of sensor signals.

[0024] Specifically, the four types of sensors form a multi-dimensional perception network. The high-temperature fiber Bragg grating sensor continuously monitors the surface temperature change of the brake disc. The laser displacement sensor obtains the thickness data of the friction plate in real time and automatically compensates for the material thermal expansion effect. The piezoelectric vibration sensor captures the abnormal vibration frequency spectrum characteristics. When the vibration energy exceeds the preset threshold, the data processing module activates the industrial camera for image verification, and identifies the surface crack propagation situation through the feature matching algorithm. After the multi-dimensional data eliminates random errors through Kalman filtering, it is input into the wear state evaluation model to generate a comprehensive diagnosis result. The warning execution module triggers audible and visual alarms, remote communication, or brake system function switching in sequence according to the diagnosis result level, forming a closed-loop link from state perception to execution control.

[0025] Compared with the prior art, the traditional method only relies on the thickness sensor for threshold judgment and cannot distinguish between normal wear and abnormal thickness caused by high-temperature heat fade. This solution can accurately identify composite fault modes such as friction plate ablation and brake disc cracking through the collaborative analysis of temperature, vibration, and image parameters. The existing brake monitoring system lacks execution layer control, and this solution constructs a complete control chain from state detection to brake intervention.

[0026] Through the above technical solutions, this application effectively solves the misjudgment problem caused by single-parameter monitoring, and significantly improves the fault identification accuracy through multi-dimensional data cross-verification. The closed-loop control system realizes seamless connection from state monitoring to safety protection, avoiding the risk of complete failure of the brake system. The multi-sensor collaborative working mode can effectively ensure the detection accuracy, and reduces the system power consumption through the trigger-based image acquisition strategy.

[0027] In some embodiments, the data processing module calculates the current vibration energy of the braking device according to the obtained vibration frequency signal. When the vibration energy of the braking device exceeds the vibration energy threshold preset inside the data processing module, the data processing module controls the industrial camera to turn on to collect the surface image of the brake disc, and the data processing module detects the surface cracks and defects of the current brake disc according to the obtained surface image information.

[0028] Among them, the vibration energy is the total mechanical vibration energy value, and this parameter is used to characterize the impact state of the braking device. The vibration energy threshold refers to the preset judgment benchmark. Specifically, the energy baseline value of each frequency band can be set based on historical normal working condition data, which is used to distinguish normal friction vibration from abnormal vibration caused by defects. This threshold serves as the criterion for triggering image detection. The industrial camera activation control refers to the strategy of driving image acquisition based on the energy overrun event. Specifically, the camera power module can be triggered by a digital signal to start, realizing the detection mode of starting and stopping on demand. This mechanism avoids resource consumption caused by continuous operation. The surface crack detection refers to the defect recognition method based on image feature extraction. This detection is used to verify the authenticity of abnormal vibration.

[0029] Specifically, during the braking process, the piezoelectric vibration sensor continuously collects vibration signals. The data processing module corrects and processes the acquired vibration signals and calculates the vibration energy value. When the ratio of the vibration energy of the braking device calculated to the vibration energy threshold is greater than or equal to 150%, that is, when the vibration energy value exceeds 150% of the preset vibration energy threshold, it is determined that there is abnormal vibration. The data processing module activates the power supply circuit of the industrial camera, controls the industrial camera to turn on, and the industrial camera starts to capture the surface image of the brake disc. The data processing module inputs the collected image into the trained crack recognition model after preprocessing, and confirms whether there is an effective crack through feature comparison. This two-level detection mechanism of vibration triggering and image verification not only ensures the timeliness of crack detection but also reduces the occupancy rate of image processing resources through conditional triggering.

[0030] Through the above technical solutions, this application effectively solves the dual problems of resource waste and defect missed detection in traditional detection methods. The dynamic monitoring of vibration energy provides accurate triggering conditions for image detection, avoiding the acquisition and processing of invalid image data. The two-level detection mechanism significantly improves the recognition accuracy of crack defects through cross-verification of physical signals and visual information, while ensuring the high efficiency of system operation.

