Brake testing method and system and application thereof

Abstract

The invention discloses a brake testing method and system and application thereof.According to the scheme, when a brake works, the torque output by the brake and the oil way condition are ingeniously monitored, so that the working condition of the brake can be better monitored, vibration and noise generated when the brake works are further monitored, and the brake testing efficiency is improved. According to the technical scheme of the invention, when the brake of the crane, which is used as a braking object, is in braking work, the manifestation problem shown by the brake is monitored, so that the vibration and noise of the brake in the braking work process can be well recorded for indirectly representing the working condition of the brake, and the comprehensiveness of brake monitoring is improved. Under the condition of multi-working-condition switching, when the test result points to brake feedback abnormity, multi-modal data fusion is carried out on the monitoring data acquired by the sensor group, a corresponding model is constructed, single-factor and multi-factor abnormity judgment is carried out on the data in the monitoring data, and more reliable abnormity judgment with relevance is provided for brake test.

Description

Technical Field

[0001] The invention relates to the fields of brake testing technology and crane brake self-testing technology, and in particular to a brake testing method, system and application thereof. Background Art

[0002] As a key braking component of a crane, the brake is related to whether the driving component of the crane can accurately cooperate with the operator's control to drive the moving component to a specified position or form a specific posture when driving; and because the working scene of the crane is complex and there are also large load changes, how to test the crane to evaluate its health status is a very positive and realistic work; however, most of the current methods for testing the brakes of cranes are to test the braking effect of the crane after the brake intervention under specific working conditions, but there is little attention to whether there are local abnormalities (abnormal fluctuations) in the components that cooperate with the brake, which makes it easy to ignore some abnormal factors that have not yet affected the expansion during the daily maintenance of the crane brake. Hydraulic brakes are a commonly used type of brakes in cranes. They are widely used because of their large output force, reliable control and convenience. However, there are currently few documents that disclose how to test hydraulic brakes in detail when they are loaded on cranes. Therefore, how to optimize the test method of crane brakes and obtain more comprehensive and detailed test results is a very positive and realistic research topic. Summary of the invention

[0003] In view of this, the purpose of the present invention is to propose a brake testing method, system and application thereof, which are convenient to test, flexible to apply, and whose testing process is close to the actual application scenario of the equipment and whose test results have good reference value.

[0004] In order to achieve the above technical objectives, the technical solution adopted by the present invention is:

[0005] A brake testing method is used for testing a hydraulic brake, wherein a sensor group is deployed on the brake and a hydraulic oil circuit system connected thereto, and the brake is installed on a braking object. The testing method comprises:

[0006] S01. Calibrate the sensor group according to preset conditions to make the working state of the sensor group meet the preset requirements;

[0007] S02, placing the brake object in a preset working condition, then starting the brake according to the preset conditions, making the brake enter an initial working state, and at the same time, monitoring the torque output by the brake and the working parameters of the hydraulic oil circuit system connected thereto in real time, generating torque monitoring information and oil circuit monitoring information respectively;

[0008] S03. After the brake is in the initial working state for a preset period of time, adjust or maintain the working state of the brake object, record the working condition information of the brake object in real time and add a timestamp to it, and then switch the working state of the brake to at least one braking working state in sequence according to the preset control instruction, and at the same time, continue to monitor the torque output by the brake and the working parameters of the hydraulic oil circuit system connected to it in real time, and add a timestamp to the data obtained by monitoring;

[0009] S04. Obtain torque monitoring information and oil circuit monitoring information, combine the working condition information of the braking object, evaluate the performance of the brake according to preset conditions, and generate test results.

[0010] As a possible implementation, further, the sensor group described in this solution includes a temperature sensor, a hydraulic sensor and a torque sensor;

[0011] The hydraulic oil circuit system of the brake is provided with a temperature sensor for monitoring the temperature change of the hydraulic oil, and a hydraulic sensor for monitoring the pressure change of the pressure oil in the hydraulic oil circuit system, and the brake is provided with a torque sensor for monitoring the output braking force of the brake;

[0012] In S01, when the sensor group is calibrated, the same reference time is also provided to the sensor group through the same clock source;

[0013] In S02, the preset working condition of the braking object is a no-load state or a rated load state; the torque monitoring information and the oil circuit monitoring information are both generated and recorded in a time series.

[0014] As a preferred implementation option, preferably, the sensor group described in this solution also includes a sound sensor and a vibration sensor; the body of the brake is also equipped with a volume sensor for monitoring the decibel number of noise when it is working, and a vibration sensor for monitoring the vibration of the brake when it is working;

[0015] In S02 and S03, after the brake is started, the state of the brake is also monitored by a volume sensor and a vibration sensor, and noise monitoring information and vibration monitoring information with timestamps are generated respectively;

[0016] Correspondingly, in the present scheme S04, when acquiring the torque monitoring information and the oil circuit monitoring information, the noise monitoring information and the vibration monitoring information are also acquired synchronously, and the performance of the brake is evaluated according to the preset conditions in combination with the working condition information of the braking object to obtain the test results.

[0017] As a preferred implementation option, preferably, in the present solution S03, when the working state of the brake is switched to at least one braking working state in sequence according to the preset control instruction, the time point t0 at which the control instruction is issued and the time point t1 at which the brake responds to the control instruction and performs the action are calculated. z Record and generate response record information;

[0018] Among them, the stability of the brake in the corresponding working state is judged by obtaining the torque monitoring information and the oil circuit monitoring information. When it works stably for a preset time, the working state of the brake is switched to the next braking working state according to the preset control instruction.

[0019] As a preferred implementation option, preferably, this solution S04 includes:

[0020] S041, acquiring torque monitoring information, oil circuit monitoring information, noise monitoring information and vibration monitoring information, as well as response record information and working condition information of the braking object;

[0021] S042, determining the working condition change of the braking object according to the working condition information of the braking object, and extracting the time line of the brake intervention or braking release on the braking object in combination with the corresponding timestamp, and then marking the braking state or braking release therein, and generating the braking object state information recorded in a time series;

[0022] S043. According to the braking object status information, one of the torque monitoring information, oil circuit monitoring information, noise monitoring information, vibration monitoring information, and response record information is judged and evaluated separately or multiple of them are judged and evaluated jointly, and then the obtained judgment and evaluation results are collected to generate a test result.

