Intelligent brake and drum integrated cylinder

Abstract

An intelligent brake integrated drum includes a permanent magnetic drum, a brake mechanism, a hydraulic system, a monitoring device and a brake torque monitoring device, characterized in that the permanent magnetic drum and the brake mechanism share a fixed shaft to directly connect the brake mechanism, an outer tooth hollow shaft sleeve of the brake mechanism is sleeved on the fixed shaft to rotate and axially move with the permanent magnetic drum, a front end cover of the brake mechanism is fixedly connected with a shell-inner tooth ring, a shell-oil cylinder and a rear end cover of the brake mechanism, and the permanent magnetic drum realizes intelligent control of a wet friction brake permanent magnetic drum belt conveyor, especially a coal mine explosion-proof belt conveyor, long-time operation and safe braking through real-time monitoring of cooling oil temperature and pressure oil pressure and real-time monitoring of pressure size change of a disc spring.

Description

Technical Field

[0001] This invention relates to an integrated drive and braking device for a belt conveyor, specifically an intelligent integrated start-and-brake roller. Background Technology

[0002] Belt conveyors are widely used in bulk material conveying in industries such as coal, cement, and power generation, featuring continuous conveying, high efficiency, energy saving, and environmental friendliness. The drive, braking, and transmission drums are the core components of a belt conveyor. Traditional drive systems typically consist of a motor, soft starter, reducer, and coupling. During system installation, the user assembles individual components on-site. Some low-power drive systems (less than 90kW) integrate the motor, reducer, and drum using electric drums; however, for inclined conveying, separate braking or backstop devices must be considered. For applications requiring parking or deceleration braking, pushrod brakes are typically installed on the high-speed shaft, or disc brakes on the low-speed shaft, depending on system requirements. However, this approach cannot meet the requirements for continuous and reliable braking of downward-moving belt conveyors over extended periods.

[0003] The above methods have the following problems: 1. Poor performance of key products or components; long-term continuous braking of the conveyor results in high temperature rise, low efficiency of the braking device after overheating, poor safety and controllability, and a high risk of runaway accidents; to prevent sparks, the braking device uses materials such as asbestos, which leads to environmental pollution, rapid brake shoe wear, and the need for frequent adjustment and replacement. 2. The system is assembled from independent products or components, resulting in a complex system, dispersed layout, large size, and large footprint, limiting its installation and use in confined spaces such as underground coal mines. 3. The system is assembled from discrete components on-site, resulting in low assembly precision, high system vibration and noise, and affecting equipment lifespan. 4. Long transmission chain, low efficiency, and difficult maintenance and management. 5. Low system integration, lack of efficient integration of various components, resulting in a high failure rate and low system reliability. 6. Lack of effective monitoring of key state parameters such as system braking torque, braking displacement, and brake shoe wear; poor fault diagnosis capability; and low level of intelligence. Summary of the Invention

[0004] To address the aforementioned issues, this invention provides an intelligent integrated starting and braking roller, which integrates the functions of a drive motor, roller, and brake. It also solves the problem of the inability to brake inclined belt conveyors using permanent magnet rollers, and enables long-term safe braking of belt conveyors. Furthermore, it features high assembly precision, saves installation space, and reduces installation workload. The design incorporates comprehensive condition monitoring and fault diagnosis functions, providing big data support for intelligent development, making the system more reliable, intelligent, and easier to manage and maintain.