[0031] In a specific embodiment, the industrial camera uses a circularly polarized light source and combines with the YOLOv5 model to realize crack and defect recognition, and its detection sensitivity is 0.1 mm / pixel, and the false alarm rate < 2%. Among them, the circularly polarized light source is an illuminating device with a specific polarization direction arranged around the lens. Specifically, it can be realized by using a uniformly distributed LED array combined with a linear polarization filter, and the specular reflection interference is suppressed by adjusting the incident light angle and polarization direction. The YOLOv5 model refers to a deep learning algorithm based on a single-stage object detection architecture. Specifically, it can be realized by using pre-trained weights combined with transfer learning, and the small object detection ability is improved through multi-scale feature fusion and anchor box optimization.

[0032] Specifically, during the process of collecting the image of the brake disc surface, the circularly polarized light source adjusts the polarization angle by matching the reflection characteristics of the metal surface, effectively eliminating the masking phenomenon of the crack edge features by the high-light area. After the industrial camera synchronously triggers the image acquisition, the image is input into the YOLOv5 model trained with brake disc defect samples, and the convolutional neural network is used to automatically extract the morphological features and spatial distribution rules of the cracks. The output layer of the model filters the duplicate detection frames through the non-maximum suppression algorithm, and finally outputs the defect category and accurate coordinate information.

[0033] Through the above technical solution, the present application solves the technical problem of low recognition accuracy of surface cracks in a strong reflection environment, realizes the stable detection and reliable classification of brake disc defects, and provides accurate visual detection data support for the state evaluation of the braking device.

[0034] In some embodiments, a wear-temperature coupling prediction algorithm is integrated in the data processing module. The remaining life of the brake friction lining is calculated according to the real-time temperature, and the recommended maintenance time is displayed on the cab instrument interface. The calculation formula of the wear-temperature coupling prediction algorithm is: , where t is the remaining time, in h 当前 - the current thickness of the brake friction lining, in h 临界 - the critical value of the brake friction lining thickness, Δh / Δt is the wear rate of the brake friction lining.

[0035] Among them, the wear-temperature coupling prediction algorithm refers to a mathematical model that dynamically correlates the temperature variable with the wear rate. Specifically, the surface temperature data of the brake disc can be collected in real time by a high-temperature fiber Bragg grating sensor, and combined with the preset material thermal expansion coefficient and historical wear data, the wear rate parameter of the friction lining is dynamically corrected to achieve this. The remaining life calculation refers to predicting the remaining time required for the friction lining to reach the safe thickness threshold based on the difference between the current thickness and the critical thickness, combined with the wear rate corrected by temperature.

[0036] Specifically, the temperature data is collected in real time by the high-temperature fiber Bragg grating sensor and input into the data processing module; the wear rate parameter is dynamically adjusted according to the temperature change. For example, when the temperature rises, the thermal expansion of the friction lining material intensifies, resulting in an accelerated wear rate. At this time, the value of Δh∕Δt increases with the increase of temperature; the remaining time t is calculated by dividing the difference between the current thickness and the critical thickness by the adjusted wear rate, and the calculation result is transmitted to the cab instrument interface and displayed in the form of the recommended maintenance time.

[0037] Through the above technical solution, the present application solves the problem of error accumulation caused by traditional remaining life prediction methods ignoring the influence of temperature, realizes the dynamic and accurate calculation of the remaining life of the brake friction lining, avoids the risks of premature maintenance or delayed maintenance caused by prediction deviation, and at the same time displays the maintenance recommendation in real time through the cab interface, providing a clear basis for maintenance decision-making for the operator.