[0023] As a preferred implementation option, preferably, the brake described in this scheme is also equipped with a force sensor for monitoring the positive pressure generated between the friction pad on the brake caliper and the brake disc; the brake disc radius of the brake and the friction coefficient μ between the friction pad and the brake disc are known parameters measured in advance.

[0024] As a preferred implementation option, preferably, in the present solution S043, the method for judging and evaluating the torque monitoring information according to the braking object state information includes one of the following:

[0025] (1) A braking torque calculation model is established to measure the braking output performance of the brake. The calculation formula is defined as follows:

[0026] T=F·R

[0027] Wherein, T is the braking torque, its unit is N·m, F is the braking force, which is generated by the friction between the brake caliper and the brake disc, its unit is N, and R is the effective radius of the brake disc, its unit is m;

[0028] When the braking object state information indicates that the brake is in the braking state, the positive pressure N generated by the friction pad on the brake disc is measured by the force sensor, and the braking force is calculated in combination with the friction coefficient μ. The formula is defined as follows:

[0029] F=N·μ

[0030] According to the pressure data measured by the force sensor, combined with the friction coefficient μ and the effective radius R of the brake disc, the torque F when the brake is working is calculated. n , and then aggregate them into time series to obtain the moment data set F t =[F1, F2, F3, ..., F n ], and then compare it with the preset threshold value. When it exceeds the preset threshold value, the torque output abnormality is generated as the evaluation result, otherwise it is generated as the evaluation result, and the judgment evaluation result about the braking torque monitoring data is generated;

[0031] (2) Based on the pressure data measured by the force sensor, combined with the friction coefficient μ and the effective radius R of the brake disc, the torque of the brake during operation is calculated, and then compared with the torque directly measured by the torque sensor to evaluate the change in the friction coefficient between the brake pad and the brake disc under braking, and generate a judgment and evaluation result on the braking torque monitoring data;

[0032] (3) The torque F directly measured by the torque sensor m Aggregate by time series to obtain the moment data set F t =[F1, F2, F3, ..., F m ] and then compared with the preset threshold. When it exceeds the preset threshold, an abnormal torque output is generated as the evaluation result, otherwise a normal torque output is generated as the evaluation result to obtain a judgment evaluation result on the braking torque monitoring data.

[0033] As a preferred implementation option, preferably, in the present solution S043, according to the braking object state information, a single judgment and evaluation is performed on one of the torque monitoring information, the oil circuit monitoring information, the noise monitoring information, the vibration monitoring information, and the response record information, or a combined judgment and evaluation of multiple information includes one of the following:

[0034] (1) Obtain oil circuit monitoring information, extract the time line of intervention braking or release braking from it according to the state information of the braking object, so as to obtain the time interval for grouping data extraction, and then extract the hydraulic data in the oil circuit monitoring information according to the time interval; then perform pressure fluctuation assignment calculation on it to obtain the hydraulic pressure change of the hydraulic oil circuit system in the time interval when the state information of the braking object is in different states, which is expressed as follows:

[0035] P=P max -P min

[0036] Among them, P max is the maximum pressure measured by the hydraulic sensor in the corresponding time interval, P min is the minimum pressure value measured by the hydraulic sensor in the corresponding time interval, and P is the fluctuation amplitude of the hydraulic oil system pressure in the corresponding time interval;

[0037] A threshold value judgment is performed on the fluctuation amplitude. When it exceeds the preset threshold value, a hydraulic oil circuit abnormality is generated as an evaluation result. Otherwise, a normal value is generated as an evaluation result to obtain a judgment evaluation result on the oil circuit monitoring information.

[0038] (2) Obtain response records and torque monitoring information, combine them with the braking object status information, and calculate the braking response time t from the issuance of the control command to the initiation of the brake action so that the braking torque reaches the set range value r , whose formula is defined as follows:

[0039] t r =t f -t s

[0040] Among them, t s is the time when the control command is issued, t f It is the time point when the braking torque reaches the set range value;

[0041] Performing a threshold judgment on the braking response time, when it exceeds a preset threshold, generating a braking response abnormality as an evaluation result, otherwise generating a normal as an evaluation result, and obtaining a judgment evaluation result on the response record;

[0042] (3) Acquire noise monitoring information, vibration monitoring information, and brake object status information, and extract the timeline of intervention braking or release braking from the brake object status information to obtain a time interval for grouping data extraction, and then extract noise data and vibration data from the noise monitoring information and vibration monitoring information according to the time interval;

[0043] Threshold judgment is performed on the noise data and vibration data. When they exceed the preset threshold, a braking feedback abnormality is generated as an evaluation result, otherwise a normal is generated as an evaluation result, and a judgment and evaluation result on the noise monitoring information and the vibration monitoring information is obtained.

[0044] As a preferred implementation option, preferably, in the present solution S03, while the working state of the brake is switched to at least one of the above brake working states in sequence, interference factors are also added to the working environment of the brake, and the parameters and types corresponding to the interference factors are recorded, wherein the interference factors include adjusting the temperature, humidity, and magnetic field of the working environment of the brake; when generating torque monitoring information, oil circuit monitoring information, noise monitoring information, vibration monitoring information, and response records, the interference factor information associated therewith is also generated synchronously;

[0045] Correspondingly, in the present solution S04, when generating the test results, the interference factor information is also added thereto.

