Brake detection system and method

Abstract

The embodiment of the application discloses a brake detection system and method, which comprises a controller, a driver, a motor and a relay. The driver is used for receiving a control signal sent by the controller and outputting a driving current to drive the motor to rotate according to the control signal. The relay is used for receiving an opening signal or a closing signal output by the controller to open or close the brake in the motor. The controller is used for controlling the driver to drive the motor and acquiring the value of an encoder in the motor, judging whether the motor rotates according to the value of the encoder, saving the torque value corresponding to the rotation of the motor when the motor rotates, and detecting the brake according to the torque value. The embodiment of the application does not need manual operation, is simple to detect and has high efficiency.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of motor brake detection, and particularly relates to a brake detection system and method. BACKGROUND

[0002] A motor brake is a kind of brake device, which can lock the position of a motor when the motor stops, and prevent the motor from rotating accidentally, and is extremely important for safety protection. Before a motor is shipped or stored in a warehouse, the quality of the motor brake will be detected. At present, in order to realize the quality detection of the motor brake, motor manufacturers usually measure the friction force of the motor brake in the released or clamped state by using a torque wrench, or measure the voltage variation waveform of the brake coil when the brake coil is powered on by using an oscilloscope to judge the action time of the motor brake, so as to judge whether the motor brake is abnormal. However, the detection method needs manual operation, is low in efficiency, and is complex in method and cumbersome in steps. SUMMARY

[0003] Embodiments of the present application provide a brake detection system and method, which aims to improve the efficiency of the existing motor brake detection system.

[0004] In order to achieve the above-mentioned purpose, on one hand, the present application provides a brake detection system, which comprises a controller, a driver, a motor and a relay, wherein,

[0005] The driver is used for receiving the control signal sent by the controller, and outputting a driving current to drive the motor to rotate according to the control signal;

[0006] The relay is used for receiving the opening signal or the closing signal output by the controller to open or close the brake in the motor;

[0007] The controller is used for controlling the driver to drive the motor and acquiring the value of the encoder in the motor, and judging whether the motor rotates according to the value of the encoder, saving the torque value corresponding to the rotation of the motor when the motor rotates, and detecting the brake according to the torque value.

[0008] Further technical solutions are as follows: the controller comprises a storage device, and the storage device is used for storing the value of the encoder and the torque value.

[0009] Further technical solutions are as follows: the driver comprises an encoder interface, the encoder interface is connected with the encoder, and is used for receiving the value sent by the encoder.

[0010] To achieve the above object, in another aspect, the present application also provides a brake detection method, which comprises: a controller outputs an opening signal or a closing signal to a relay for controlling the relay to open or close a motor brake, and sends a torque value to a driver; the driver outputs a corresponding driving current according to the torque value to drive the motor to rotate; the controller acquires a value of an encoder in the motor and judges whether the motor rotates according to the value of the encoder; and the controller detects the motor brake according to the torque value saved when the motor rotates and the opening signal or the closing signal.

[0011] Further technical solutions are: the step of the controller acquiring the value of the encoder in the motor and judging whether the motor rotates according to the value of the encoder comprises: the controller acquires a current encoder value in the motor as a comparison encoder value and compares the comparison encoder value with a previous encoder value; if the value of the encoder changes, the controller determines that the motor rotates.

[0012] Further technical solutions are: the step of comparing the comparison encoder value with the previous encoder value further comprises: if the value of the encoder does not change, the controller increases the torque value according to a preset torque increase amount and sends the increased torque value to the driver; and the step of the controller acquiring the current encoder value in the motor as the comparison encoder value is executed again.

[0013] Further technical solutions are: the step of the controller detecting the motor brake according to the torque value saved when the motor rotates and the opening signal or the closing signal comprises: if the controller outputs the opening signal to the relay, the controller controls the relay to open the motor brake; saves a corresponding torque value when the motor rotates to obtain a first target torque value; compares the first target torque value with a first preset torque threshold value; and if the first target torque value is greater than the first preset torque threshold value, it is determined that the motor brake is not normally opened or the motor brake has an assembly problem.

