Braking torque online monitoring system and method

Abstract

The present invention discloses an online monitoring system and method for braking torque, which includes: a slide rail and slider mechanism, two sensing modules, and a control module; the slide rail and slider mechanism includes: a slider arranged on the bottom surface of the brake and a slide rail arranged on the top surface of the support, the slide rail extending along the rotation direction of the brake wheel, the contact surface between the slider and the slide rail being an arc surface concentric with the brake wheel, and the slider being restricted to rotation along the extension direction of the slide rail; two sensing modules are respectively arranged on both sides of the slide rail and slider mechanism and abut against the ends of the slider to restrict the rotation of the slider and perform pressure detection; the control module is connected to the two sensing modules to receive the pressure measured by the sensing modules and obtain the braking torque based on the pressure data. The sensing module is installed on the side of the drum brake or disc brake base to avoid the complex type of installation on the brake body, and can monitor the braking torque of the brake acting on the transmission chain online, ensuring the safety and reliability of the braking system.

Description

Technical Field

[0001] The present invention relates to the technical field of lifting equipment, and in particular to an online monitoring system and method for braking torque. Background Art

[0002] In traditional crane hoisting mechanisms, drum brakes or disc brakes are often used to stop the transmission chain and hold heavy objects. However, drum brakes or disc brakes are usually not equipped with sensors to detect the braking torque acting on the brake wheel or brake disc. Generally, regular inspections by equipment inspectors are relied upon to detect whether the braking force setting of the brake is appropriate, whether the friction plate thickness is sufficient, whether the back-off distance of the pusher is within the required range, and other issues. These issues are then handled and resolved on site to ensure the performance of the brake, the safety and reliability of the hoisting mechanism, and to prevent accidents such as hook slippage.

[0003] In recent years, with the increasing demand for intelligence, more and more users require that the crane's brakes should be able to promptly sense the braking torque loaded on the lifting mechanism transmission chain. If the braking torque can be sensed in real time, it will be possible to judge whether the braking performance is intact based on the changes in the braking torque, and then promptly remind the staff to maintain the brakes to ensure their condition and performance are intact. Figure 1 and Figure 2 They are the front view and side view of the drum brake respectively. Figure 3 and Figure 4 The figures are the front and side views of a disc brake, respectively. In the prior art, some brake manufacturers use the pins that articulate and secure the friction pads in the brake as sensors, or install sensors on the arm that secures the pins to sense the reaction force generated when the friction pads act on the brake wheel or disc. While these methods meet the aforementioned requirements to a certain extent, the limited size of the pins and arm requires the enlargement of certain components to accommodate the sensors. Furthermore, the pins themselves are frequently used and often bear full loads, which poses certain safety risks by changing the original structural design. Furthermore, these sensor-equipped brakes can only sense the positive pressure exerted by the friction pads on the brake wheel or disc. The product of this positive pressure, the friction coefficient, and the arm is the braking torque generated by the brake. However, the friction coefficient is not constant and varies depending on the use of the friction pads, brake wheel, or disc. Therefore, these sensor-equipped brakes cannot fully and accurately sense the braking torque applied to the lifting mechanism's transmission chain. Summary of the Invention

[0004] To solve some or all of the technical problems existing in the above-mentioned prior art, the present invention provides a braking torque online monitoring system and method. The technical solution is as follows:

[0005] In the first aspect, a braking torque online monitoring system is provided, comprising: a slide rail slider mechanism, two sensor modules and a control module; the slide rail slider mechanism comprises: a slider arranged on the bottom surface of the brake and a slide rail arranged on the top surface of the support, the slide rail extending along the rotation direction of the brake wheel, the contact surface between the slider and the slide rail is an arc surface concentric with the brake wheel, and the slider is restricted to rotate along the extension direction of the slide rail; two sensor modules are respectively arranged on both sides of the slide rail slider mechanism, and are against the end of the slider, for limiting the rotation of the slider and completing pressure detection; the control module is connected to the two sensor modules, for receiving the pressure measured by the sensor modules and obtaining the braking torque based on the pressure data.