[0038] In some embodiments, the laser displacement sensor measures that the spot diameter ≤ 0.5 mm, and eliminates the thermal expansion error through the temperature-thickness expansion model. The calculation formula of the temperature-thickness expansion model is: , where h 校正 - The thickness of the brake friction lining after data correction, h 实测 - The actually measured thickness of the brake friction lining, T - the actually measured temperature, α - the thermal expansion coefficient of the friction lining material, T0 - the reference temperature.

[0039] Among them, the measured spot diameter is the size of the spot formed by the laser beam on the surface of the brake friction lining. By controlling the spot diameter, the interference of the thermal diffusion effect caused by high temperature on the thickness measurement can be reduced. The temperature-thickness expansion model is a thickness compensation algorithm established based on the physical law of material thermal expansion. Specifically, it can be implemented by multiplying the thermal expansion coefficient by the difference between the real-time temperature and the reference temperature as the compensation factor. Through this model, the material expansion amount caused by high temperature is deducted from the measured thickness. The reference temperature refers to the reference temperature of the friction lining in the non-thermally deformed state. Specifically, the calibration temperature under normal temperature conditions can be used as the reference value to provide a zero reference for thermal expansion calculation.

[0040] Specifically, under high-temperature working conditions, the thermal expansion of the friction lining will cause the measured thickness value to be inflated. By limiting the laser spot diameter, the spatial resolution of the thickness measurement can be improved, and the interference of the thermal diffusion area on the spot edge can be avoided. After obtaining the measured thickness, real-time correction is performed based on the temperature-thickness expansion model: substituting the thermal expansion coefficient of the friction lining material, the actually measured temperature of the sensor, and the preset reference temperature into the calculation formula to calculate the thickness inflation increment caused by thermal expansion, and then subtracting this inflation increment from the original measurement value to obtain the true thickness value. This correction process is completed by the data processing module within the data acquisition cycle to ensure the accuracy of the output thickness data.

[0041] Through the above technical solutions, the present application effectively solves the problem of thickness measurement distortion caused by material thermal expansion in a high-temperature environment, ensures the accuracy of the monitoring data of the wear state of the brake friction lining, and provides reliable data support for subsequent wear warning and life prediction.

[0042] In some embodiments, there are two levels of early warning plans in the early warning execution module. Among them, the first-level early warning plan is to send a maintenance prompt, and the second-level early warning plan is to lock the current braking system function and activate the standby electric braking unit to decelerate and brake the whole vehicle until it stops completely. Specifically, when the data processing module determines that any of the following conditions is met, it sends a first-level early warning signal to the early warning execution module: the thickness of the current brake friction plate is less than or equal to 30% of the original thickness, the temperature of the brake disc and the brake friction plate is greater than or equal to 280 °C, the crack length on the brake disc is greater than or equal to 3 mm, and the ratio of the vibration energy of the braking device to the vibration energy threshold is greater than or equal to 150%; when the data processing module determines that any of the following conditions is met, it sends a second-level early warning signal to the early warning execution module: the thickness of the current brake friction plate is less than or equal to 50% of the original thickness, the temperature of the brake disc and the brake friction plate is greater than or equal to 320 °C, the crack length on the brake disc is greater than or equal to 5 mm, and the ratio of the vibration energy of the braking device to the vibration energy threshold is greater than or equal to 300%.

[0043] Among them, the maintenance prompt refers to transmitting the maintenance requirements to the operator through acoustic and optical signals or wireless communication methods. Specifically, it can display alarm icons and text information on the cab instrument interface, or send a maintenance request to the remote monitoring platform through the vehicle-mounted wireless module to achieve a non-intrusive reminder function. Locking the current braking system function means cutting off the power supply of the hydraulic or pneumatic braking circuit through the electronic control unit to prevent the continued use of damaged braking components in case of failure. The standby electric braking unit refers to a redundant braking power source independent of the mechanical braking system, which generates braking torque through electric energy conversion when the mechanical braking fails.