[0046] As a preferred implementation option, preferably, the testing method described in this solution also includes:

[0047] S05. Obtaining test results. When the test results contain abnormal brake feedback, further comprehensive analysis is performed on the test results to determine the cause of the abnormal brake noise data or vibration data, which includes:

[0048] Construct a multimodal data fusion model to integrate the data in torque monitoring information, oil circuit monitoring information, noise monitoring information, and vibration monitoring information into the multimodal data fusion model, which is defined as follows:

[0049] D={T(t),P(t),X(t),A(t)}

[0050] Wherein, D is a multimodal data fusion data set, T(t), P(t), X(t), and A(t) are data groups formed by collecting corresponding data in torque monitoring information, oil circuit monitoring information, noise monitoring information, and vibration monitoring information, respectively. They are collected in time series and are set as torque monitoring data group, oil circuit monitoring data group, noise monitoring data group, and vibration monitoring data group, respectively;

[0051] The data in the multimodal data fusion dataset is normalized so that the data of different physical quantities are unified to the same scale. Its definition is as follows:

[0052]

[0053] Among them, D" is the normalized multimodal data fusion dataset, x i is the data value of a single data in the multimodal data fusion data D, max(x) and min(x) are x respectively.i The maximum and minimum values ​​in the data group;

[0054] The torque monitoring data group, oil circuit monitoring data group, and vibration monitoring data group in the multimodal data fusion data set D" are subjected to a low-pass filter to eliminate high-frequency noise, and the noise monitoring data are subjected to environmental noise removal to eliminate the frequency bands interfered by environmental noise;

[0055] Perform univariate anomaly judgment on the data in the multimodal data fusion data set D" by using the 3-times standard deviation rule or the sliding window average method to generate a univariate anomaly judgment result;

[0056] Perform multivariate anomaly judgment on the data in the multimodal data fusion data set D" through the trained detection neural network or random forest algorithm to generate a multivariate anomaly judgment result;

[0057] The cause of the abnormality inducing the brake noise data or vibration data is determined based on the single variable abnormality determination result and / or the multivariate abnormality determination result.

[0058] Based on the above, the present invention also provides a crane brake testing method, which is applied with the above brake testing method, and further includes:

[0059] In response to the work start signal of the crane, S01 to S04 are executed to realize a safety self-test of the brake of the crane;

[0060] Obtain test results and make threshold adjustments to the operating parameters of the crane drive components.

[0061] Based on the above, the present invention also provides a brake testing system, which is applied to the brake of a crane and includes:

[0062] A sensor group, including a plurality of temperature sensors, hydraulic sensors, torque sensors, sound sensors and vibration sensors; a temperature sensor for monitoring the temperature change of the hydraulic oil and a hydraulic sensor for monitoring the pressure change of the pressure oil in the hydraulic oil system are deployed on the hydraulic oil circuit system of the brake, and a torque sensor for monitoring the output braking force of the brake is deployed on the brake; a volume sensor for monitoring the decibel number of noise when the brake is working and a vibration sensor for monitoring the vibration condition of the brake when working are deployed on the main body of the brake;

[0063] A sensor calibration unit, used to calibrate the sensor group according to preset conditions so that the working state of the sensor group meets the preset requirements;

[0064] A working control unit is used to place the brake object in a preset working condition, and then start the brake according to the preset conditions, so that the brake enters the initial working state, and at the same time, sends monitoring information to the sensor group to enable it to monitor the torque output by the brake and the working parameters of the hydraulic oil circuit system connected to it in real time, and generate torque monitoring information and oil circuit monitoring information respectively; after the brake is started, the brake state is also monitored through the volume sensor and the vibration sensor, and noise monitoring information and vibration monitoring information with timestamps are generated respectively; it is also used to adjust or maintain the working state of the brake object after the brake is in the initial working state for a preset period of time, record the working condition information of the brake object in real time and add a timestamp to it, and then switch the working state of the brake to at least one or more braking working states in sequence according to the preset control instructions, and at the same time, continue to maintain real-time monitoring of the torque output by the brake and the working parameters of the hydraulic oil circuit system connected to it, and add a timestamp to the data obtained by monitoring;

[0065] The response recording unit is used to record the time point t0 when the control command is issued and the time point t0 when the brake responds to the control command and performs the action when the brake switches the working state of the brake to at least one braking working state in sequence according to the preset control command. z Recording and generating response record information; also used to determine the working condition change of the braking object according to the working condition information of the braking object, and extract the time line of the brake intervention or release of the braking object in combination with the corresponding attached timestamp, and then mark the braking state or release of the braking in it to generate the braking object state information recorded in time series;

[0066] The data detection unit is used to obtain the state information of the braking object, and to make judgment and evaluation on one of the torque monitoring information, oil circuit monitoring information, noise monitoring information, vibration monitoring information, and response record information separately or on multiple combined judgment and evaluation, and then to collect the obtained judgment and evaluation results to generate the test results.

[0067] By adopting the above-mentioned technical scheme, the present invention has the following beneficial effects compared with the prior art: the scheme cleverly monitors the torque output and the oil circuit condition of the brake when it is working, so that the working condition of the brake can be better monitored. At the same time, the scheme also switches the braking object to different working conditions to monitor the torque output by the brake and the working parameters of the hydraulic oil circuit system connected to it in real time. This test strategy makes the test scenario of the brake closer to the actual working condition of the braking object, and provides excellent test data for the reliability of the subsequent use of the brake; and on this basis, when testing the brake, the scheme further monitors the vibration and noise of the brake during braking operation, so that the brake of the crane as the braking object can monitor the superficial problems during braking operation, so that the vibration and noise generated by the brake during braking operation can be better recorded, so as to indirectly characterize its working condition, thereby improving the comprehensiveness of brake monitoring. In the case of switching between multiple working conditions, this solution can further monitor the temperature of the hydraulic oil in the hydraulic oil circuit system through a temperature sensor to determine whether the temperature of the hydraulic oil in the hydraulic oil circuit is abnormal after the brake has worked frequently. In addition, when the test results point to abnormal brake feedback, this solution also performs multimodal data fusion on the monitoring data collected by the sensor group, constructs a corresponding model, and performs single-factor and multi-factor abnormality judgment on the data, thereby providing more reliable and relevant abnormality judgment for brake testing. BRIEF DESCRIPTION OF THE DRAWINGS

[0068] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0069] Figure 1 This is one of the simplified implementation flow diagrams of the test method of this scheme;

[0070] Figure 2 This is the second schematic diagram of the brief implementation process of the test method of this scheme;

[0071] Figure 3 This is a schematic diagram of the unit module connection of the test system of this scheme. DETAILED DESCRIPTION

[0072] The present invention will be further described in detail below in conjunction with the accompanying drawings and examples. It is particularly noted that the following examples are only used to illustrate the present invention, but are not intended to limit the scope of the present invention. Similarly, the following examples are only partial embodiments of the present invention rather than all embodiments, and all other embodiments obtained by those of ordinary skill in the art without creative work are within the scope of protection of the present invention.