[0006] In some optional implementations, the upper surface of the slider is a plane for connecting to the brake, and the lower surface of the slider is an arc surface concentric with the brake wheel; the upper surface of the slide rail is a concave arc surface concentric with the brake wheel, and the lower surface of the slide rail is a plane for connecting to the support.

[0007] In some optional implementations, a T-slot is provided on the arc surface of the bottom of the slider, and a T-track adapted to the T-slot is provided on the upper surface of the slide rail, and the T-track is confined within the T-slot.

[0008] In some optional implementations, the sensing module includes: a bracket and a sensor, the bracket is spaced apart and arranged opposite to the slide rail slider mechanism, and the sensor is connected to the top end of the bracket and abuts against the end of the slider.

[0009] In some optional implementations, the sensor is arranged perpendicular to the end of the slider.

[0010] In some optional implementations, the system further includes an alarm module, which is connected to the control module and is configured to issue an alarm signal when the control module detects abnormal braking torque.

[0011] In a second aspect, a method for online monitoring of braking torque using any of the above-mentioned online monitoring systems for braking torque is provided, the method comprising:

[0012] When the brake is applied, the slider applies pressure to the sensor module on one side, and the sensor module sends the monitored pressure data to the control module;

[0013] The control module obtains the braking torque based on the pressure data.

[0014] In some optional implementations, the control module obtains the braking torque according to the pressure data using the following formula:

[0015] Mz=FXL

[0016] Where Mz is the braking torque applied by the brake on the brake disc or brake wheel, F is the pressure measured by the sensor module, and L is the force arm of the pressure measured by the sensor module relative to the center of the brake disc or brake wheel.

[0017] In some optional implementations, the method further includes: when the control module detects that the braking torque is abnormal, the alarm module issues an alarm signal.

[0018] The main advantages of the technical solution of the present invention are as follows:

[0019] The braking torque online monitoring system and method of the present invention can be applied to crane hoisting mechanisms or other systems equipped with similar brakes. The sensor module is mounted on the side of the drum brake or disc brake base, avoiding the complex installation method of the brake body. The system can monitor the braking torque of the brake acting on the transmission chain online, promptly reflecting the magnitude of the transmission chain braking torque, and intelligently determine whether the brake performance is intact, thereby ensuring the safety and reliability of the braking system. This invention is simple and reliable, can directly reflect the braking torque of the brake, and provides relatively accurate detection results. It has broad application prospects and replaces the existing complex and expensive installation of a braking torque sensor on the brake body. It also eliminates the need for negotiation with the brake manufacturer or replacement of a new brake. Simply installing a sensor on the side of the brake base allows all currently used brakes to be retrofitted at a low cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The drawings described herein are used to provide a further understanding of the embodiments of the present invention and constitute a part of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0021] Figure 1 A front view of a drum brake provided in the prior art;

[0022] Figure 2 A side view of a drum brake provided for prior art;

[0023] Figure 3 A front view of a disc brake provided in the prior art;

[0024] Figure 4 A side view of a disc brake provided for prior art;

[0025] Figure 5 A schematic structural diagram of an online monitoring system for braking torque provided in one embodiment of the present invention applied to a drum brake;

[0026] Figure 6A schematic structural diagram of an online braking torque monitoring system provided in one embodiment of the present invention applied to a disc brake;

[0027] Figure 7 A cross-sectional view of a slide rail and slider mechanism in an online braking torque monitoring system provided by one embodiment of the present invention;

[0028] Figure 8 A curve diagram of the change in braking torque after the brake is applied provided by one embodiment of the present invention. DETAILED DESCRIPTION

[0029] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with specific embodiments of the present invention and corresponding drawings. Obviously, 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 are within the scope of protection of the present invention.