[0044] During the operation of the system, each sensor continuously collects data on thickness, temperature, vibration, and surface images. After being fused and analyzed by the data processing module, they are compared with the preset threshold conditions in turn. When it is detected that any parameter reaches the first-level early warning threshold, for example, the temperature rises to 280 °C or the vibration energy ratio reaches 150%, the system preferentially triggers the first-level early warning signal. At this time, the early warning execution module only performs prompt operations; if the parameter further deteriorates to the second-level early warning threshold, for example, the temperature breaks through 320 °C or the crack expands to 5 mm, the data processing module immediately sends a higher-level control instruction to forcibly start the standby braking unit to implement deceleration. By setting the thresholds of different parameters to change in a gradient manner, the early warning response mechanism can dynamically adjust the intervention intensity according to the real-time working conditions, avoid false triggering caused by short-term fluctuations of a single parameter, and ensure that the early warning level is upgraded in time when multiple parameters deteriorate jointly.

[0045] Compared with the prior art, traditional methods mostly adopt fixed thresholds or single-parameter judgment logics. For example, only when the thickness of the brake friction plate drops to a fixed percentage is a warning triggered, which is prone to misjudgment due to temperature drift or sensor errors. In contrast, this solution establishes a threshold judgment system with multi-parameter coupling. For example, by simultaneously monitoring the correlation between the thickness decrease trend and the temperature increase rate, it can automatically activate the temperature compensation algorithm when the thickness measurement is abnormal due to material thermal expansion, eliminating the limitations of single-parameter judgment. In addition, the prior art lacks a hierarchical response mechanism and often directly performs the highest-level braking when an anomaly is detected. In this solution, by setting two levels of warning conditions, for example, only maintenance information is prompted in the first-level warning stage, and forced braking is only initiated when the parameters continue to deteriorate to the second-level threshold, the frequency of unnecessary braking interventions is significantly reduced.

[0046] Through the above technical solution, this application effectively solves the problem of warning delay in the scenario of multi-parameter coupling failure. For example, when the thickness of the friction plate has not reached the critical value but the temperature rises abnormally, the system can trigger a warning in a timely manner based on the temperature threshold, avoiding the missed judgment caused by traditional single-thickness monitoring. At the same time, by differentially setting the vibration energy ratio threshold, for example, image review is initiated when it reaches 150% and direct braking is performed when it reaches 300%, it not only reduces the resource consumption of image processing but also ensures the fast response ability under severe vibration conditions.

[0047] The present invention also proposes a multi-parameter monitoring and intelligent warning method for a dry disc braking device of a mining truck, which is applied to the multi-parameter monitoring and intelligent warning system for the dry disc braking device of a mining truck in the above embodiment, and includes: S1, synchronously collecting thickness, temperature, vibration, and image data; S2, performing temperature drift compensation on the thickness and wavelet noise reduction on the vibration signal; S3, if the vibration energy exceeds the limit, initiating image review and calculating the damaged area; S4, generating a joint fault code according to the multi-parameter priority weight and executing the corresponding warning strategy.

[0048] Among them, temperature drift compensation refers to correcting the thickness measurement value based on the material thermal expansion characteristics. Wavelet noise reduction refers to performing frequency-domain decomposition and reconstruction on the vibration signal using wavelet transform. Image review refers to performing secondary verification on the surface defects of the brake disc through machine vision. The priority weight is to set the parameter response order according to the degree of fault hazard. Specifically, a logical rule that temperature anomalies trigger warnings first can be adopted to ensure that high-risk faults are processed first.

[0049] Specifically, in the data acquisition stage, the synchronous trigger mechanism is used to ensure that the acquisition timestamps of thickness, temperature, vibration, and image data are consistent, avoiding data association failure caused by signal delay. In the data processing stage, temperature drift compensation dynamically corrects the laser thickness measurement results based on the coefficient of thermal expansion to ensure that the thickness measurement is not interfered by the temperature fluctuation of the brake disc. After wavelet denoising of the vibration signal, the vibration energy value is calculated to accurately capture the abnormal impact signal of the friction plate. When the vibration energy exceeds the preset threshold, the industrial camera immediately starts image acquisition, and combines with the crack recognition algorithm to calculate the actual damaged area, avoiding misjudgment by a single vibration parameter. In the decision execution stage, the joint fault code is generated based on the comprehensive evaluation results of temperature anomaly, crack propagation degree, and thickness loss. Among them, the temperature parameter has the highest priority. When the detected temperature exceeds the critical value, the highest-level braking protection is directly triggered.