[0073] Combination Figure 1 As shown, this embodiment provides a brake testing method for testing a hydraulic brake, wherein a sensor group is deployed on the brake and the hydraulic oil circuit system connected thereto, and the brake is installed on a crane for application, that is, the braking object of the brake is a driving component of the crane, and the testing method comprises:

[0074] S01. Calibrate the sensor group according to preset conditions to make the working state of the sensor group meet the preset requirements;

[0075] S02, placing the brake object in a preset working condition, then starting the brake according to the preset conditions, making the brake enter an initial working state, and at the same time, monitoring the torque output by the brake and the working parameters of the hydraulic oil circuit system connected thereto in real time, generating torque monitoring information and oil circuit monitoring information respectively;

[0076] S03. After the brake is in the initial working state for a preset period of time, adjust or maintain the working state of the brake object, record the working condition information of the brake object in real time and add a timestamp to it, and then switch the working state of the brake to at least one braking working state in sequence according to the preset control instruction, and at the same time, continue to monitor the torque output by the brake and the working parameters of the hydraulic oil circuit system connected to it in real time, and add a timestamp to the data obtained by monitoring;

[0077] S04. Obtain torque monitoring information and oil circuit monitoring information, combine the working condition information of the braking object, evaluate the performance of the brake according to preset conditions, and generate test results.

[0078] This solution cleverly monitors the output torque and oil circuit conditions of the brake when it is working, so that the working condition of the brake can be better monitored. At the same time, this solution also switches the braking object to different working conditions to monitor the torque output by the brake and the working parameters of the hydraulic oil circuit system connected to it in real time. This test strategy makes the test scenario of the brake closer to the actual working condition of the braking object, providing excellent test data for the reliability of the subsequent use of the brake.

[0079] As an implementation example of the sensor group, further, the sensor group described in this solution includes a temperature sensor, a hydraulic sensor and a torque sensor;

[0080] The hydraulic oil circuit system of the brake is equipped with a temperature sensor for monitoring the temperature change of the hydraulic oil, and a hydraulic sensor for monitoring the pressure change of the pressure oil in the hydraulic oil circuit system. The brake is equipped with a torque sensor for monitoring the output braking force of the brake.

[0081] In order to improve the time consistency of data collection and avoid time misalignment of data, in the present solution S01, when calibrating the sensor group, the same reference time is provided to the sensor group through the same clock source.

[0082] In S02, the preset working condition of the braking object is a no-load state or a rated load state; the torque monitoring information and the oil circuit monitoring information are both generated and recorded in a time series.

[0083] In addition to the sensors mentioned above, as a better implementation option, preferably, the sensor group described in this scheme also includes a sound sensor and a vibration sensor; the main body of the brake is also equipped with a volume sensor for monitoring the decibel number of noise when it is working, and a vibration sensor for monitoring the vibration conditions of the brake when it is working.

[0084] On the basis of the above, in S02 and S03, after the brake is started, the brake status is also monitored through the volume sensor and the vibration sensor, and noise monitoring information and vibration monitoring information with timestamps are generated respectively.

[0085] Correspondingly, in the present scheme S04, when acquiring the torque monitoring information and the oil circuit monitoring information, the noise monitoring information and the vibration monitoring information are also acquired synchronously, and the performance of the brake is evaluated according to the preset conditions in combination with the working condition information of the braking object to obtain the test results.

[0086] When testing the brake, this solution further monitors the vibration and noise during braking operation, so that the crane, as the braking object, can monitor the superficial problems exhibited by the brake during braking operation, and the vibration and noise generated by the brake during braking operation can be better recorded to indirectly characterize its working condition, thereby improving the comprehensiveness of brake monitoring.

[0087] In the case of switching between multiple working conditions, the present solution can further monitor the temperature of the hydraulic oil in the hydraulic oil circuit system through a temperature sensor to determine whether the temperature of the hydraulic oil in the hydraulic oil circuit is abnormal after the brake has worked frequently.

[0088] As for the command response, as a preferred implementation option, preferably, in the present scheme S03, when the working state of the brake is switched to at least one braking working state in sequence according to the preset control command, the time point t0 at which the control command is issued and the time point t1 at which the brake responds to the control command and performs the action are calculated. z Record and generate response record information;

[0089] Among them, the stability of the brake in the corresponding working state is judged by obtaining the torque monitoring information and the oil circuit monitoring information. When it works stably for a preset time, the working state of the brake is switched to the next braking working state according to the preset control instruction.

[0090] This solution can determine whether the brake is in a stable working state through the change of torque in the torque monitoring information, so that when it switches to the next working state, the data of the previous working state can more reliably indicate the normal working condition of the brake, reducing the distortion of test results caused by occasional abnormalities.

[0091] In the comprehensive analysis of monitoring data, as a better implementation option, preferably, this solution S04 includes:

[0092] S041. Obtaining torque monitoring information, oil circuit monitoring information, noise monitoring information, and vibration monitoring information, as well as response record information and working condition information of the braking object;

[0093] S042, determining the working condition change of the braking object according to the working condition information of the braking object, and extracting the time line of the brake intervention or braking release on the braking object in combination with the corresponding timestamp, and then marking the braking state or braking release therein, and generating the braking object state information recorded in a time series;

[0094] S043. According to the braking object status information, one of the torque monitoring information, oil circuit monitoring information, noise monitoring information, vibration monitoring information, and response record information is judged and evaluated separately or multiple of them are judged and evaluated jointly, and then the obtained judgment and evaluation results are collected to generate a test result.