[0014] Further technical solutions are: the step of the controller detecting the motor brake according to the torque value saved when the motor rotates and the opening signal or the closing signal comprises: if the controller outputs the closing signal to the relay, the controller controls the relay to close the motor brake; saves a corresponding torque value when the motor rotates to obtain a second target torque value; compares the second target torque value with a second preset torque threshold value; and if the second target torque value is less than the second preset torque threshold value, it is determined that the motor brake is not normally closed or the motor brake has a wear problem.

[0015] Further technical solutions are: the method further comprises: the controller outputs the closing signal to the relay, and the relay is controlled to close the motor brake; the controller sends the torque value to the driver, wherein the torque value is greater than the first target torque value and less than the second target torque value; the controller outputs the opening signal to the relay, and the relay is controlled to open the motor brake, and an initial time is obtained as a current time; when the motor rotates, the current time is obtained as an end time, and a time difference is calculated by subtracting the initial time from the end time; whether the motor brake opening has a delay is detected according to the time difference.

[0016] Further technical solutions are: the step of detecting whether the motor brake opening has a delay according to the time difference comprises: judging whether the time difference is greater than a preset time threshold; if the time difference is greater than the preset time threshold, it is determined that the motor brake opening has a delay.

[0017] The embodiment of the application provides a brake detection system and method, wherein the system comprises: a controller, a driver, a motor and a relay, the driver is used for receiving a control signal sent by the controller and outputting a driving current to drive the motor to rotate according to the control signal; the relay is used for receiving an opening signal or a closing signal output by the controller to open or close a brake in the motor; the controller is used for controlling the driver to drive the motor and acquiring a value of an encoder in the motor, and judging whether the motor rotates according to the value of the encoder, saving a torque value corresponding to the motor rotation when the motor rotates, and detecting the brake according to the torque value. The system controls the brake of the motor to be in an open or closed state through the relay, sends the torque value to the driver to drive the motor to rotate by the controller, detects whether the brake of the motor has an abnormality according to the torque value when the motor rotates, and the detection method of the embodiment of the application does not need manual operation, is simple to detect and high in efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0018] In order to more clearly illustrate the technical solutions of the embodiments of the application, the following will briefly introduce the drawings needed to be used in the embodiment description. Obviously, the drawings in the following description are some embodiments of the application, and other drawings can also be obtained by those skilled in the art without creative labor.

[0019] Figure 1 It is a structure block diagram of an embodiment of a brake detection system of the application;

[0020] Figure 2 It is a specific structure block diagram of an embodiment of a brake detection system of the application;

[0021] Figure 3 Flowchart of an embodiment of the brake detection method of the present application;

[0022] Figure 4 Flowchart of an embodiment of the brake detection method of the present application;

[0023] Figure 5 Flowchart of an embodiment of the brake detection method of the present application;

[0024] Figure 6 Flowchart of an embodiment of the brake detection method of the present application. DETAILED DESCRIPTION

[0025] The technical solutions in the embodiments of the present application will be clearly and completely described with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are some but not all of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0026] It should be understood that the terms "comprising" and "including" as used in the specification and the appended claims indicate the presence of the described features, integers, steps, operations, elements, and / or components but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0027] It should also be understood that the terms used in the present application specification are only for the purpose of describing particular embodiments and are not intended to limit the present application. As used in the present application specification and the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms unless the context clearly indicates otherwise.

[0028] It should be further understood that the term "and / or" as used in the present application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations thereof.

[0029] As used in the present application specification and the appended claims, the term "if" can be interpreted as meaning "when" or "once" or "in response to a determination" or "in response to detecting" depending on the context. Similarly, the phrases "if determined" or "if [the described condition or event] is detected" can be interpreted as meaning "once determined" or "in response to a determination" or "once [the described condition or event] is detected" or "in response to detecting [the described condition or event]" depending on the context.