[0030] The technical solutions provided by the embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0031] In the first aspect, an embodiment of the present invention provides a braking torque online monitoring system 6, as shown in the attached Figures 5 to 7 As shown, it includes: a slide rail and slider mechanism, two sensing modules and a control module; the slide rail and slider mechanism includes: a slider 63 arranged on the bottom surface of the brake and a slide rail 64 arranged on the top surface of the support, the slide rail 64 extends along the rotation direction of the brake wheel, and the contact surface between the slider 63 and the slide rail 64 is an arc surface concentric with the brake wheel, and the slider 63 is restricted to rotate along the extension direction of the slide rail 64; the two sensing modules are respectively arranged on both sides of the slide rail and slider mechanism, and are against the end of the slider 63, for limiting the rotation of the slider 63 and completing pressure detection; the control module is connected to the two sensing modules, for receiving the pressure measured by the sensing modules and obtaining the braking torque based on the pressure data.

[0032] The working principle of the braking torque online monitoring system 6 provided in an embodiment of the present invention is described below:

[0033] Compared to the prior art brakes, which are directly mounted on the support, this embodiment incorporates a slide rail and slider mechanism between the brake and the support. The slide rail 64 extends along the direction of rotation of the brake wheel, while the slider 63 is confined within the slide rail 64 and can only rotate along the direction of extension of the slide rail 64, limiting its freedom in all other directions. Thus, with the cooperation of the slide rail 64 and the slider 63, the brake can only rotate along the axis of the brake wheel, limiting its freedom in all other directions. During braking, regardless of which direction the brake wheel rotates, the brake will tend to rotate under the influence of the brake wheel. However, because the sensor modules on both sides of the slide rail and slider mechanism restrict the rotation of the slider 63, the brake does not actually rotate. However, the tendency to rotate does exert a certain amount of pressure on the sensor module. The product of this pressure and the arm of force acting on the center of the brake wheel is equal in magnitude and opposite in direction to the braking torque applied by the brake on the brake wheel. Therefore, the pressure data detected by the sensor module can be used to monitor the braking torque.

[0034] In summary, the braking torque online monitoring system 6 provided in the embodiments of the present invention can be applied to crane hoisting mechanisms or other systems equipped with similar brakes. Its sensor module is mounted on the side of the drum brake or disc brake base, avoiding the complex installation required on the brake body. This system can online monitor the braking torque applied by the brake to the transmission chain, promptly reflecting the magnitude of the transmission chain's braking torque, and intelligently determine whether the brake's braking performance is intact, thereby ensuring the safety and reliability of the braking system. This invention is simple and reliable, directly reflecting the braking torque of the brake, providing relatively accurate detection results, and has broad application prospects. It replaces the existing complex and expensive installation of a braking torque sensor on the brake body, eliminating the need for negotiation with the brake manufacturer or replacement of a new brake. Simply installing the sensor 62 on the side of the brake base allows for the cost-effective retrofit of all currently used brakes.

[0035] Optionally, the upper surface of slider 63 is flat for connection to the brake, while the lower surface is an arcuate surface concentric with the brake wheel. The upper surface of slide rail 64 is a concave arcuate surface concentric with the brake wheel, while the lower surface of slide rail 64 is flat for connection to the support. This arrangement facilitates connection between the slide rail and the brake and the support. Furthermore, the contact surface of the slide rail and the slider is an arcuate surface concentric with the brake disc (or brake wheel), facilitating force transmission between the brake disc (or brake wheel) and slider 63 without force loss during the transmission process, thereby ensuring more accurate torque detection results.

[0036] In some optional implementations of this embodiment, as shown in the attached Figure 7As shown, a T-slot is provided on the curved surface at the bottom of the slider 63, and a T-track is provided on the upper surface of the slide rail 64 to match the T-slot. The T-track is confined within the T-slot. The cooperation between the T-track and the T-slot restricts the freedom of the slider 63 in other directions, so that the slider 63 can only rotate along the extension direction of the slide rail 64.

