Multifunctional wheel brake test system and method

Abstract

A multifunctional wheel brake test system and method, which are connected to a hydraulic motor unit A and a hydraulic motor unit B through a hydraulic power source, two sets of variable ratio gear transmission mechanisms are respectively connected to the output ends of the hydraulic motor unit A and the hydraulic motor unit B to generate torque, a multi-stage variable torque is input to a windproof simulation disk, and a rated windproof torque is input to a brake disk. A control unit of a control system is electrically connected to the hydraulic power source, the hydraulic motor unit A and the hydraulic motor unit B, and a data conversion unit is electrically connected to a data acquisition and operation unit. The clamping force, friction force, braking torque and other related performance parameters of the wheel brake are accurately tested, and repeated tests and inspections are performed at the same time. Whether the product is qualified is also quickly detected according to the initially set technical parameters and a corresponding judgment result is given, thereby improving the standardization and accuracy of the production test of the wheel brake and reducing the difficulty of testing and inspection.

Description

Technical Field

[0001] The invention belongs to the technical field of wheel brake testing, and relates to a multifunctional wheel brake testing system and method. Background Art

[0002] Braking torque is the torque generated by wheel brakes, which is used to prevent the wheels of crane equipment from rolling on the track under the action of wind. Wheel brakes are used to apply clamping force to the driven wheel of crane equipment to generate friction resistance to brake the wheel rolling, thereby achieving wind-proof braking effect. With the increase of the lifting tonnage of crane equipment, the requirements for performance such as braking torque are also increasing. Wheel brakes are one of the commonly used wind-proof brakes for crane equipment. At present, there are few special supporting comprehensive test systems or devices for testing their performance, parameters, and functions, and there are certain defects.

[0003] At present, there are few dedicated test systems for testing this product. Most of them are debugged and rectified on site, which is difficult to operate and cumbersome. In addition, most companies do not conduct similar comprehensive tests. Since the braking torque of the wheel brake is large and there are many types, the test process has high requirements for the power output range, installation fixtures, and detection units. During the test process, it must be able to be controlled, regulated, and monitored in real time. However, the current conventional test devices have a single function setting, cannot be regulated in real time, and have low detection unit accuracy. Once damaged, it is difficult to repair and the subsequent operation and maintenance costs are high.

[0004] The clamping force of the wheel brake plays a very important role in the windproof braking performance. Too small a clamping force will result in a small braking torque and failure to achieve the braking effect. Too large a clamping force will cause the wheel to be over-locked, resulting in severe wear of the wheel and friction pad, and at the same time cause the "big horse pulling a small cart" phenomenon, increasing unnecessary energy consumption. Therefore, in the product factory test process, the wheel brake clamping force needs to be adjusted to an appropriate value and tested multiple times. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide a multifunctional wheel-side brake testing system and method, which adopts a hydraulic power source to connect with a hydraulic motor unit A and a hydraulic motor unit B, two sets of variable ratio gear transmission mechanisms are respectively connected with the output ends of the hydraulic motor unit A and the hydraulic motor unit B to generate torque, multi-stage variable torque is input to the windproof simulation disk, and the rated windproof torque is input to the brake disk. The control unit of the control system is electrically connected with the hydraulic power source, the hydraulic motor unit A and the hydraulic motor unit B, and the data conversion unit is electrically connected with the data acquisition and operation unit. The clamping force, friction force, braking torque and other related performance parameters of the wheel-side brake are accurately tested, and repeated tests and inspections are performed at the same time. The product is also quickly detected whether it is qualified according to the initially set technical parameters and a corresponding judgment result is given, thereby improving the standardization and accuracy of the wheel-side brake production test and reducing the difficulty of testing and inspection.

[0006] In order to solve the above technical problems, the technical solution adopted by the present invention is: a multifunctional wheel-side brake testing system, which includes a hydraulic motor unit A and a hydraulic motor unit B connected to a hydraulic power source, two sets of variable ratio gear transmission mechanisms are respectively connected to the output ends of the hydraulic motor unit A and the hydraulic motor unit B and generate torque; multi-stage variable torque is input to the windproof simulation disk, and the rated windproof torque is input to the brake disk; the control unit of the control system is electrically connected to the hydraulic power source, the hydraulic motor unit A and the hydraulic motor unit B, and the data conversion unit is electrically connected to the data acquisition and operation unit.