[0030] With reference to Figures 1 to 2 The brake detection system 10 provided by the embodiment of the present application comprises a controller 11, a driver 12, a motor 13 and a relay 14. The driver 12 is configured to receive a control signal sent by the controller 11 and output a driving current to drive the motor 13 to rotate according to the control signal. The relay 14 is configured to receive an opening signal or a closing signal output by the controller 11 to open or close the brake in the motor. The controller 11 is configured to control the driver 12 to drive the motor 13 and acquire a value of an encoder in the motor 13, and determine whether the motor 13 rotates according to the value of the encoder. When the motor 13 rotates, a torque value corresponding to the rotation of the motor 13 is saved, and the brake is detected according to the torque value. The brake detection system provided by the embodiment controls the brake of the motor 13 to be in an open or closed state by the relay 14, sends a torque value to the driver 12 by the controller 11 to drive the motor 13 to rotate, and detects whether the brake of the motor 13 is abnormal according to the torque value when the motor 13 rotates. The detection method is simple and efficient.

[0031] In some embodiments, for example in the present embodiment, as Figure 2As shown, the controller 11 comprises a storage device 111, the driver 12 comprises an encoder interface 121, and the motor 13 comprises an encoder 131 and a brake 132. The storage device 111 is configured to store the value of the encoder 131 and the torque value. The encoder interface 121 is connected to the encoder 131 and configured to receive the value sent by the encoder 131. Specifically, the controller 11 can be any one of a PLC (Programmable Logic Controller), a motion controller, and a PC computer, and the controller 11 is configured to send a control signal to the driver 12. The driver 12 can be a servo driver, a frequency converter, or any other motor driving device, and the driver 12 is configured to drive the motor 13 to rotate by outputting a corresponding current according to the control signal sent by the controller 11. The encoder interface 121 is connected to the encoder 131, and further, the encoder interface 121 can be connected to the encoder 131 through an encoder line, acquire the value of the encoder 131 from the encoder 131, and send the acquired value of the encoder 131 to the controller 11 through the driver 12. Alternatively, if the driver 12 does not comprise the encoder interface 121, the encoder interface 121 can be installed on the controller 11, and the controller 11 directly acquires the value of the encoder 131 through the encoder interface 121. The motor 13 can be an asynchronous motor or a servo motor, the encoder 131 outputs a corresponding encoding value according to the rotation of the motor 13, so that the rotation speed of the motor 13 can be detected, and the brake 132 is installed on the motor 13 and configured to provide a braking force for the motor 13. The relay 14 can be a mechanical relay, a solid-state relay, or any other controllable switching circuit, and is configured to turn on or off the power supply of the brake 132 to control the opening or closing of the brake 132.

[0032] Referring to Figure 3 , Figure 3 FIG. 1 shows a flowchart of an embodiment of the brake detection method of the present application, which is applied to the brake detection system described above. The specific working principle of the brake detection system of the present application will be further described in detail below by using the method. Figure 3 As shown in FIG. 1, the method comprises the following steps.

[0033] S200, the controller sends an opening signal or a closing signal to the relay to control the relay to open or close the motor brake, and sends a torque value to the driver.

[0034] In the embodiment of the present application, the relay opens the power supply of the motor brake to open the motor brake after receiving the opening signal sent by the controller, or the relay closes the power supply of the motor brake to close the motor brake after receiving the closing signal sent by the controller. When the motor brake is opened, the controller sends a torque value P1 to the driver, wherein the value of the torque value P1 is 0 in the first sending; when the motor brake is closed, the controller sends a torque value P2 to the driver, wherein the value of the torque value P2 is 0 in the first sending.

[0035] S210, the driver controls the motor to rotate according to the torque value.

[0036] In the embodiment of the present application, the driver receives the torque value sent by the controller, and outputs a corresponding current according to the torque value to drive the motor to rotate. It should be noted that in the present embodiment, the driver has a torque control mode, and has an encoder interface, through which the value of the encoder sent by the encoder in the motor is received, and the value of the encoder is returned to the controller.

[0037] S220, the controller acquires the value of the encoder in the motor, and judges whether the motor rotates according to the value of the encoder.

