A real-time monitoring method for the braking force of a disc brake device

Abstract

The present invention belongs to the technical field of drilling equipment, and in particular relates to a method for real-time monitoring of the braking force of a disc brake device. The method comprises: obtaining the theoretical friction force of the friction surface of the disc brake device at each temperature based on the mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient and the braking pressure; obtaining the average working friction force of the friction surface of the disc brake device at each temperature under actual working conditions; calculating the ratio of the working average friction force to the theoretical friction force at each temperature to obtain a material friction coefficient correction factor; and obtaining the real-time braking force of the disc brake device based on the material friction coefficient correction factor and the mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient. The present invention only needs to determine the current temperature and the disc brake material to quickly obtain the magnitude of the real-time braking force. Compared with traditional methods, the calculation process is more in line with actual working conditions, and the calculation results are more instructive.

Description

Technical Field

[0001] The invention belongs to the technical field of drilling equipment, and in particular relates to a real-time monitoring method for the braking force of a disc brake device. Background Art

[0002] The winch is the load-lifting equipment used in drilling operations and is a core, critical piece of equipment on the drilling platform. The safe operation of the winch is crucial for both operations and personnel. Disc brakes are a crucial component of the winch. Currently, hydraulic disc brakes are primarily used in drilling operations. These brakes consist of a brake actuator, a hydraulic station, and an operating console. The brake actuator consists of a brake caliper, a caliper frame, and a brake disc. A failure in the hydraulic disc brake can compromise the safe operation of the drilling rig. During operation, the disc brake converts the kinetic energy of the drum into heat through braking force, achieving the desired braking effect. This process involves a complex thermo-mechanical coupling. Frictional heat raises the temperature of the brake caliper, affecting its physical properties, primarily the material's friction coefficient. Frictional heat also creates a temperature gradient. This uneven heating can cause thermal deformation at the contact surface between the brake disc and the caliper, leading to variations in braking force. Furthermore, wear on the caliper can also affect braking force. Real-time monitoring of disc brake braking force is crucial for mitigating drilling risks and ensuring safe and reliable operations.

[0003] Existing technologies mostly use thermo-solid coupling simulation for monitoring and do not consider the impact of temperature increase and deformation of the friction contact surface on the friction coefficient. This assumption does not conform to actual operating conditions. At the same time, thermo-solid coupling simulation monitoring cannot quickly obtain the current real-time braking force. Summary of the Invention

[0004] The present invention provides a real-time monitoring method for the braking force of a disc brake device, which solves at least one problem existing in the prior art.

[0005] The technical solution of the present invention is as follows: A method for real-time monitoring of the braking force of a disc brake device, comprising:

[0006] Obtaining the theoretical friction force of the friction surface of the disc brake device at each temperature based on a mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient and the braking pressure, wherein the braking pressure is the pressure applied to the disc brake friction surface;

[0007] Obtaining the average friction force of the friction surface of the disc brake device at each temperature under actual working conditions;

[0008] Calculate the ratio of the average friction force under the working condition to the theoretical friction force at each temperature to obtain a correction factor for the material friction coefficient;

[0009] The real-time braking force of the disc brake device is obtained according to the material friction coefficient correction factor and the mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient.

[0010] Furthermore, obtaining the theoretical friction force of the friction surface of the disc brake device at each temperature based on the mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient and the braking pressure includes:

[0011] Obtain the mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient;

[0012] A material friction coefficient curve is formed according to the mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient;

[0013] The theoretical friction force of the friction surface of the disc brake device at each temperature is calculated based on the material friction coefficient curve and the braking pressure.

[0014] Furthermore, obtaining the mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient includes:

[0015] Based on experimental tests on multiple groups of material friction coefficients of the friction surface of the disc brake device at different temperatures, a mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient is formed.

[0016] Furthermore, obtaining the average friction force of the friction surface of the disc brake device under actual working conditions at each disc brake friction surface temperature includes:

[0017] The actual working condition of the disc brake device is simulated according to the simulation data to obtain the working condition average friction force of the friction surface of the disc brake device at each temperature. The simulation data are the initial working condition and performance parameters of the disc brake device.

[0018] Furthermore, the actual working condition of the disc brake device is simulated according to the simulation data, including:

[0019] The simulation data is input into a thermo-solid coupling simulation software to simulate the actual working condition of the disc brake device, wherein the thermo-solid coupling simulation software can output the average friction force of the friction surface of the disc brake device at each temperature.