[0095] As a preferred implementation option, preferably, the brake described in this solution is also equipped with a force sensor for monitoring the positive pressure generated between the friction pad on the brake caliper and the brake disc; the brake disc radius and the friction coefficient μ between the friction pad and the brake disc are known parameters measured in advance. On this basis, as a preferred implementation option, preferably, in S043 of this solution, the method for judging and evaluating the torque monitoring information according to the braking object state information includes one of the following:

[0096] (1) A braking torque calculation model is established to measure the braking output performance of the brake. The calculation formula is defined as follows:

[0097] T=F·R

[0098] Wherein, T is the braking torque, its unit is N·m, F is the braking force, which is generated by the friction between the brake caliper and the brake disc, its unit is N, and R is the effective radius of the brake disc, its unit is m;

[0099] When the braking object state information indicates that the brake is in the braking state, the positive pressure N generated by the friction pad on the brake disc is measured by the force sensor, and the braking force is calculated in combination with the friction coefficient μ. The formula is defined as follows:

[0100] F=N·μ

[0101] According to the pressure data measured by the force sensor, combined with the friction coefficient μ and the effective radius R of the brake disc, the torque F when the brake is working is calculated. n , and then aggregate them into time series to obtain the moment data set F t =[F1, F2, F3, ..., F n ] and then compare it with the preset threshold. When it exceeds the preset threshold, an abnormal torque output is generated as the evaluation result. Otherwise, a normal torque output is generated as the evaluation result to generate a judgment evaluation result on the braking torque monitoring data.

[0102] (2) Based on the pressure data measured by the force sensor, combined with the friction coefficient μ and the effective radius R of the brake disc, the torque of the brake during operation is calculated, and then compared with the torque directly measured by the torque sensor to evaluate the change in the friction coefficient between the brake friction pad and the brake disc under braking, and generate a judgment and evaluation result on the braking torque monitoring data.

[0103] (3) The torque F directly measured by the torque sensor m Aggregate by time series to obtain the moment data set F t =[F1, F2, F3, ..., F m ] and then compared with the preset threshold. When it exceeds the preset threshold, an abnormal torque output is generated as the evaluation result, otherwise a normal torque output is generated as the evaluation result to obtain a judgment evaluation result on the braking torque monitoring data.

[0104] In addition to the above, as a preferred implementation option, preferably, in the present solution S043, according to the braking object state information, judging and evaluating one of the torque monitoring information, the oil circuit monitoring information, the noise monitoring information, the vibration monitoring information, and the response record information separately or jointly judging and evaluating multiple items may also include one of the following:

[0105] (1) Obtain oil circuit monitoring information, extract the time line of intervention braking or release braking from it according to the state information of the braking object, so as to obtain the time interval for grouping data extraction, and then extract the hydraulic data in the oil circuit monitoring information according to the time interval; then perform pressure fluctuation assignment calculation on it to obtain the hydraulic pressure change of the hydraulic oil circuit system in the time interval when the state information of the braking object is in different states, which is expressed as follows:

[0106] P=P max -P min

[0107] Among them, P max is the maximum pressure measured by the hydraulic sensor in the corresponding time interval, P min is the minimum pressure value measured by the hydraulic sensor in the corresponding time interval, and P is the fluctuation amplitude of the hydraulic oil system pressure in the corresponding time interval;

[0108] A threshold judgment is performed on the fluctuation amplitude. When it exceeds the preset threshold, a hydraulic oil circuit abnormality is generated as an evaluation result, otherwise a normal is generated as an evaluation result, and a judgment evaluation result on the oil circuit monitoring information is obtained.

[0109] (2) Obtain response records and torque monitoring information, combine them with the braking object status information, and calculate the braking response time t from the issuance of the control command to the initiation of the brake action so that the braking torque reaches the set range value r , whose formula is defined as follows:

[0110] t r =t f -t s

[0111] Among them, t s is the time when the control command is issued, t f It is the time point when the braking torque reaches the set range value;

[0112] A threshold judgment is performed on the braking response time. When it exceeds the preset threshold, a braking response abnormality is generated as an evaluation result, otherwise a normal is generated as an evaluation result, and a judgment evaluation result about the response record is obtained.

[0113] (3) Acquire noise monitoring information, vibration monitoring information, and brake object status information, and extract the timeline of intervention braking or release braking from the brake object status information to obtain a time interval for grouping data extraction, and then extract noise data and vibration data from the noise monitoring information and vibration monitoring information according to the time interval;

[0114] Threshold judgment is performed on the noise data and vibration data. When they exceed the preset threshold, a braking feedback abnormality is generated as an evaluation result, otherwise a normal is generated as an evaluation result, and a judgment and evaluation result on the noise monitoring information and the vibration monitoring information is obtained.

[0115] This solution cleverly makes judgments and evaluations on one of the torque monitoring information, oil circuit monitoring information, noise monitoring information, vibration monitoring information, and response record information separately or on multiple combined judgments and evaluations based on the braking object status information, so that the brake test results can be more comprehensive and reduce the correlation anomaly problem caused by single factor judgment, that is, the multi-factor problem.

[0116] In order to better simulate the actual usage and provide the brake test with a field condition closer to that of the crane in operation, as a better implementation option, preferably, in this scheme S03, while the working state of the brake is switched to at least one braking working state in sequence, interference factors are added to the working environment of the brake, and the parameters and types corresponding to the interference factors are recorded, wherein the interference factors include adjusting the temperature, humidity, and magnetic field of the brake working environment; when generating torque monitoring information, oil circuit monitoring information, noise monitoring information, vibration monitoring information, and response records, the interference factor information associated therewith is also generated synchronously.

[0117] Correspondingly, in the present solution S04, when generating the test results, the interference factor information is also added thereto.