[0038] In the embodiment of the present application, the motor includes an encoder, and the value of the encoder changes when the motor rotates, so that whether the motor rotates can be detected. Specifically, the encoder is connected with the encoder interface of the driver through an encoder line, the value of the encoder is sent to the encoder interface through the encoder line, and the value of the encoder sent by the encoder interface is sent to the controller by the driver. The controller acquires the current value of the encoder in the motor as a comparison encoder value, and compares the comparison encoder value with the last encoder value. If the value of the encoder changes, the controller determines that the motor rotates. The controller can judge whether the motor rotates in real time by acquiring the value of the encoder, which is more timely and accurate.

[0039] In the embodiment of the present application, after the step of comparing the encoder value with the previous encoder value, the controller further increases the torque value according to a preset torque increment if the encoder value does not change, and sends the increased torque value to the driver; and the step of obtaining the current encoder value of the motor as the comparison encoder value is performed again. Specifically, if the encoder value does not change, it indicates that the motor does not rotate, and the controller increases the torque value according to the preset torque increment and sends the increased torque value to the driver until the increased torque value can drive the motor to rotate or the torque value reaches the maximum torque value that the motor can output. It should be noted that in the embodiment, the preset torque increment is determined according to the actual measurement accuracy, for example, the preset torque increment can be set to one thousandth of the rated torque value of the motor, or greater than one thousandth of the rated torque value of the motor. It can be understood that the torque increment is determined according to the torque value accuracy that the driver can receive and the user's desired detection accuracy, for example, if the torque increment is set to be large, the detection accuracy is low; if the torque increment is set to be small, the detection takes a long time, therefore, the user can determine the torque increment according to the actual needs, which is not limited in the present application.

[0040] S230, the controller detects the motor brake according to the torque value saved when the motor rotates and the opening instruction or the closing instruction.

[0041] In the embodiment of the present application, when the motor brake is in the opening state, the controller detects the motor brake by comparing the torque value saved when the motor rotates with the first preset torque threshold; and when the motor brake is in the closing state, the controller detects the motor brake by comparing the torque value saved when the motor rotates with the second preset torque threshold.

[0042] In an embodiment, for example, in the present embodiment, please refer to Figure 4 The step S230 can include the following steps S231a-S234a.

[0043] S231a, if the controller outputs the opening signal to the relay, the relay opens the motor brake according to the opening signal;

[0044] S232a, save the torque value corresponding to the motor rotating to obtain a first target torque value;

[0045] S233a, compare the first target torque value with the first preset torque threshold;

[0046] S234a, if the first target torque value is greater than the first preset torque threshold, it is determined that the motor brake is not normally opened or the motor brake has assembly problems.

[0047] In the embodiment of the application, the controller outputs an opening signal to the relay, and after the relay opens the motor brake according to the opening signal, the controller sends a torque value P1 to the driver, wherein the torque value P1 sent for the first time is 0, the driver outputs a corresponding current to the motor according to the torque value P1 to drive the motor, if the motor does not rotate, the torque value P1 is increased according to a preset torque increase and sent to the driver until the driver can drive the motor to rotate, the current torque value is saved as a first target torque value P1a, and the first target torque value P1a is compared with a first preset torque threshold PA, if the first target torque value P1a is greater than the first preset torque threshold PA, i.e. P1a>PA, it is determined that the motor brake is not normally opened or the motor brake has assembly problems. It should be noted that in the embodiment, the first target torque value P1a is the rotational static friction of the motor. It can be understood that if P1a≤PA, it is determined that the motor brake is normal. The method of comparing the torque value with the preset torque threshold for detection in the embodiment of the application has less equipment investment, is convenient and fast, and has high detection precision and strong reliability.

[0048] In an embodiment, for example, in the embodiment, please refer to Figure 5 The above step S230 can also include the following steps S231b-S234b.

[0049] S231b, if the controller outputs a closing signal to the relay, the relay closes the motor brake;

[0050] S232b, save the torque value corresponding to the rotation of the motor to obtain a second target torque value;

[0051] S233b, compare the second target torque value with a second preset torque threshold;

[0052] S234b, if the second target torque value is less than the second preset torque threshold, it is determined that the motor brake is not normally closed or the motor brake has wear problems.