[0050] Through the above technical solutions, this application solves the problems of response lag and false triggering caused by data singularity and static thresholds in traditional detection means. The multi-parameter coordination mechanism effectively suppresses the interference of factors such as high-temperature expansion and mechanical vibration on the measurement accuracy, and the dynamic priority rule ensures that high-risk working conditions such as high temperature and crack propagation are preferentially handled when multiple faults occur concurrently. The image review and joint fault code generation mechanism further reduces the false alarm rate, realizes the closed-loop control from data acquisition to braking intervention, and significantly improves the safety and reliability of the mine car braking system.

[0051] Further, in step S4, the priority weight is temperature > damage > thickness. When any one of the parameters exceeds the first-level warning threshold, the second-level warning braking protection is triggered. Specifically, during the operation of the braking device, the temperature sensor, crack detection module, and thickness sensor upload the monitoring data to the data processing module in real time. When the temperature parameter exceeds the first-level warning threshold while other parameters are within the normal range, the system determines that the temperature anomaly has the highest handling priority according to the preset priority rule. At this time, the second-level warning judgment condition is automatically skipped, and the second-level braking protection program is directly activated. After detecting that any parameter exceeds the level across the board, the data processing module immediately sends a second-level warning signal to the warning execution module without waiting for the status update of other parameters.

[0052] Through the above technical solutions, this application solves the problem of chaotic execution order of protection measures when multiple faults are coupled, ensuring that the braking protection is preferentially activated in case of emergencies such as sudden temperature rise. At the same time, it breaks through the limitation that multiple parameters in the traditional system must exceed the standard jointly, and can trigger the protection action in time when a single parameter shows extreme abnormality, effectively avoiding the risk of braking failure caused by asynchronous parameter detection.

[0053] Other components and operations of the mine car dry disc braking device multi-parameter monitoring and method according to the embodiments of the present invention are known to those of ordinary skill in the art and will not be described in detail here.

[0054] In the description of this specification, the descriptions referring to terms such as "one embodiment", "some embodiments", "examples", "specific examples", or "some examples", etc., mean that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. In addition, without contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples.

[0055] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the claims and their equivalents.

Claims

1. A multi-parameter monitoring and intelligent warning system for the dry disc braking device of a mine car, characterized in that, Including: A data processing module, a high-temperature fiber Bragg grating sensor, a laser displacement sensor, a piezoelectric vibration sensor, an industrial camera, and an early warning execution module that are signal-connected thereto; the high-temperature fiber Bragg grating sensor collects the surface temperature of the brake disc in real time, the laser displacement sensor measures the remaining thickness of the brake friction pad in real time, the piezoelectric vibration sensor collects the vibration frequency of the braking device in real time, the industrial camera collects the surface image of the brake disc, the data processing module corrects and processes the obtained temperature signal, thickness signal, vibration frequency signal, and surface image signal, judges the wear state of the current braking device according to the signal processing result, and simultaneously judges whether to send an early warning signal to the early warning execution module according to the wear state, and the early warning execution module implements corresponding early warning actions according to the early warning signal.

2. The multi-parameter monitoring and intelligent early warning system for the dry disc braking device of the mine car according to claim 1, wherein, The data processing module calculates the vibration energy of the current braking device according to the obtained vibration frequency signal. When the vibration energy of the braking device exceeds the vibration energy threshold preset inside the data processing module, the data processing module controls the industrial camera to turn on to collect the surface image of the brake disc, and the data processing module detects the surface cracks and defects of the current brake disc according to the obtained surface image information.