[0005] The objective of this invention is achieved as follows: An intelligent integrated starting and braking roller, comprising a permanent magnet roller, a braking mechanism, a hydraulic system and its monitoring device and braking torque monitoring device, characterized in that: the permanent magnet roller and the braking mechanism share a fixed shaft directly connected to the braking mechanism; the external toothed hollow shaft of the braking mechanism is sleeved on the fixed shaft and rotates and moves axially with the permanent magnet roller; the front end cover of the braking mechanism is fixedly connected to the housing-internal gear ring, the housing-cylinder, and the rear end cover of the braking mechanism; internal toothed friction plates are embedded on the external teeth of the external toothed hollow shaft, and external toothed friction plates are embedded on the internal teeth of the housing-internal gear ring; the internal toothed friction plates and the external toothed friction plates are interleaved and inserted together to form... A static and dynamic friction pair; the static and dynamic friction pair composed of the internal tooth friction plate group and the external tooth friction plate group is located in the brake cavity formed by the front cover of the brake mechanism, the housing-internal tooth ring, and the piston outer ring end face; the housing-cylinder contains a piston, the piston end face shape is formed by the outer ring end face, the inner ring end face and the groove between them, wherein the groove is inserted into the middle partition wall of the cylinder, and the piston inner ring end face extends into the cylinder cavity and drives the entire piston to move under the push of the pressurized oil; multiple blind holes are opened on the end face of the piston opposite to the rear cover of the brake mechanism, and disc springs are built into the blind holes. A guide rod is installed in the middle hole of the disc spring, and the outer end of the guide rod abuts against the adjusting screw mounted on the end cover of the brake mechanism. The adjusting screw is locked by an external adjusting nut.

[0006] The objective of this invention can also be achieved as follows: the hydraulic system includes a hydraulic station, a cooling oil system, and a pressure oil system; the cooling oil system, through the hydraulic station, supplies cooling oil from the cooling oil inlet of the brake into the gap between the friction pads in the brake chamber, thereby cooling the friction pads, and returns the cooling oil to the hydraulic station through the cooling oil outlet, preventing the friction pads from overheating and generating sparks during braking.

[0007] The pressure oil system, through the hydraulic station, fills the cylinder cavity with pressure oil via the oil circuit of the pressure oil system. Driven by the pressure oil, the piston reciprocates, realizing the pressing and releasing separation between the inner and outer friction plates of the braking mechanism.

[0008] The hydraulic system monitoring device includes a cooling oil temperature sensor installed on the cooling oil inlet or return channel to monitor the temperature of the cooling oil entering the brake chamber and adjust the oil supply flow rate in a timely manner according to the oil temperature change to ensure the cooling effect; and a pressure oil sensor installed on the pressure oil inlet channel to monitor the oil pressure change of the pressure oil entering the cylinder chamber and adjust the oil supply pressure in a timely manner according to the oil pressure change to ensure the braking effect.

[0009] The braking torque monitoring device includes a disc spring pressure sensor mounted on the outer end of the guide rod for real-time monitoring of changes in disc spring pressure. This sensor converts electrical signals into digital signals and displays the pressure values, calculating the braking torque value from the measured disc spring pressure. Based on this braking torque value, the setting torque of the assembly torque wrench is determined during the manufacturing and assembly of the braking mechanism. Furthermore, during operation, the disc spring pressure sensor monitors and analyzes the wear degree of the friction plates, predicting their remaining service life. When excessive wear of the friction plates leads to a significant drop in braking torque, the pressure value of the disc spring is adjusted and calibrated using an adjusting screw to ensure the necessary braking torque value.

[0010] This invention offers the following advantages: By real-time monitoring of cooling oil temperature and pressure, as well as changes in disc spring pressure, it achieves intelligent control of wet friction brake permanent magnet roller conveyors, especially for long-term operation and safe braking in explosion-proof environments like coal mines. It avoids overheating and sparking during braking. By designing and calculating the oil volume of the cooling system, it enables long-term, continuous, controllable, and safe braking of high-power conveyors, with braking times reaching and exceeding 180 seconds, representing a breakthrough and significant technological advancement in this field. Furthermore, the integrated design of the drive, braking, and intermediate connecting components saves installation space, improves assembly accuracy, and reduces installation workload. It also enhances condition monitoring and fault diagnosis functions, making the conveyor system more reliable, intelligent, and easier to manage and maintain. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of an intelligent starting and braking integrated drum structure according to the present invention;

[0012] Figure 2 This is a left view of an intelligent starting and braking integrated drum structure according to the present invention;

[0013] Figure 3 This is a partially enlarged view of an intelligent integrated starting and braking drum brake mechanism of the present invention;

[0014] Figure 4 This is a magnified view of a portion of the disc spring pressure sensor installation. Detailed Implementation

[0015] The present invention will be further described below with reference to specific embodiments, and the advantages and features of the present invention will become clearer as a result. However, these embodiments are merely exemplary and do not constitute any limitation on the scope of protection of the present invention. Those skilled in the art should understand that modifications or substitutions to the details and form of the technical solutions of the present invention can be made without departing from the scope of disclosure of the present invention, but such modifications and substitutions all fall within the scope of protection of the present invention.