[0053] In the embodiment, after determining that the motor brake is not abnormally opened or the motor brake does not have an assembly problem through the steps S231a-S234a, the controller outputs a closing signal to the relay, the relay closes the motor brake according to the closing signal, and the controller sends a torque value P2 to the driver, where the torque value P2 sent for the first time is 0. The driver outputs a corresponding current to the motor according to the torque value P2 to drive the motor. If the motor does not rotate, the torque value P2 is increased according to a preset torque increase and is sent to the driver until the driver can drive the motor to rotate or the torque value P1 reaches a maximum torque value of the motor. When the motor rotates or the torque value P1 reaches the maximum torque value of the motor, a current torque value is saved as a second target torque value P2a. The second target torque value P2a is compared with a second preset torque threshold PB. If the second target torque value P2a is less than the second preset torque threshold PB, that is, P2a

[0054] In an embodiment, for example, the embodiment, refer to Figure 6 After the steps S231-S234a and S231b-S234b are performed, the brake detection method further includes the following steps S300-S340.

[0055] S300, the controller outputs the closing signal to the relay, and controls the relay to close the motor brake;

[0056] S310, the controller sends the torque value to the driver, where the torque value is greater than the first target torque value and less than the second target torque value;

[0057] S320, the controller outputs the opening signal to the relay, and controls the relay to open the motor brake, and simultaneously acquires a current time as an initial time;

[0058] S330, when the motor rotates, the current time is acquired as an end time, and a time difference is calculated according to a difference between the end time and the initial time;

[0059] S340, the time difference is detected to determine whether the motor brake opening has a delay.

[0060] In the embodiment of the present application, after the motor brake is detected to be normal after the steps S231-S234a and S231b-S234b are performed, the controller outputs a closing signal to the relay, the relay closes the motor brake according to the closing signal, the controller sends a torque value P3 to the driver, wherein the torque value P3 is greater than the first target torque value P1a and less than the second target torque value P2a, i.e. P1a < P3 < P2a, and it should be noted that the first target torque value P1a can be the first preset torque threshold PA and the second target torque value P2a can be the second preset torque threshold PB. The driver outputs a corresponding current according to the torque value P3, and the current can drive the motor to rotate when the motor brake is opened. Then the controller outputs an opening signal to the relay, the relay opens the motor brake according to the opening signal, and at the same time the controller starts timing, obtains the current time as the initial time, and judges whether the motor rotates by obtaining the value of the encoder, when the motor rotates, the timing is stopped, the current time is obtained as the end time, and the difference between the end time and the initial time is calculated to obtain the time difference, thereby obtaining the time required from when the motor brake is opened to when the motor rotates, and according to the time difference, whether the motor brake opening is delayed can be detected. Specifically, for ease of understanding, it is assumed that the time difference is T3 and the preset time threshold is TA, if the time difference T3 is greater than the preset time threshold TA, i.e. T3 > TA, it is determined that the motor brake opening is delayed. By detecting the time difference, whether the motor brake has a brake action delay fault when switching between closing and opening can be detected, which is not only comprehensive and reliable, but also can detect whether the performance of the motor brake meets the requirements. It should be noted that in the embodiment, the time difference T3 is less than the sum of the brake delay time provided by the motor manufacturer and the relay delay time, wherein the relay delay time is set by the relay manufacturer, for example, the delay time of a general power mechanical relay is less than 20 ms, the delay time of a high-power mechanical relay is less than 30 ms, and the delay time of an optical coupling relay is less than 1 ms. More specifically, the result obtained by subtracting the delay time generated by the relay from the time difference T3 is compared with the preset time threshold TA, if the result is greater than the preset time threshold TA, it is determined that the motor brake opening is delayed. Understandably, if the result is not greater than the preset time threshold TA, it is determined that the motor brake is normal. It should be noted that in another embodiment, the preset time threshold is determined by the motor manufacturer according to the actual performance requirements, for example, the motor brake delay time is usually 0.1-0.3 s.