[0020] Furthermore, the simulation data includes initial temperature, material friction coefficient at the initial temperature, rotation speed, braking pressure, Young's modulus and temperature rise.

[0021] Furthermore, the method for real-time monitoring of the braking force of a disc brake device further includes, after the step of obtaining the material friction coefficient correction factor:

[0022] The actual working condition friction force of the friction surface of the disc brake device at each temperature under actual working conditions is collected, and the material friction coefficient correction factor is corrected according to the error between the actual working condition friction force and the working condition average friction force.

[0023] Furthermore, the method of obtaining the real-time braking force of the disc brake device according to the material friction coefficient correction factor and the mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient includes:

[0024] Calculate a corrected friction coefficient based on the material friction coefficient correction factor and the material friction coefficient;

[0025] Obtain the initial temperature, temperature rise and brake pressure of the disc brake device;

[0026] Performing curve fitting on the corrected friction coefficient, initial temperature and temperature rise to obtain a corrected friction coefficient curve;

[0027] determining a corrected friction coefficient corresponding to the current temperature according to the corrected friction coefficient curve;

[0028] The real-time braking force is calculated based on the corrected friction coefficient and brake pressure corresponding to the current temperature.

[0029] Furthermore, the ratio of the working condition average friction force to the theoretical friction force is calculated at each temperature to obtain the material friction coefficient correction factor, including:

[0030] Calculate the ratio of the average friction force under the working condition to the theoretical friction force at each temperature;

[0031] The ratio is fitted with a linear method using the least squares method to obtain a correction factor for the material friction coefficient.

[0032] The present invention provides the following beneficial effects: The present invention obtains the material friction coefficient under different temperature conditions through experimental testing, and then obtains the real-time friction force under actual operating conditions (i.e., taking into account the influence of deformation) through experiments or simulations. The correction factor is determined by the ratio of the real-time friction force to the material friction force, thereby obtaining the real-time correction factor and determining the real-time braking force at any temperature. The present invention only needs to determine the current temperature and the disc brake material to quickly determine the real-time braking force. Compared to traditional methods, the calculation process is more consistent with actual operating conditions, and the results are more instructive. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 Flowchart of the present invention.

[0034] Figure 2 Schematic diagram of the material friction coefficient curve in the present invention.

[0035] Figure 3 This is one of the friction cloud maps generated by the thermo-solid coupling simulation software in the present invention.

[0036] Figure 4 This is the second friction cloud map generated by the thermo-solid coupling simulation software in the present invention.

[0037] Figure 5 This is a graph showing the modified friction coefficient in the present invention. DETAILED DESCRIPTION

[0038] In order to enable those skilled in the art to better understand the solutions of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. The described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of the present invention.

[0039] In an embodiment of the present invention, Figure 1 Flowchart provided by the method for real-time monitoring of the braking force of a disc brake device according to the present invention. Figure 1 As shown, the present invention includes:

[0040] S1: Obtaining a theoretical friction force of the friction surface of the disc brake device at each temperature based on a mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient and a braking pressure, wherein the braking pressure is the pressure applied to the disc brake friction surface.

[0041] Conventional solutions generally don't consider the effect of temperature on the material friction coefficient of the disc brake friction surface. However, the present invention's solution first requires consideration of the relationship between the material friction coefficient and temperature of the disc brake friction surface. To achieve this, a mapping relationship between the temperature and material friction coefficient of the disc brake friction surface is required. This mapping relationship can be determined by experimentally testing the material friction coefficient of the disc brake friction surface at multiple different temperatures to establish a mapping relationship between the temperature and material friction coefficient of the disc brake friction surface. The specific mapping relationship can be a table of corresponding temperatures and material friction coefficients, or corresponding point values ​​within a coordinate system. Multiple experiments can be performed to ensure more accurate data.

[0042] The material friction coefficient curve is formed based on the mapping relationship between the temperature of the friction surface of the disc brake and the material friction coefficient. Among them, the formation of the material friction coefficient curve can be carried out by curve fitting. The present invention obtains multiple sets of relationship points between temperature and material friction coefficient through experimental testing. The more the number, the closer the fitting curve is to the actual situation. The number of point values ​​obtained by the test is not limited in this patent. In this method, a continuous change curve of temperature and material friction coefficient is obtained by polynomial fitting, such as Figure 2As shown in the figure, this curve is the material friction coefficient curve, which can quickly find the material friction coefficient under different temperature conditions.