[0016] The present invention describes an intelligent starting and braking integrated roller, such as... Figure 1-4 As shown, the system includes: support 1; pressure oil connector 2; cooling oil inlet 3; adjusting screw 4; cooling oil outlet 5; disc spring pressure sensor 6; rear end cover of the braking mechanism 7; housing-internal gear ring 8; drum skin 9; front end cover of the braking mechanism 10; external gear hollow shaft 11; fixed shaft 12; guide rod 13; piston 14; housing-cylinder 15; disc spring 16; internal gear friction plate assembly 17; external gear friction plate assembly 18; stator 19; external rotor 20; adjusting nut 21. Note: The hydraulic station, cooling oil inlet and return channels, pressure oil inlet channel, cooling oil temperature sensor, and pressure oil pressure sensor are not shown in the diagram.

[0017] An intelligent integrated starting and braking drum includes a permanent magnet drum, a braking mechanism, a hydraulic system and its monitoring devices, and a braking torque monitoring device. The braking mechanism operates in a normally closed manner, wherein the outer toothed hollow shaft 11 of the braking mechanism is mounted on the fixed shaft 12 of the permanent magnet motor and rotates with the permanent magnet drum; the front end cover 10 of the braking mechanism is fixedly connected to the housing-inner toothed ring 8, the housing-cylinder 15 and the rear end cover 7 of the braking mechanism; the inner toothed friction plate group 17 and the outer toothed friction plate group 18 are fitted onto the outer toothed hollow shaft 11 in an alternating manner, the inner toothed friction plate group 17 is embedded in the outer toothed hollow shaft 11, and the outer toothed friction plate 18 is embedded in the housing-inner toothed ring 8; the friction force between the inner toothed friction plate 17 and the outer toothed friction plate 18 is set and adjusted by the disc spring pressure, forming a compact integrated structure of the braking mechanism and the permanent magnet drum drive.

[0018] The internal and external tooth friction plates are pressed together and released by the piston. Part of the piston is inserted into the cylinder cavity, and the other part is inserted into the annular channel connecting the brake cavity to push the internal and external tooth friction plates to press together and release. The piston end face shape inside the housing-cylinder 15 is formed by the outer ring end face, the inner ring end face and the groove between them. The groove is inserted into the middle partition wall of the housing-cylinder. The inner ring end face of the piston extends into the cylinder cavity and drives the entire piston to move under the pressure of the oil. Twenty blind holes are opened on the end face of the piston opposite to the rear end cover 7 of the brake mechanism. Each blind hole has a disc spring 16 installed inside. A guide rod 13 is installed in the middle hole of the disc spring. The outer end of the guide rod abuts against the adjusting screw 4 installed on the rear end cover 7 of the brake mechanism. The adjusting screw 4 is locked by the external adjusting nut 21.

[0019] A disc spring pressure sensor is installed at the outer end of one of the guide rods 13 to monitor changes in the disc spring pressure in real time. This sensor converts electrical signals into digital signals and displays the pressure value, calculating the braking torque value from the measured pressure. Based on this braking torque value, the set torque of the assembly torque wrench is determined during the manufacturing and assembly of the braking mechanism. Furthermore, during operation, the wear degree of the friction plates is monitored and analyzed by the pressure sensor to predict their remaining service life. When excessive wear of the friction plates leads to a significant drop in braking torque, the disc spring pressure value is adjusted and calibrated using the adjusting screw to ensure the necessary braking torque value. The remaining pressure is adjusted using the torque wrench to maintain consistency.