[0061] In summary, the brake detection system and method provided by the embodiment can determine whether the motor brake is not normally opened or has assembly problems by detecting the corresponding torque value of the motor rotation when the motor brake is opened; can determine whether the motor brake is not normally closed or has wear problems by detecting the corresponding torque value of the motor rotation when the motor brake is closed; and can determine whether the motor brake opening is delayed by detecting the time difference from the opening of the motor brake to the motor rotation. Through the detection from multiple aspects, the on-site device failure rate and the accident occurrence probability can be reduced. The detection method is simple, accurate and reliable, and the detection is comprehensive, the number of detection devices is small, and the cost is saved.

[0062] The application has been described in conjunction with the preferred embodiments, but the application is not limited to the embodiments disclosed above, but should cover various modifications, equivalent combinations made according to the essence of the application.

Claims

1. A brake detection method characterized by, The application is applied to a brake detection system, and the brake detection system comprises a controller, a driver, a motor and a relay, The driver is used for receiving a control signal sent by the controller and outputting a driving current to drive the motor to rotate according to the control signal; The relay is used for receiving an opening signal or a closing signal output by the controller to open or close the brake in the motor; The controller is used for controlling the driver to drive the motor and acquiring a value of an encoder in the motor, judging whether the motor rotates according to the value of the encoder, saving a torque value corresponding to the rotation of the motor, and detecting the brake according to the torque value; The method comprises: The controller sends an opening signal or a closing signal to the relay to control the relay to open or close the brake in the motor, and sends a torque value to the driver; The driver outputs a corresponding driving current to drive the motor to rotate according to the torque value; The controller acquires a value of an encoder in the motor and judges whether the motor rotates according to the value of the encoder; If the value of the encoder does not change, the controller increases the torque value according to a preset torque increase amount and sends the increased torque value to the driver until the motor rotates; The controller detects the brake in the motor according to the torque value saved when the motor rotates and the opening signal or the closing signal; If the controller outputs the opening signal to the relay, the relay is controlled to open the brake in the motor; The torque value corresponding to the rotation of the motor is saved to obtain a first target torque value; The first target torque value is compared with a first preset torque threshold value; If the first target torque value is greater than the first preset torque threshold value, it is determined that the brake in the motor is not normally opened or the brake in the motor has an assembly problem; If the controller outputs the closing signal to the relay, the relay is controlled to close the brake in the motor; The torque value corresponding to the rotation of the motor is saved to obtain a second target torque value; The second target torque value is compared with a second preset torque threshold value; If the second target torque value is less than the second preset torque threshold value, it is determined that the brake in the motor is not normally closed or the brake in the motor has a wear problem.

2. The brake detection method according to claim 1, characterized by, The controller comprises a storage device for storing the value of the encoder and the torque value.

3. The brake detection method according to claim 1, characterized by, The driver comprises an encoder interface connected with the encoder for receiving the value sent by the encoder.

4. The brake detection method according to claim 1, characterized by, The step that the controller acquires the value of the encoder in the motor and judges whether the motor rotates according to the value of the encoder comprises: The controller acquires the value of the current encoder in the motor as a comparison encoder value and compares the comparison encoder value with the value of the last encoder; If the value of the encoder changes, the controller determines that the motor rotates.

5. The brake detection method according to claim 4, characterized by, The step of comparing the comparison encoder value with the value of the last encoder further comprises: If the value of the encoder does not change, the controller increases the torque value according to a preset torque increase amount, and sends the increased torque value to the driver; Return to execute the step of obtaining the value of the current encoder in the motor as the comparison encoder value by the controller.

6. The brake detection method according to claim 1, wherein The method further comprises: The controller outputs the closing signal to the relay, thereby controlling the relay to close the motor brake; The controller sends the torque value to the driver, wherein the torque value is greater than the first target torque value and less than the second target torque value; The controller outputs the opening signal to the relay, thereby controlling the relay to open the motor brake, and obtaining the current time as the initial time; When the motor rotates, the current time is obtained as the end time, and the difference between the end time and the initial time is calculated to obtain a time difference; According to the time difference, it is detected whether there is a delay in opening the motor brake.

7. The brake detection method according to claim 6, wherein The step of detecting whether there is a delay in opening the motor brake according to the time difference comprises: Determine whether the time difference is greater than a preset time threshold; If the time difference is greater than the preset time threshold, it is determined that there is a delay in opening the motor brake.

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