3. The multi-parameter monitoring and intelligent early warning system for the dry disc braking device of the mine car according to claim 2, wherein When the ratio of the calculated vibration energy of the braking device to the vibration energy threshold is greater than or equal to 150%, the data processing module controls the industrial camera to turn on.

4. The multi-parameter monitoring and intelligent early warning system for the dry disc braking device of a mine car according to claim 2, characterized in that The industrial camera uses a circularly polarized light source and combines with the YOLOv5 model to realize crack and defect recognition, with a detection sensitivity of 0.1 mm / pixel and a false alarm rate < 2%.

5. The multi-parameter monitoring and intelligent warning system for the dry disc braking device of a mine car according to claim 1, characterized in that, The data processing module integrates a wear-temperature coupling prediction algorithm, calculates the remaining life of the brake friction pad according to the real-time temperature, and displays the recommended maintenance time on the cab instrument interface; The calculation formula of the wear-temperature coupling prediction algorithm is as follows: , where t is the remaining time, in h 当前 is the current thickness of the brake friction lining, in h 临界 is the critical value of the brake friction lining thickness, and Δh / Δt is the wear rate of the brake friction lining.

6. The multi-parameter monitoring and intelligent early warning system for the dry disc braking device of the mine car according to claim 1, characterized in that, The laser displacement sensor measures a spot diameter ≤ 0.5 mm and eliminates the thermal expansion error through a temperature-thickness expansion model. The calculation formula of the temperature-thickness expansion model is: , where h 校正 - the thickness of the brake friction plate after data correction, h 实测 - the actually measured thickness of the brake friction plate, T - the actually measured temperature, α - the thermal expansion coefficient of the friction plate material, T0 - the reference temperature.

7. The multi-parameter monitoring and intelligent warning system for the dry disc braking device of a mine car according to claim 1, wherein The early warning execution module is provided with two levels of early warning plans. Among them, the first-level early warning plan is to send a maintenance reminder, and the second-level early warning plan is to lock the function of the current braking system and start the standby electric braking unit to decelerate and brake the whole vehicle until it stops completely.

8. The multi-parameter monitoring and intelligent warning system for the dry disc braking device of the mine car according to claim 7, characterized in that, When the data processing module judges that any of the following conditions is established, it sends a first-level early warning signal to the early warning execution module: the thickness of the current brake friction pad is less than or equal to 30% of the original thickness, the temperature of the brake disc and the brake friction pad is greater than or equal to 280 °C, the crack length on the brake disc is greater than or equal to 3 mm, and the ratio of the vibration energy of the braking device to the vibration energy threshold is greater than or equal to 150%; When the data processing module judges that any of the following conditions is established, it sends a second-level early warning signal to the early warning execution module: the thickness of the current brake friction pad is less than or equal to 50% of the original thickness, the temperature of the brake disc and the brake friction pad is greater than or equal to 320 °C, the crack length on the brake disc is greater than or equal to 5 mm, and the ratio of the vibration energy of the braking device to the vibration energy threshold is greater than or equal to 300%.

9. A multi-parameter monitoring and intelligent warning method for a dry disc braking device of a mine car, characterized in that, Applied to the multi-parameter monitoring and intelligent early warning system of the mine car dry disc braking device described in any one of the above claims 1-8, including: S1. Synchronously collect thickness, temperature, vibration, and image data; S2. Perform temperature drift compensation on the thickness and wavelet denoising on the vibration signal; S3. If the vibration energy exceeds the limit, start image review and calculate the damaged area; S4. Generate a combined fault code based on the multi-parameter priority weights and execute the corresponding warning strategy.

10. The multi-parameter monitoring and intelligent early warning method for the dry disc braking device of a mine car according to claim 9, characterized in that, In step S4, the priority weights are temperature > damage > thickness. When any one of the parameters exceeds the primary warning threshold, trigger the secondary warning braking protection.

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