[0007] The hydraulic power source is a hydraulic station, which drives the hydraulic motor unit A and the hydraulic motor unit B to rotate, and at the same time adjusts the rotation speed and torque of the hydraulic motor unit A and the hydraulic motor unit B through a hydraulic pressure regulating device.

[0008] The output torque of the hydraulic motor unit A and the hydraulic motor unit B is M=P*Q / 20π, where P is the nominal pressure of the hydraulic station, Q is the flow rate, and π is the pi. The motor frequency of the hydraulic station is regulated by frequency conversion technology to achieve the output torque of the hydraulic motor unit A and the hydraulic motor unit B. The input and output ends of the hydraulic motor unit A and the hydraulic motor unit B are respectively provided with pressure detection devices, and the pressure P of the hydraulic motor unit A and the hydraulic motor unit B is measured by a pressure transmitter. 1 and P 2 Transmitted to the control system for subsequent logical data operations.

[0009] The transmission ratio M of the two sets of variable ratio gear transmission mechanisms is 1 :M 2 =4, that is, i=4 or i=0.25, increases and decreases the motor torque to match the torque required for different working conditions and loads; organically combines the transmission ratio and frequency conversion technology to increase the torque floating range to meet the test and simulation under various loads; a set of gear pairs WL 1For testing, another set of gear pair WL 2 Used for wind safety simulation test.

[0010] The brake disc is customized according to the wheel structure of the crane equipment, and a wheel width adjustment block, an encoder and an infrared temperature monitoring point are set on the wheel side of the brake disc; the wheel width adjustment block is used to adjust the wheel width to meet the test and simulation of brakes of different wheel width models; the wheel side brake is installed with a bracket, and the relative position is adjustable to meet the installation test and simulation of wheel side brakes of different models; the encoder is used to determine the test results; the infrared temperature monitoring is used to control the system to correct the friction coefficient u in real time; the friction coefficient of the same material is different at different temperatures; a set of brake discs ZDP 1 For testing, another set of brake discs ZDP 2 Used for wind safety simulation test.

[0011] The control system is a PLC, which mainly includes a touch screen, an encoder, an AD module and a communication module; the internal logic language instructions of the programmable controller execute and store instructions for logical operations and sequential control, timing, counting and arithmetic operations, and control each stage of testing and simulation through digital or analog input I and output O interfaces, and output all data and alarm signals at the same time.

[0012] The testing and inspection method of the multifunctional wheel brake testing system as described above comprises the following steps:

[0013] S1, installation, installing the wheel brake on the windshield simulation disc and the brake disc;

[0014] S2, setting, setting multiple groups of target test values;

[0015] S3, calibration, calibrating the test range according to multiple sets of target test values;

[0016] S4, programming, writing corresponding control programs according to multiple sets of set target values;

[0017] S5, execution, the programmable controller executes the control program, generates control instructions, and the power device executes the control instructions and outputs corresponding logic values;

[0018] S6, detection, the power device outputs the first-level braking torque, and generates the first-level braking detection information at the same time, and controls the output of the second-level braking torque according to the first-level detection information;

[0019] S7, first-level determination, determining the first-level detection information; if qualified, the power device outputs the second-level braking torque, and generates the second-level braking detection information at the same time, and controls the output of the third-level braking torque according to the second-level detection information;

[0020] S8, level 2 determination, determining the level 2 detection information; if qualified, the power device outputs level 3 braking torque and generates level 3 braking detection information at the same time;

[0021] S9, three-level determination, determine the three-level detection information; if qualified, output qualified information and generate a test data table;

[0022] In S7, S8 and S9, if the test fails, the test stops, an alarm message is output, and a failure data table is generated.

[0023] The simulation method of the multifunctional wheel brake test system as described above comprises the following steps:

[0024] S1, set, set the simulation target value;

[0025] S2, calibration, calibrating the simulation range according to the simulation setting target value;

[0026] S3, programming, writing the corresponding control program according to the simulation setting target value;

[0027] S4, execution, the programmable controller executes the control program, generates control instructions, and the power device executes the control instructions and outputs corresponding logic values;

[0028] S5, simulation, the power device outputs a simulated braking torque and generates simulated braking detection information;

[0029] S6, analyze and output, analyze the simulation test information; and output the simulation information to generate a simulation data status chart.