[0037] Alternatively, mirroring, a T-shaped track may be provided on the arc surface at the bottom of the slider 63 and a T-shaped slot may be provided on the upper surface of the slide rail 64 to achieve the same or similar technical effects.

[0038] Optionally, the slide rail 64 and the slider 63 may be made of wear-resistant materials with a low friction coefficient, which can both increase the service life and reduce friction loss.

[0039] It should be noted that the above structure is only a specific example of a slide rail slider mechanism. Those skilled in the art may also adopt other connection methods to limit the slider 63 within the slide rail 64, as long as it can cooperate to limit the degrees of freedom in directions other than the arc direction. This embodiment will not be repeated here.

[0040] In some optional implementations of this embodiment, the sensor module includes a bracket 61 and a sensor 62. Bracket 61 is spaced apart and positioned relative to the slide rail mechanism. Sensor 62 is connected to the top of bracket 61 and abuts the end of slider 63. Bracket 61 serves as a mounting base, supporting sensor 62 at a predetermined position so that it abuts the end of slider 63. Sensor 62 abuts the end of slider 63, limiting the slider's arc-shaped freedom and monitoring pressure data when slider 63 tends to rotate during braking.

[0041] The sensor 62 may be a heavy-duty pressure sensor commonly used in the prior art, for example, including a pressure sensitive element and a signal processing unit. The structure of the sensor 62 is not specifically limited in this embodiment, as long as it is made of a rigid material, can limit the movement of the slider 63, and can perform pressure detection.

[0042] Furthermore, the sensor 62 is arranged perpendicular to the end of the slider 63, so that there is no loss of force during the transmission process, thereby improving the detection accuracy.

[0043] As attached Figure 5 and 6 As shown, the main body of the bracket 61 is set vertically, and the top end can extend toward the direction close to the slide rail slider mechanism. The top end is located obliquely above the end face of the slider 63, which is convenient for setting the sensor 62 on the lower side of the top end to abut against the end face of the slider 63.

[0044] In some optional implementations of this embodiment, the online braking torque monitoring system 6 further includes an alarm module, connected to the control module, configured to issue an alarm signal when the control module detects an abnormal braking torque. The alarm module facilitates the issuance of an alarm when a problem occurs, prompting maintenance personnel to promptly perform brake maintenance, thereby ensuring the safety and reliability of the braking system.

[0045] The alarm module may be an acoustic signal alarm module and / or an optical signal alarm module, etc., as long as it can serve as an alarm to remind the staff, and this is not specifically limited in this embodiment.

[0046] In a second aspect, an embodiment of the present invention provides a method for online monitoring of braking torque using any of the above-mentioned online monitoring systems 6 for braking torque, the method comprising:

[0047] When the brake is applied, pressure is applied to the sensor module on one side through the slider 63, and the sensor module sends the monitored pressure data to the control module; the control module obtains the braking torque based on the pressure data.

[0048] The control module obtains the braking torque based on the pressure data using the following formula:

[0049] Mz=FXL

[0050] In the formula, Mz is the braking torque applied by the brake on the brake disc or brake wheel, F is the pressure measured by the sensing module (specifically, sensor 62), which is the pressure formed on sensor 62 when the brake wheel or brake disc has a tendency to rotate when the brake is applied, and L is the force arm of the pressure measured by the sensing module (specifically, sensor 62) relative to the center of the brake disc.

[0051] Optionally, the method further includes: when the control module detects abnormal braking torque, the alarm module issues an alarm signal. By providing the alarm module, it is convenient to issue the alarm signal in time to notify the staff.