[0043] The theoretical friction force of the friction surface of the disc brake device at each temperature is calculated based on the material friction coefficient curve and the braking pressure.

[0044] The obtained material friction coefficient curve allows for quick lookup of the material friction coefficient at any temperature. The theoretical friction force is obtained by multiplying the material friction coefficient by the brake pressure, which is the pressure applied to the disc brake's friction surface and is detected by the disc brake's sensor. This theoretical friction force is ideal, accounting only for the effect of temperature on the material friction coefficient and ignoring disc brake deformation caused by temperature.

[0045] S2: Obtaining the average friction force of the friction surface of the disc brake device at each temperature under actual working conditions.

[0046] The actual operating conditions in this step refer to the actual operating conditions of the disc brake. Considering the impact of deformation on the friction force due to the disc brake friction surface's deformation, the friction force at each location will be uneven. Therefore, the average friction force is used as the friction force under the current operating conditions. The specific method for obtaining the average friction force can be through simulation or experimental testing. The simulation method is as follows: The actual operating conditions of the disc brake device are simulated based on simulation data to obtain the average friction force of the disc brake device's friction surface at each operating temperature. The simulation data represents the initial operating conditions and performance parameters of the disc brake device.

[0047] The simulation data is used to input into the thermo-solid coupling simulation software, so that the thermo-solid coupling simulation software simulates the actual working conditions of the disc brake device, wherein the thermo-solid coupling simulation software can output the average friction force of the friction surface of the disc brake device at each temperature.

[0048] These include initial temperature, material friction coefficient at the initial temperature, rotational speed, brake pressure, Young's modulus, and temperature rise. ANSYS simulation software can be used for thermo-mechanical coupling simulation. Temperature rise is the value of the temperature increase. Figure 3 and Figure 4 It is the average friction force cloud map of the working condition generated based on the thermal-solid coupling simulation software. Figure 3 The Chinese explanations from top to bottom are: coupled transient analysis; total deformation; type: total deformation; unit: millimeter; time: 0.1. Figure 4 The Chinese explanations from top to bottom are: coupled transient analysis; friction; type: friction; unit: MPa; time: 90.

[0049] S3: Calculate the ratio of the average friction force under the working condition to the theoretical friction force at each temperature to obtain a correction factor for the material friction coefficient.

[0050] Calculating the ratio of the average friction force under the operating conditions to the theoretical friction force at each temperature will yield multiple sets of ratio data, which will all converge to the same value. These ratios are then linearly fitted using the least squares method, and the fitting result is the material friction coefficient correction factor, thereby obtaining the material friction coefficient correction factor.

[0051] S4: obtaining a real-time braking force of the disc brake device according to the material friction coefficient correction factor and a mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient.

[0052] A data model is established based on the material friction coefficient correction factor, the mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient (this mapping relationship is specifically presented in the form of the material coefficient friction curve mentioned above), the initial temperature, the temperature rise, and the brake pressure to quickly determine the real-time braking force, as follows:

[0053] The modified friction coefficient is calculated based on the material friction coefficient correction factor and the material friction coefficient. The calculation method is to multiply the material friction coefficient correction factor by the material friction coefficient to obtain the modified friction coefficient.

[0054] Obtain the initial temperature, temperature rise, and brake pressure of the disc brake device. The initial temperature and brake pressure can be obtained through sensors on the disc brake device. The temperature rise can be obtained by obtaining the current temperature through the sensor and then subtracting the initial temperature from the current temperature.

[0055] The corrected friction coefficient, initial temperature and temperature rise are subjected to curve fitting to obtain a corrected friction coefficient curve. By performing curve fitting on the corrected friction coefficient obtained, the initial temperature and temperature rise can be used to obtain a corrected friction coefficient curve, such as Figure 5 As shown, the X-axis and Y-axis are the initial temperature and temperature rise respectively, and the Z-axis is the corrected friction coefficient.

[0056] The corrected friction coefficient corresponding to the current temperature is determined based on the corrected friction coefficient curve. The search process is as follows: determine the initial temperature, measure the temperature of the friction contact surface, and then determine the temperature rise. This is marked as point G on the graph. At point G, a plane perpendicular to the X-axis intersects the model surface at curve AB. The projection of AB on the YZ plane, A'B', is the curve showing the relationship between the friction coefficient and temperature under this operating condition.

[0057] The real-time braking force is calculated based on the corrected friction coefficient corresponding to the current temperature and the brake pressure. Here, real-time braking force = corrected friction coefficient * brake pressure.