[0030] The main beneficial effects of the present invention are:

[0031] The present invention can accurately test the relevant performance parameters of the wheel brake such as the clamping force, friction force, braking torque, etc., and can be repeatedly tested and inspected; the standardization and accuracy of the wheel brake production test are improved, and the difficulty of testing and inspection is reduced.

[0032] The test and simulation are integrated into one, and the test and simulation are carried out on the same device. The test and simulation status can be monitored in real time, and the inspection data can be formed into reports for query, analysis or output.

[0033] It can be applied to the testing and simulation of wheel brakes of various specifications and models: the relative position of the mounting bracket is specially designed and can be adjusted, the brake disc width is customized to suit different wheel widths, and the initial target values ​​for testing and simulation can be calibrated or modified in real time according to actual working conditions.

[0034] The high degree of automation improves the efficiency of production inspection and testing, reduces production costs, reduces the safety hazards of manual testing and inspection by personnel, and at the same time improves the level of industrial intelligent production.

[0035] The frequency conversion control technology and the high torque of the hydraulic motor are integrated to increase the load test range, which can be applied to the testing and simulation of wheel brakes of more specifications.

[0036] The encoder and time relay are used to monitor the rotation state of the brake disc during the test to verify the braking effect, such as: the test is set at the initial value torque M 1 The current speed N of the brake disc is obtained through the encoder pulse signal. 1 The wheel side brake is applied at a uniform speed to brake the brake disc, and the speed of the brake disc decreases. When the speed N 1 = 0 for t (t = 3s), the initial torque M 1 If the brake disc is still in a stationary state, the test is passed and the test parameters are output; for example, the test is performed at the initial value torque M 2 The current speed N of the brake disc is obtained through the encoder pulse signal. 2 The wheel side brake is applied at a uniform speed to brake the brake disc, and the speed of the brake disc cannot be reduced or the speed N 2 >0, the brake disc cannot be in a static state, then the test fails and an alarm message is output; the same is true for the windproof simulation process. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0038] Figure 1 It is a system diagram of the present invention.

[0039] Figure 2 This is a process flow chart for testing and inspecting the present invention.

[0040] Figure 3 This is a simulation process flow chart of the present invention.

[0041] Figure 4 This is the wheel brake clamping force curve during the test.

[0042] Figure 5 This is the static friction force curve of the wheel brake during the simulation process. DETAILED DESCRIPTION

[0043] like Figure 1~Figure 5In the invention, a multifunctional wheel brake test system is provided, which includes a hydraulic motor unit A and a hydraulic motor unit B connected to a hydraulic power source, two sets of variable ratio gear transmission mechanisms are respectively connected to the output ends of the hydraulic motor unit A and the hydraulic motor unit B and generate torque; a multi-level variable torque is input to a windproof simulation disc, and a rated windproof torque is input to a brake disc; a control unit of a control system is electrically connected to the hydraulic power source, the hydraulic motor unit A and the hydraulic motor unit B, and a data conversion unit is electrically connected to a data acquisition operation unit. When in use, the wheel brake is installed on the windproof simulation disc and the brake disc, and the functional parameters such as the clamping force, friction force, and temperature of the wheel brake under different working conditions are accurately input, monitored, and displayed through the internal logic operation of the control unit; at the same time, it can also quickly detect whether the product is qualified according to the initial set technical parameters and give the corresponding judgment results, thereby reducing labor and increasing the accuracy of inspection.

[0044] In a preferred solution, the hydraulic power source is a hydraulic station, which drives the hydraulic motor unit A and the hydraulic motor unit B to rotate, and at the same time, the hydraulic pressure regulating device is used to regulate the speed and torque of the hydraulic motor unit A and the hydraulic motor unit B. When in use, the hydraulic station drives the hydraulic motor, which is regulated by the hydraulic pressure regulating device, with a high degree of automation, improving the efficiency of production inspection and testing, reducing production costs, reducing the safety hazards of manual testing by personnel, and improving the level of industrial intelligent production.