[0118] Combination Figure 2 As shown, in order to facilitate the location of the abnormal source when the brake test result indicates an abnormality, as a preferred implementation option, preferably, the test method described in this solution also includes:

[0119] S05. Obtaining test results. When the test results contain abnormal brake feedback, further comprehensive analysis is performed on the test results to determine the cause of the abnormal brake noise data or vibration data, which includes:

[0120] Construct a multimodal data fusion model to integrate the data in torque monitoring information, oil circuit monitoring information, noise monitoring information, and vibration monitoring information into the multimodal data fusion model, which is defined as follows:

[0121] D={T(t),P(t),X(t),A(t)}

[0122] Wherein, D is a multimodal data fusion data set, T(t), P(t), X(t), and A(t) are data groups formed by collecting corresponding data in torque monitoring information, oil circuit monitoring information, noise monitoring information, and vibration monitoring information, respectively. They are collected in time series and are set as torque monitoring data group, oil circuit monitoring data group, noise monitoring data group, and vibration monitoring data group, respectively;

[0123] The data in the multimodal data fusion dataset is normalized so that the data of different physical quantities are unified to the same scale. Its definition is as follows:

[0124]

[0125] Among them, D" is the normalized multimodal data fusion dataset, x i is the data value of a single data in the multimodal data fusion data D, max(x) and min(x) are x respectively. i The maximum and minimum values ​​in the data group;

[0126] The torque monitoring data group, oil circuit monitoring data group, and vibration monitoring data group in the multimodal data fusion data set D" are subjected to a low-pass filter to eliminate high-frequency noise, and the noise monitoring data are subjected to environmental noise removal to eliminate the frequency bands interfered by environmental noise;

[0127] Perform univariate anomaly judgment on the data in the multimodal data fusion data set D" by using the 3-times standard deviation rule or the sliding window average method to generate a univariate anomaly judgment result;

[0128] Perform multivariate anomaly judgment on the data in the multimodal data fusion data set D" through the trained detection neural network or random forest algorithm to generate a multivariate anomaly judgment result;

[0129] The cause of the abnormality inducing the brake noise data or vibration data is determined based on the single variable abnormality determination result and / or the multivariate abnormality determination result.

[0130] The three-times standard deviation rule mentioned in this solution refers to the process of making a single variable anomaly judgment on the data in the multimodal data fusion data set D", for example, comparing one of the torque data in the torque monitoring data set with three times the standard deviation fitted by all the data in the data set. When it exceeds the standard deviation, it is defined as an anomaly.

[0131] Combination Figure 3 As shown, based on the above, this solution also provides a crane brake testing method, which is applied with the above brake testing method, and further includes:

[0132] In response to the work start signal of the crane, S01 to S04 are executed to realize a safety self-test of the brake of the crane;

[0133] Obtain test results and make threshold adjustments to the operating parameters of the crane drive components.

[0134] Based on the above, the present invention also provides a brake testing system, which is applied to the brake of a crane and includes:

[0135] A sensor group, including a plurality of temperature sensors, hydraulic sensors, torque sensors, sound sensors and vibration sensors; a temperature sensor for monitoring the temperature change of the hydraulic oil and a hydraulic sensor for monitoring the pressure change of the pressure oil in the hydraulic oil system are deployed on the hydraulic oil circuit system of the brake, and a torque sensor for monitoring the output braking force of the brake is deployed on the brake; a volume sensor for monitoring the decibel number of noise when the brake is working and a vibration sensor for monitoring the vibration condition of the brake when working are deployed on the main body of the brake;

[0136] A sensor calibration unit, used to calibrate the sensor group according to preset conditions so that the working state of the sensor group meets the preset requirements;

[0137] A working control unit is used to place the brake object in a preset working condition, and then start the brake according to the preset conditions, so that the brake enters the initial working state, and at the same time, sends monitoring information to the sensor group to enable it to monitor the torque output by the brake and the working parameters of the hydraulic oil circuit system connected to it in real time, and generate torque monitoring information and oil circuit monitoring information respectively; after the brake is started, the brake state is also monitored through the volume sensor and the vibration sensor, and noise monitoring information and vibration monitoring information with timestamps are generated respectively; it is also used to adjust or maintain the working state of the brake object after the brake is in the initial working state for a preset period of time, record the working condition information of the brake object in real time and add a timestamp to it, and then switch the working state of the brake to at least one or more braking working states in sequence according to the preset control instructions, and at the same time, continue to maintain real-time monitoring of the torque output by the brake and the working parameters of the hydraulic oil circuit system connected to it, and add a timestamp to the data obtained by monitoring;

[0138] The response recording unit is used to record the time point t0 when the control command is issued and the time point t0 when the brake responds to the control command and performs the action when the brake switches the working state of the brake to at least one braking working state in sequence according to the preset control command. zRecording and generating response record information; also used to determine the working condition change of the braking object according to the working condition information of the braking object, and extract the time line of the brake intervention or release of the braking object in combination with the corresponding attached timestamp, and then mark the braking state or release of the braking in it to generate the braking object state information recorded in time series;

[0139] The data detection unit is used to obtain the state information of the braking object, and to make judgment and evaluation on one of the torque monitoring information, oil circuit monitoring information, noise monitoring information, vibration monitoring information, and response record information separately or on multiple combined judgment and evaluation, and then to collect the obtained judgment and evaluation results to generate the test results.

[0140] In addition, each functional unit in each embodiment of the present invention may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit. The above-mentioned integrated unit may be implemented in the form of hardware or in the form of software functional units.

[0141] If the integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution can be embodied in the form of a software product, and the computer software product is stored in a storage medium, including a number of instructions for a computer device (which can be a personal computer, server, or network device, etc.) or a processor (processor) to perform all or part of the steps of each embodiment of the present invention. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), disk or optical disk and other media that can store program codes.