[0058] In one embodiment of the present method, when obtaining the correction factor through simulation, it is necessary to add a step after the step of obtaining the material friction coefficient correction factor: collecting the actual working condition friction force of the friction surface of the disc brake device at each temperature under actual working conditions, and correcting the material friction coefficient correction factor based on the error between the actual working condition friction force and the working condition average friction force.

[0059] The test experiment is mainly to obtain the actual working condition friction force under different temperature conditions and different braking pressures. Based on the above, the working condition average friction force can be obtained through simulation. By comparing the working condition average friction force obtained by the test experiment under the same conditions with the actual working condition friction force, the material friction coefficient correction factor obtained above is corrected according to the difference and correlation between the two.

[0060] Finally, it should be noted that the above specific implementation methods are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to examples, those skilled in the art should understand that the technical solutions of the present invention can be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A method for real-time monitoring of the braking force of a disc brake device, characterized in that: include: Obtaining the theoretical friction force of the friction surface of the disc brake device at each temperature based on a mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient and the braking pressure, wherein the braking pressure is the pressure applied to the disc brake friction surface; Obtaining the average friction force of the friction surface of the disc brake device at each temperature under actual working conditions; Calculate the ratio of the average friction force under the working condition to the theoretical friction force at each temperature to obtain a correction factor for the material friction coefficient; Obtaining a real-time braking force of the disc brake device according to the material friction coefficient correction factor and a mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient; Calculate a corrected friction coefficient based on the material friction coefficient correction factor and the material friction coefficient; Obtain the initial temperature, temperature rise and brake pressure of the disc brake device; Performing curve fitting on the corrected friction coefficient, initial temperature and temperature rise to obtain a corrected friction coefficient curve; determining a corrected friction coefficient corresponding to the current temperature according to the corrected friction coefficient curve; The real-time braking force is calculated based on the corrected friction coefficient corresponding to the current temperature and the brake pressure, where real-time braking force = corrected friction coefficient * brake pressure.

2. The method for real-time monitoring of the braking force of a disc brake device according to claim 1, wherein: Obtaining the theoretical friction force of the friction surface of the disc brake device at each temperature based on the mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient and the braking pressure includes: Obtain the mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient; A material friction coefficient curve is formed according to the mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient; The theoretical friction force of the friction surface of the disc brake device at each temperature is calculated based on the material friction coefficient curve and the braking pressure.

3. The method for real-time monitoring of the braking force of a disc brake device according to claim 2, wherein: The obtaining of the mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient includes: Based on experimental tests on multiple groups of material friction coefficients of the friction surface of the disc brake device at different temperatures, a mapping relationship between the temperature of the disc brake friction surface and the material friction coefficient is formed.

4. The method for real-time monitoring of braking force of a disc brake device according to claim 1, wherein: The obtaining of the working condition average friction force of the friction surface of the disc brake device under actual working conditions at each disc brake friction surface temperature includes: The actual working condition of the disc brake device is simulated according to the simulation data to obtain the working condition average friction force of the friction surface of the disc brake device at each temperature. The simulation data are the initial working condition and performance parameters of the disc brake device.

5. The method for real-time monitoring of braking force of a disc brake device according to claim 4, wherein: Simulate the actual working conditions of the disc brake device based on the simulation data, including: The simulation data is input into a thermo-solid coupling simulation software to simulate the actual working condition of the disc brake device, wherein the thermo-solid coupling simulation software can output the average friction force of the friction surface of the disc brake device at each temperature.

6. The method for real-time monitoring of the braking force of a disc brake device according to claim 5, wherein: The simulation data include initial temperature, material friction coefficient at the initial temperature, rotation speed, braking pressure, Young's modulus and temperature rise.

7. The method for real-time monitoring of braking force of a disc brake device according to claim 4, wherein: The method for real-time monitoring of the braking force of a disc brake device further includes, after the step of obtaining the material friction coefficient correction factor: The actual working condition friction force of the friction surface of the disc brake device at each temperature under actual working conditions is collected, and the material friction coefficient correction factor is corrected according to the error between the actual working condition friction force and the working condition average friction force.

8. The method for real-time monitoring of braking force of a disc brake device according to claim 1, wherein: The calculating the ratio of the working condition average friction force to the theoretical friction force at each temperature to obtain the material friction coefficient correction factor includes: Calculate the ratio of the average friction force under the working condition to the theoretical friction force at each temperature; The ratio is fitted with a linear method using the least squares method to obtain a correction factor for the material friction coefficient.

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