[0045] In the preferred solution, the output torque M of the hydraulic motor unit A and the hydraulic motor unit B is P*Q / 20π, where P is the nominal pressure of the hydraulic station, Q is the flow rate, and π is the pi; the motor frequency of the hydraulic station is regulated by frequency conversion technology to achieve the output torque of the hydraulic motor unit A and the hydraulic motor unit B. The input and output ends of the hydraulic motor unit A and the hydraulic motor unit B are respectively provided with pressure detection devices, and the pressure P of the hydraulic motor unit A and the hydraulic motor unit B is measured by a pressure transmitter. 1 and P 2 The data is transmitted to the control system for subsequent logic data calculation. When in use, the frequency conversion control technology and the high torque of the hydraulic motor are integrated to increase the load test range, which can be applied to more specifications of wheel brake testing and simulation.

[0046] Example 1, logical operation:

[0047] Test: clamping force, friction;

[0048] Mh =P*Q / 20π motor output torque;

[0049] Mz=Mh *i The friction torque borne by the brake disc;

[0050] d = n, the distance from the brake caliper to the center of the brake disc;

[0051] Fm=2*Mz / d is the friction force of a single brake caliper and a single friction plate;

[0052] u=0.4 friction coefficient, that is, the friction coefficient value at the corresponding temperature;

[0053] Fj=Fm / 2 / u brake clamping force;

[0054] P: motor input pressure Q: motor flow π: pi i: transformation ratio.

[0055] In the preferred solution, the transmission ratio M of the two sets of variable ratio gear transmission mechanisms is 1 :M 2 =4, that is, i=4 or i=0.25, increases and decreases the motor torque to match the torque required for different working conditions and loads; organically combines the transmission ratio and frequency conversion technology to increase the torque floating range to meet the test and simulation under various loads; a set of gear pairs WL 1 For testing, another set of gear pair WL 2 Used for wind safety simulation test.

[0056] Embodiment 2,

[0057] Wind simulation: wheel pressure, resistance;

[0058] Mh =P*Q / 20π motor output torque;

[0059] Mz=Mh *i The friction torque borne by the brake disc;

[0060] d = n, the distance from the brake caliper to the center of the brake disc;

[0061] Fm=2*Mz / d=T*u The friction force of a single brake caliper and a single friction plate;

[0062] u=0.4 friction coefficient, that is, the friction coefficient value at the corresponding temperature;

[0063] Fj=Fm / 2 / u brake clamping force;

[0064] T: wheel pressure P: motor input pressure Q: motor flow π: pi i: transformation ratio.

[0065] In the preferred solution, the brake disc is customized according to the wheel structure of the crane equipment, and a wheel width adjustment block, an encoder and an infrared temperature monitoring point are set on the wheel side of the brake disc; the wheel width adjustment block is used to adjust the wheel width to meet the test and simulation of brakes of different wheel width models; the wheel side brake is installed with a bracket, and the relative position is adjustable to meet the installation test and simulation of wheel side brakes of different models; the encoder is used to determine the test results; the infrared temperature monitoring is used to control the system to correct the friction coefficient u in real time; the friction coefficient of the same material is different at different temperatures; a set of brake discs ZDP1 For testing, another set of brake discs ZDP 2 Used for windproof safety simulation test. When in use, the wheel width adjustment block and mounting support tool are used, which is suitable for testing and simulating wheel side brakes of various specifications and models: the relative position of the mounting support tool is specially designed to be adjustable, the brake disc width is customized to adapt to different wheel widths, and the initial target value of the test and simulation can be calibrated or modified in real time according to the actual working conditions.

[0066] Preferably, an infrared temperature measuring device is used to accurately capture the temperature variation range of the brake disc during the test, and the captured information is transmitted to the control unit in real time so that the friction coefficient u can be corrected synchronously internally in real time, thereby accurately calculating the test and simulation data.