[0020] When the conveyor is in a stationary braking state, the pressure oil is released and returned to the oil. Under the action of the disc spring, the piston 14 causes the inner tooth friction plate group 17 and the outer tooth friction plate group 18 to quickly press together. Since the outer tooth friction plate 18 is embedded in the housing-inner tooth ring 8, and the housing-inner tooth ring 8 is fixed together with the brake mechanism end cover 7 and the motor end cover 10 by screws, the inner and outer tooth friction plates of the brake mechanism are in a pressed state, realizing the parking brake of the conveyor.

[0021] Before startup, cooling oil is introduced, and during operation, overheating is monitored in real time: Cooling oil from the hydraulic station and cooling oil system is introduced into the gap between the inner and outer tooth friction plates in the brake chamber of the braking mechanism through the cooling oil inlet 3 to cool the friction plates. The cooling oil returns to the hydraulic station through the cooling oil outlet 5. Then, the pressure of the controlled pressure oil is slowly increased, the piston 14 compresses the disc spring 16, and the positive pressure between the inner and outer tooth friction plates 17 and 18 slowly decreases, gradually increasing the gap between the inner and outer tooth friction plates 17 and 18 until they are completely separated. The braking mechanism is released, and then the permanent magnet drum begins to rotate forward under electrical control, and the equipment operates normally. The cooling oil temperature is monitored in real time by a cooling oil temperature sensor, the oil volume of the cooling system is calculated, and the cooling oil pressure and flow rate are intelligently adjusted to ensure that the inner and outer tooth friction plate groups do not overheat, achieving long-term continuous and controllable safe braking. The braking time can reach and exceed 180 seconds, avoiding overheating and spark generation.

[0022] During normal shutdown, the permanent magnet drum gradually decreases in speed under electrical control until it approaches zero. This reduces the pressure of the hydraulic oil controlling the braking mechanism to zero, causing the disc spring to extend and push the piston to press against the friction pads of the braking mechanism, thus achieving parking brake operation. During this period, the power loss due to slippage is converted into heat, which is carried away by the circulating cooling oil between the friction pads.

[0023] When the machine decelerates and stops, the pressure oil of the control braking mechanism is released and returned to the oil. Under the action of the disc spring, the piston 14 reduces the gap between the inner tooth friction plate 17 and the outer tooth friction plate 18 to zero. Since the outer tooth friction plate 18 is embedded in the housing-inner tooth ring 8, and the housing-inner tooth ring 8 is fixed as a whole with the rear end cover 7 and the front end cover 10 of the braking mechanism, the braking force gradually increases and the speed of the permanent magnet drum gradually decreases, realizing intelligent and controllable braking.

[0024] The hydraulic station includes a cooling oil temperature sensor and a control oil pressure sensor. The cooling oil temperature sensor is installed on the cooling oil inlet or return channel to monitor the temperature of the cooling oil entering the wet brake. The control oil pressure sensor is installed on the control oil inlet channel to monitor the pressure changes of the brake pressure adjustment mechanism.

[0025] A disc spring pressure sensor 6 is installed at the outer end of the guide rod 13 connected to one of the disc springs 16 in the braking mechanism. This sensor monitors the pressure changes of the disc spring in real time. It converts electrical signals into digital signals and displays the pressure value, measuring the pressure of the disc spring 16 and calculating the braking torque. On one hand, this can be used to determine the set torque of the assembly torque wrench during brake manufacturing and assembly. On the other hand, when the friction pads wear excessively after long-term use, resulting in a decrease in braking torque, the braking torque can be accurately calibrated by adjusting the screw 4 and then detecting the pressure through the disc spring pressure sensor 6. This allows for analysis and judgment of the wear degree of the friction pads, and prediction of their remaining service life.