[0052] The following describes in detail the braking torque online monitoring system provided by the embodiment of the present invention with reference to specific examples:

[0053] In one embodiment:

[0054] As attached Figure 5As shown, the drum brake 1 is bolted to a slider 63. The top of the slider 63 is flat, with a threaded hole for securing the drum brake 1. The bottom has a concave, arc-shaped, T-slotted groove, whose radius R is concentric with the radius r of the brake wheel 2. The slider 63 is mounted on a rail 64 and can rotate circumferentially along the arc-shaped T-track at the top of the rail 64. The rail 64 has a circular T-track at the top that matches the T-slot of the slider 63. The bottom is flat and fixed to the upper surface of the trolley frame 3. Thus, due to the fixed action of the slider 63 and rail 64, the drum brake 1 can only rotate along the axis of the brake wheel 2, and its degrees of freedom in all other directions are restricted. A bracket 61 and a sensor 62 are located on either side of the slider 63. The bracket 61 is fixed to the upper surface of the trolley frame 3, and the sensor 62 is fixed to the top and bottom side, facing the side of the slider 63. Bracket 61 and sensor 62 are tightly pressed against both sides of slider 63, restricting left and right rotation of slider 63. This also restricts the drum brake 1's freedom of rotation along the axis of brake wheel 2. Thus, slider 63 and drum brake 1 are fixed to the periphery of brake wheel 2. During operation, regardless of the direction of brake wheel 2 rotation, drum brake 1 will tend to rotate under the influence of brake wheel 2. However, due to the positional constraints of bracket 61 and sensor 62, drum brake 1 does not actually rotate. However, its tendency to rotate will cause a certain amount of pressure on sensor 62. The product of this pressure and the force arm acting on the center of brake wheel 2 is equal in magnitude and opposite in direction to the braking torque applied by drum brake 1 on brake wheel 2. The calculation formula is as follows:

[0055] Mz=FxL

[0056] Among them, Mz is the braking torque applied by the drum brake 1 on the brake wheel 2, F is the pressure measured by the sensor 62, which is the pressure formed on the sensor 62 when the drum brake 1 has a tendency to rotate driven by the brake wheel 2 during braking, and L is the force arm of the pressure measured by the sensor 62 relative to the center of the brake wheel 2.

[0057] In another embodiment:

[0058] As attached Figure 6As shown, the two disc brakes 5 are fixed to the slider 63 by bolts. The top of the slider 63 is flat and has a threaded hole for fixing the disc brake 5. The bottom is a concave, arc-shaped slide groove with a T-slot cross section. The arc radius R is concentric with the radius r of the brake disc 4. The slider 63 is installed on the slide rail 64 and can rotate circumferentially along the arc-shaped T-track at the top of the slide rail 64. The top of the slide rail 64 is provided with an arc-shaped T-track that matches the size of the T-slot of the slider 63. The bottom is flat and fixed to the upper plane of the trolley frame 3. In this way, under the fixing action of the slider 63 and the slide rail 64, the disc brake 5 can only rotate along the axis of the brake disc 2, and the freedom in other directions is restricted. Brackets 61 and sensors 62 are provided on both sides of the slider 63. The bracket 61 is fixed to the upper plane of the trolley frame 3, and the sensor 62 is fixed on the top side and bottom, facing the side of the slider 63. Bracket 61 and sensor 62 are tightly pressed against both sides of slider 63, limiting the left and right rotation of slider 63. This also limits the freedom of disc brake 5 to rotate along the axis of brake disc 4. In this way, slider 63 and disc brake 5 are fixed to the periphery of brake disc 4. During operation, no matter which direction the brake disc 4 rotates, the disc brake 5 will tend to rotate under the influence of the brake disc 4 when braking. However, due to the positional restrictions of bracket 61 and sensor 62, the disc brake 5 does not actually rotate. However, its tendency to rotate will cause a certain amount of pressure on sensor 62. The product of this pressure and the force arm acting from this pressure to the center of brake disc 4 is equal in magnitude and opposite in direction to the braking torque applied by the disc brake 5 on the brake disc 4. The calculation formula is as follows:

[0059] Mzp=FpXLp

[0060] Among them, Mzp is the braking torque of the disc brake 5 acting on the brake disc 4, Fp is the pressure measured by the sensor 62, which is the pressure formed on the sensor 62 when the disc brake 5 has a tendency to rotate under the drive of the brake disc 4 during braking, and Lp is the force arm of the pressure measured by the sensor 62 relative to the center of the brake disc 4.