[0067] Embodiment 3,

[0068] Determination and selection of friction coefficient;

[0069]

[0070] Preferably, the friction coefficient values ​​at different temperatures are as follows:

[0071]

[0072] In the preferred solution, the control system is a PLC, which mainly includes a touch screen, an encoder, an AD module and a communication module; the programmable controller internal logic language instructions execute and store instructions for logic operations and sequential control, timing, counting and arithmetic operations, and control each stage of testing and simulation through digital or analog input I and output O interfaces, and output all data and alarm signals at the same time. When in use, the encoder and time relay device are used to monitor the rotation state of the brake disc during the test to check the braking effect, such as: the test is set at the initial value torque M 1 The current speed N of the brake disc is obtained through the encoder pulse signal. 1 The wheel side brake is applied at a uniform speed to brake the brake disc, and the speed of the brake disc decreases. When the speed N 1 =0 for t, t=3s, initial torque M 1 If the brake disc is still in a stationary state, the test is passed and the test parameters are output; for example, the test is performed at the initial value torque M 2 The current speed N of the brake disc is obtained through the encoder pulse signal. 2 The wheel side brake is applied at a uniform speed to brake the brake disc, and the speed of the brake disc cannot be reduced or the speed N 2 >0, the brake disc cannot be in a static state, then the test fails and an alarm message is output; the same is true for the windproof simulation process.

[0073] In a preferred embodiment, the test and inspection method of the multifunctional wheel brake test system as described above comprises the following steps:

[0074] S1, installation, installing the wheel brake on the windshield simulation disc and the brake disc;

[0075] S2, setting, setting multiple groups of target test values;

[0076] S3, calibration, calibrating the test range according to multiple sets of target test values;

[0077] S4, programming, writing corresponding control programs according to multiple sets of set target values;

[0078] S5, execution, the programmable controller executes the control program, generates control instructions, and the power device executes the control instructions and outputs corresponding logic values;

[0079] S6, detection, the power device outputs the first-level braking torque, and generates the first-level braking detection information at the same time, and controls the output of the second-level braking torque according to the first-level detection information;

[0080] S7, first-level determination, determining the first-level detection information; if qualified, the power device outputs the second-level braking torque, and generates the second-level braking detection information at the same time, and controls the output of the third-level braking torque according to the second-level detection information;

[0081] S8, level 2 determination, determining the level 2 detection information; if qualified, the power device outputs level 3 braking torque and generates level 3 braking detection information at the same time;

[0082] S9, three-level determination, determine the three-level detection information; if qualified, output qualified information and generate a test data table;

[0083] In S7, S8 and S9, if the test fails, the test stops, an alarm message is output, and a failure data table is generated.

[0084] In the above method, two sets of variable ratio gear transmission mechanisms are used to connect the windproof simulation disk and the brake disk, and the gear pair WL of one set of variable ratio gear transmission mechanisms is 1 Match a set of brake discs ZDP 1 Used for windproof safety simulation tests; can accurately test wheel brake clamping force, friction, braking torque and other related performance parameters, and can be tested and inspected repeatedly; improves the standardization and accuracy of wheel brake production tests, while reducing the difficulty of testing and inspection; integrates testing and simulation, and performs testing and simulation on the same device. The test and simulation status can be monitored in real time, and the inspection data can be generated into reports for query, analysis or output.

[0085] In a preferred embodiment, the simulation method of the multifunctional wheel brake test system as described above comprises the following steps:

[0086] S1, set, set the simulation target value;

[0087] S2, calibration, calibrating the simulation range according to the simulation setting target value;

[0088] S3, programming, writing the corresponding control program according to the simulation setting target value;

[0089] S4, execution, the programmable controller executes the control program, generates control instructions, and the power device executes the control instructions and outputs corresponding logic values;

[0090] S5, simulation, the power device outputs a simulated braking torque and generates simulated braking detection information;

[0091] S6, analyze and output, analyze the simulation test information; and output the simulation information to generate a simulation data status chart.

[0092] In the above method, two sets of variable ratio gear transmission mechanisms are used to connect the windproof simulation disk and the brake disk, and the gear pair WL of one set of variable ratio gear transmission mechanisms is 2 Match a set of brake discs ZDP 2 Used for wind safety simulation test.

[0093] The above-mentioned embodiments are only preferred technical solutions of the present invention and should not be regarded as limitations of the present invention. The embodiments and features in the embodiments of the present application can be arbitrarily combined with each other without conflict. The protection scope of the present invention shall be the technical solutions recorded in the claims, including the equivalent replacement solutions of the technical features in the technical solutions recorded in the claims. That is, equivalent replacement improvements within this scope are also within the protection scope of the present invention.