[0142] The above descriptions are only some embodiments of the present invention, and are not intended to limit the protection scope of the present invention. Any equivalent device or equivalent process transformation made using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A brake testing method for testing a hydraulic brake, wherein a sensor group is disposed on the brake and the hydraulic oil circuit system connected thereto, and the brake is installed on a brake object, characterized in that: The test method includes: S01. Calibrate the sensor group according to preset conditions to make the working state of the sensor group meet the preset requirements; S02, placing the brake object in a preset working condition, then starting the brake according to the preset conditions, making the brake enter an initial working state, and at the same time, monitoring the torque output by the brake and the working parameters of the hydraulic oil circuit system connected thereto in real time, generating torque monitoring information and oil circuit monitoring information respectively; S03. After the brake is in the initial working state for a preset period of time, adjust or maintain the working state of the brake object, record the working condition information of the brake object in real time and add a timestamp to it, and then switch the working state of the brake to at least one braking working state in sequence according to the preset control instruction, and at the same time, continue to monitor the torque output by the brake and the working parameters of the hydraulic oil circuit system connected to it in real time, and add a timestamp to the data obtained by monitoring; S04. Obtain torque monitoring information and oil circuit monitoring information, combine the working condition information of the braking object, evaluate the performance of the brake according to preset conditions, and generate test results.

2. The brake testing method according to claim 1, characterized in that: The sensor group includes a temperature sensor, a hydraulic sensor and a torque sensor; The hydraulic oil circuit system of the brake is provided with a temperature sensor for monitoring the temperature change of the hydraulic oil, and a hydraulic sensor for monitoring the pressure change of the pressure oil in the hydraulic oil circuit system, and the brake is provided with a torque sensor for monitoring the output braking force of the brake; In S01, when the sensor group is calibrated, the same reference time is also provided to the sensor group through the same clock source; In S02, the preset working condition of the braking object is a no-load state or a rated load state; the torque monitoring information and the oil circuit monitoring information are both generated and recorded in a time series.

3. The brake testing method according to claim 2, characterized in that: The sensor group also includes a sound sensor and a vibration sensor; the body of the brake is also equipped with a volume sensor for monitoring the decibel of noise when it is working, and a vibration sensor for monitoring the vibration of the brake when it is working; In S02 and S03, after the brake is started, the state of the brake is also monitored by a volume sensor and a vibration sensor, and noise monitoring information and vibration monitoring information with timestamps are generated respectively; In S04, when acquiring the torque monitoring information and the oil circuit monitoring information, the noise monitoring information and the vibration monitoring information are also acquired synchronously, and the performance of the brake is evaluated according to the preset conditions in combination with the working condition information of the braking object to obtain the test results.

4. The brake testing method according to claim 3, characterized in that: In S03, when the working state of the brake is switched to at least one of the above braking working states in sequence according to the preset control command, the time point t0 at which the control command is issued and the time point t1 at which the brake responds to the control command and performs the action are calculated. z Record and generate response record information; Among them, the stability of the brake in the corresponding working state is judged by obtaining the torque monitoring information and the oil circuit monitoring information. When it works stably for a preset time, the working state of the brake is switched to the next braking working state according to the preset control instruction.

5. The brake testing method according to claim 4, characterized in that: S04 includes: S041, acquiring torque monitoring information, oil circuit monitoring information, noise monitoring information and vibration monitoring information, as well as response record information and working condition information of the braking object; S042, determining the working condition change of the braking object according to the working condition information of the braking object, and extracting the time line of the brake intervention or braking release on the braking object in combination with the corresponding timestamp, and then marking the braking state or braking release therein, and generating the braking object state information recorded in a time series; S043. According to the braking object status information, one of the torque monitoring information, oil circuit monitoring information, noise monitoring information, vibration monitoring information, and response record information is judged and evaluated separately or multiple of them are judged and evaluated jointly, and then the obtained judgment and evaluation results are collected to generate a test result.

6. The crane brake testing method according to claim 5, characterized in that: The brake is also provided with a force sensor for monitoring the positive pressure generated between the friction pad on the brake caliper and the brake disc; the brake disc radius and the friction coefficient μ between the friction pad and the brake disc are known parameters measured in advance; In S043, the method for judging and evaluating the torque monitoring information according to the braking object state information includes one of the following: (1) A braking torque calculation model is established to measure the braking output performance of the brake. The calculation formula is defined as follows: T=F·R Wherein, T is the braking torque, its unit is N·m, F is the braking force, which is generated by the friction between the brake caliper and the brake disc, its unit is N, and R is the effective radius of the brake disc, its unit is m; When the braking object state information indicates that the brake is in the braking state, the positive pressure N generated by the friction pad on the brake disc is measured by the force sensor, and the braking force is calculated in combination with the friction coefficient μ. The formula is defined as follows: F=N·μ According to the pressure data measured by the force sensor, combined with the friction coefficient μ and the effective radius R of the brake disc, the torque F when the brake is working is calculated. n , and then aggregate them into time series to obtain the moment data set F t =[F1, F2, F3, ..., F n ], and then compare it with the preset threshold value. When it exceeds the preset threshold value, the torque output abnormality is generated as the evaluation result, otherwise it is generated as the evaluation result, and the judgment evaluation result about the braking torque monitoring data is generated; (2) Based on the pressure data measured by the force sensor, combined with the friction coefficient μ and the effective radius R of the brake disc, the torque of the brake during operation is calculated, and then compared with the torque directly measured by the torque sensor to evaluate the change in the friction coefficient between the brake pad and the brake disc under braking, and generate a judgment and evaluation result on the braking torque monitoring data; (3) The torque F directly measured by the torque sensor m Aggregate by time series to obtain the moment data set F t =[F1, F2, F3, ..., F m ] and then compared with the preset threshold. When it exceeds the preset threshold, an abnormal torque output is generated as the evaluation result, otherwise a normal torque output is generated as the evaluation result to obtain a judgment evaluation result on the braking torque monitoring data.