Claims

1. An intelligent integrated starting and braking drum, comprising a permanent magnet drum, a braking mechanism, a hydraulic system and its monitoring device and a braking torque monitoring device, characterized in that: The permanent magnet drum and the braking mechanism share a fixed shaft and are directly connected to the braking mechanism. The external toothed hollow shaft of the braking mechanism is sleeved on the fixed shaft and rotates and moves axially with the permanent magnet drum. The front end cover of the braking mechanism is fixedly connected to the housing-inner toothed ring, the housing-cylinder, and the rear end cover of the braking mechanism. An internal toothed friction plate set is embedded on the external teeth of the external toothed hollow shaft, and an external toothed friction plate set is embedded on the internal teeth of the housing-inner toothed ring. The internal toothed friction plate set and the external toothed friction plate set are interleaved to form a static and dynamic friction pair. The static and dynamic friction pair formed by the internal toothed friction plate set and the external toothed friction plate set is located in the braking cavity formed by the front end cover of the braking mechanism, the housing-inner toothed ring, and the piston outer ring end face. The internal and external tooth friction plates are pressed together and released by a piston. Part of the piston is inserted into the cylinder cavity, and the other part is inserted into the annular channel connecting the brake cavity to push the internal and external tooth friction plates to press together and release. The piston is installed inside the housing-cylinder. The piston end face is formed by the outer ring end face, the inner ring end face and the groove between them. The groove is inserted into the middle partition wall of the cylinder. The inner ring end face of the piston extends into the cylinder cavity and drives the entire piston to move under the pressure of the oil. There are multiple blind holes on the end face of the piston opposite to the rear end cover of the brake mechanism. The blind holes are equipped with disc springs. The guide rod is installed in the middle hole of the disc spring. The outer end of the guide rod abuts against the adjusting screw installed on the end cover of the brake mechanism. The adjusting screw is locked by the external adjusting nut. The hydraulic system monitoring device includes a cooling oil temperature sensor installed on the cooling oil inlet or return channel to monitor the temperature of the cooling oil entering the brake chamber and adjust the oil supply flow rate in a timely manner according to the oil temperature change to ensure the cooling effect; and a pressure oil sensor installed on the pressure oil inlet channel to monitor the oil pressure change of the pressure oil entering the cylinder chamber and adjust the oil supply pressure in a timely manner according to the oil pressure change to ensure the braking effect. The braking torque monitoring device includes a disc spring pressure sensor mounted on the outer end of the guide rod for real-time monitoring of changes in disc spring pressure. This sensor converts electrical signals into digital signals and displays the pressure values, calculating the braking torque value from the measured disc spring pressure. Based on this braking torque value, the setting torque of the assembly torque wrench is determined during the manufacturing and assembly of the braking mechanism. Furthermore, during operation, the disc spring pressure sensor monitors and analyzes the wear degree of the friction plates, predicting their remaining service life. When excessive wear of the friction plates leads to a significant drop in braking torque, the pressure value of the disc spring is adjusted and calibrated using an adjusting screw to ensure the necessary braking torque value.

2. The intelligent starting and braking integrated roller according to claim 1, characterized in that, The hydraulic system includes a hydraulic station, a cooling oil system, and a pressure oil system. The cooling oil system, through the hydraulic station, supplies cooling oil from the cooling oil inlet of the brake to the gap between the friction pads in the brake chamber, thereby cooling the friction pads. The oil is then returned to the hydraulic station through the cooling oil outlet to prevent the friction pads from overheating and generating sparks during braking.

3. The intelligent starting and braking integrated roller according to claim 2, characterized in that, The pressure oil system, through the hydraulic station, fills the cylinder cavity with pressure oil via the oil circuit of the pressure oil system. Driven by the pressure oil, the piston reciprocates, realizing the pressing and releasing separation between the inner and outer friction plates of the braking mechanism.

4. The intelligent starting and braking integrated roller according to claim 3, characterized in that, The braking torque monitoring device includes a disc spring pressure sensor mounted on the outer end of the guide rod for real-time monitoring of changes in disc spring pressure. This sensor converts electrical signals into digital signals and displays the pressure values, calculating the braking torque value from the measured disc spring pressure. Based on this braking torque value, the setting torque of the assembly torque wrench is determined during the manufacturing and assembly of the braking mechanism. Furthermore, during operation, the disc spring pressure sensor monitors and analyzes the wear degree of the friction plates, predicting their remaining service life. When excessive wear of the friction plates leads to a significant drop in braking torque, the pressure value of the disc spring is adjusted and calibrated using an adjusting screw to ensure the necessary braking torque value.

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