Claims

1. A multifunctional wheel brake test system, characterized by: It includes a hydraulic power source and a hydraulic motor unit A and a hydraulic motor unit B connected to the hydraulic power source, two sets of variable ratio gear transmission mechanisms are respectively connected to the output ends of the hydraulic motor unit A and the hydraulic motor unit B to generate torque; the multi-stage variable torque is input to the windproof simulation disk, and the rated windproof torque is input to the brake disk; the control unit of the control system is electrically connected to the hydraulic power source, the hydraulic motor unit A and the hydraulic motor unit B, and the data conversion unit is electrically connected to the data acquisition and calculation unit; The output torque of the hydraulic motor unit A and the hydraulic motor unit B is M=P*Q / 20π, where P is the nominal pressure of the hydraulic station, Q is the flow rate, and π is the pi; the motor frequency of the hydraulic station is regulated by frequency conversion technology to achieve the output torque of the hydraulic motor unit A and the hydraulic motor unit B. The input and output ends of the hydraulic motor unit A and the hydraulic motor unit B are respectively provided with pressure detection devices, and the pressures P1 and P2 of the hydraulic motor unit A and the hydraulic motor unit B are transmitted to the control system by a pressure transmitter as a subsequent logic data operation; The transmission ratio of the two sets of gear transmission mechanisms is M1:M2=4, i.e., i=4 or i=0.25, which increases and decreases the motor torque to match the torque required by different working conditions and loads; the transmission ratio and frequency conversion technology are organically combined to increase the torque floating range to meet the testing and simulation under various loads; one set of gear pairs WL1 is used for testing, and the other set of gear pairs WL2 is used for windproof safety simulation test; The brake disc is customized according to the wheel structure of the crane equipment, and a wheel width adjustment block, an encoder and an infrared temperature monitoring point are set on the wheel side of the brake disc; the wheel width adjustment block is used to adjust the wheel width to meet the test and simulation of brakes of different wheel width models; the wheel side brake is installed with a bracket, and the relative position is adjustable to meet the installation test and simulation of wheel side brakes of different models; the encoder is used to determine the test results; the infrared temperature monitoring is used to control the system to correct the friction coefficient u in real time; the friction coefficient of the same material is different at different temperatures; one group of brake discs ZDP1 is used for testing, and the other group of brake discs ZDP2 is used for windproof safety simulation test; The testing and inspection method includes the following steps: S1, installation, installing the wheel brake on the windshield simulation disc and the brake disc; S2, setting, setting multiple groups of target test values; S3, calibration, calibrating the test range according to multiple sets of target test values; S4, programming, writing corresponding control programs according to multiple sets of set target values; S5, execution, the programmable controller executes the control program, generates control instructions, and the power device executes the control instructions and outputs corresponding logic values; S6, detection, the power device outputs the first-level braking torque, and generates the first-level braking detection information at the same time, and controls the output of the second-level braking torque according to the first-level detection information; S7, first-level determination, determining the first-level detection information; if qualified, the power device outputs the second-level braking torque, and generates the second-level braking detection information at the same time, and controls the output of the third-level braking torque according to the second-level detection information; S8, level 2 determination, determining the level 2 detection information; if qualified, the power device outputs level 3 braking torque and generates level 3 braking detection information at the same time; S9, three-level determination, determine the three-level detection information; if qualified, output qualified information and generate a test data table; In S7, S8 and S9, if the test fails, the test stops, an alarm message is output, and a failure data table is generated.

2. The multifunctional wheel brake test system according to claim 1 is characterized in that: The hydraulic power source is a hydraulic station, which drives the hydraulic motor unit A and the hydraulic motor unit B to rotate, and at the same time adjusts the rotation speed and torque of the hydraulic motor unit A and the hydraulic motor unit B through a hydraulic pressure regulating device.

3. The multifunctional wheel brake test system according to claim 1 is characterized in that: The control system is a PLC, including a touch screen, an encoder, an AD module and a communication module; the programmable controller internal logic language instructions execute and store instructions for logic operations and sequential control, timing, counting and arithmetic operations, and control each stage of testing and simulation through digital or analog input I and output O interfaces, and output all data and alarm signals at the same time.

Images