[0061] from Figure 8As can be seen in the figure, after the brake is applied, the braking torque quickly reaches its maximum value and stabilizes at a certain torque after dropping a certain value. Similarly, the tension or pressure measured by the sensor module 5 is the same. We can calculate the maximum braking torque of the brake acting on the brake wheel or brake disc with the maximum value, and compare this torque with the pre-set braking torque. If it is within the required range, it is considered to meet the requirements, otherwise it prompts the system to be repaired. At the same time, the change of this braking torque over a period of time can be used to judge whether the braking performance of the brake is changing, whether it is getting bigger or smaller (usually slowly). If it suddenly becomes smaller, the control system should be prompted to arrange personnel to inspect and maintain the brake in time to ensure the normal operation of the braking system.

[0062] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device that includes a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In addition, "front", "back", "left", "right", "upper" and "lower" in this document are all referenced to the placement states shown in the accompanying drawings.

[0063] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A braking torque online monitoring system, characterized in that: include: Slide rail and slider mechanism, two sensor modules and control module; The slide rail and slider mechanism includes a slider provided on the bottom surface of the brake and a slide rail provided on the top surface of the support, wherein the slide rail extends along the rotation direction of the brake wheel, and the contact surface between the slider and the slide rail is an arc surface concentric with the brake wheel, and the slider is restricted to rotate along the extension direction of the slide rail; Two sensor modules are respectively arranged on both sides of the slide rail slider mechanism and abut against the end of the slider to limit the rotation of the slider and complete pressure detection; The control module is connected to the two sensing modules and is used to receive the pressure measured by the sensing modules and obtain the braking torque according to the pressure data; The upper surface of the slider is a plane for connecting to the brake, and the lower surface of the slider is an arc surface concentric with the brake wheel; The upper surface of the slide rail is an inwardly concave arc surface concentric with the brake wheel, and the lower surface of the slide rail is a plane for connecting with a support.

2. The braking torque online monitoring system according to claim 1, characterized in that: A T-shaped slot is provided on the arc surface of the bottom of the sliding block, and a T-shaped track adapted to the T-shaped slot is provided on the upper surface of the slide rail, and the T-shaped track is limited in the T-shaped slot.

3. The braking torque online monitoring system according to claim 2, characterized in that: The sensor module includes: a bracket and a sensor. The bracket is arranged opposite to the slide rail and slider mechanism with a distance therebetween. The sensor is connected to the top end of the bracket and abuts against the end of the slider.

4. The braking torque online monitoring system according to claim 3, characterized in that: The sensor is arranged perpendicular to the end of the slider.

5. The braking torque online monitoring system according to claim 1, characterized in that: Also includes: An alarm module is connected to the control module and is used to send an alarm signal when the control module detects that the braking torque is abnormal.

6. A method for online monitoring of braking torque using the online monitoring system for braking torque according to any one of claims 1 to 5, characterized in that: The method comprises: When the brake is applied, the slider applies pressure to the sensor module on one side, and the sensor module sends the monitored pressure data to the control module; The control module obtains the braking torque based on the pressure data.

7. The online monitoring method for braking torque according to claim 6, characterized in that: The control module obtains the braking torque based on the pressure data using the following formula: Mz=F×L; Where Mz is the braking torque applied by the brake on the brake disc or brake wheel, F is the pressure measured by the sensor module, and L is the force arm of the pressure measured by the sensor module relative to the center of the brake disc or brake wheel.

8. The online monitoring method for braking torque according to claim 6, characterized in that: The method further comprises: When the control module detects abnormal braking torque, it sends an alarm signal through the alarm module.

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