7. The crane brake testing method according to claim 5, characterized in that: In S043, according to the braking object state information, one of the torque monitoring information, the oil circuit monitoring information, the noise monitoring information, the vibration monitoring information, and the response record information is judged and evaluated separately or multiple joint judgments and evaluations are performed, including one of the following: (1) Obtain oil circuit monitoring information, extract the time line of intervention braking or release braking from it according to the state information of the braking object, so as to obtain the time interval for grouping data extraction, and then extract the hydraulic data in the oil circuit monitoring information according to the time interval; then perform pressure fluctuation assignment calculation on it to obtain the hydraulic pressure change of the hydraulic oil circuit system in the time interval when the state information of the braking object is in different states, which is expressed as follows: P=P max -P min Among them, P max is the maximum pressure measured by the hydraulic sensor in the corresponding time interval, P min is the minimum pressure value measured by the hydraulic sensor in the corresponding time interval, and P is the fluctuation amplitude of the hydraulic oil system pressure in the corresponding time interval; A threshold value judgment is performed on the fluctuation amplitude. When it exceeds the preset threshold value, a hydraulic oil circuit abnormality is generated as an evaluation result. Otherwise, a normal value is generated as an evaluation result to obtain a judgment evaluation result on the oil circuit monitoring information. (2) Obtain response records and torque monitoring information, combine them with the braking object status information, and calculate the braking response time t from the issuance of the control command to the initiation of the brake action so that the braking torque reaches the set range value r , whose formula is defined as follows: t r =t f -t s Among them, t s is the time when the control command is issued, t f It is the time point when the braking torque reaches the set range value; Performing a threshold judgment on the braking response time, when it exceeds a preset threshold, generating a braking response abnormality as an evaluation result, otherwise generating a normal as an evaluation result, and obtaining a judgment evaluation result on the response record; (3) Acquire noise monitoring information, vibration monitoring information, and brake object status information, and extract the timeline of intervention braking or release braking from the brake object status information to obtain a time interval for grouping data extraction, and then extract noise data and vibration data from the noise monitoring information and vibration monitoring information according to the time interval; Threshold judgment is performed on the noise data and vibration data. When they exceed the preset threshold, a braking feedback abnormality is generated as an evaluation result, otherwise a normal is generated as an evaluation result, and a judgment and evaluation result on the noise monitoring information and the vibration monitoring information is obtained.

8. The crane brake testing method according to claim 5, characterized in that: In S03, while switching the working state of the brake to at least one of the above braking working states in sequence, an interference factor is added to the working environment of the brake, and the parameters and types corresponding to the interference factor are recorded, wherein the interference factor includes adjusting the temperature, humidity, and magnetic field of the working environment of the brake; when generating torque monitoring information, oil circuit monitoring information, noise monitoring information, vibration monitoring information, and response records, the interference factor information associated therewith is also generated synchronously; In S04, when generating the test results, the interference factor information is also added thereto; The test method also includes: S05. Obtaining test results. When the test results contain abnormal brake feedback, further comprehensive analysis is performed on the test results to determine the cause of the abnormal brake noise data or vibration data, which includes: Construct a multimodal data fusion model to integrate the data in torque monitoring information, oil circuit monitoring information, noise monitoring information, and vibration monitoring information into the multimodal data fusion model, which is defined as follows: D={T(t),P(t),X(t),A(t)} Wherein, D is a multimodal data fusion data set, T(t), P(t), X(t), and A(t) are data groups formed by collecting corresponding data in torque monitoring information, oil circuit monitoring information, noise monitoring information, and vibration monitoring information, respectively. They are collected in time series and are set as torque monitoring data group, oil circuit monitoring data group, noise monitoring data group, and vibration monitoring data group, respectively; The data in the multimodal data fusion dataset is normalized so that the data of different physical quantities are unified to the same scale. Its definition is as follows: Among them, D" is the normalized multimodal data fusion dataset, x i is the data value of a single data in the multimodal data fusion data D, max(x) and min(x) are x respectively. i The maximum and minimum values ​​in the data group; The torque monitoring data group, oil circuit monitoring data group, and vibration monitoring data group in the multimodal data fusion data set D" are subjected to a low-pass filter to eliminate high-frequency noise, and the noise monitoring data are subjected to environmental noise removal to eliminate the frequency bands interfered by environmental noise; Perform univariate anomaly judgment on the data in the multimodal data fusion data set D" by using the 3-times standard deviation rule or the sliding window average method to generate a univariate anomaly judgment result; Perform multivariate anomaly judgment on the data in the multimodal data fusion data set D" through the trained detection neural network or random forest algorithm to generate a multivariate anomaly judgment result; The cause of the abnormality inducing the brake noise data or vibration data is determined based on the single variable abnormality determination result and / or the multivariate abnormality determination result.

9. A crane brake testing method, characterized in that: The invention is applied with the brake testing method according to any one of claims 1 to 8, and further comprises: In response to the work start signal of the crane, S01 to S04 are executed to realize a safety self-test of the brake of the crane; Obtain test results and make threshold adjustments to the operating parameters of the crane drive components.

10. A brake test system, applied to the brake of a crane, characterized in that: It includes: A sensor group, including a plurality of temperature sensors, hydraulic sensors, torque sensors, sound sensors and vibration sensors; a temperature sensor for monitoring the temperature change of the hydraulic oil and a hydraulic sensor for monitoring the pressure change of the pressure oil in the hydraulic oil system are deployed on the hydraulic oil circuit system of the brake, and a torque sensor for monitoring the output braking force of the brake is deployed on the brake; a volume sensor for monitoring the decibel number of noise when the brake is working and a vibration sensor for monitoring the vibration condition of the brake when working are deployed on the main body of the brake; A sensor calibration unit, used to calibrate the sensor group according to preset conditions so that the working state of the sensor group meets the preset requirements; A working control unit is used to place the brake object in a preset working condition, and then start the brake according to the preset conditions, so that the brake enters the initial working state, and at the same time, sends monitoring information to the sensor group to enable it to monitor the torque output by the brake and the working parameters of the hydraulic oil circuit system connected to it in real time, and generate torque monitoring information and oil circuit monitoring information respectively; after the brake is started, the brake state is also monitored through the volume sensor and the vibration sensor, and noise monitoring information and vibration monitoring information with timestamps are generated respectively; it is also used to adjust or maintain the working state of the brake object after the brake is in the initial working state for a preset period of time, record the working condition information of the brake object in real time and add a timestamp to it, and then switch the working state of the brake to at least one or more braking working states in sequence according to the preset control instructions, and at the same time, continue to maintain real-time monitoring of the torque output by the brake and the working parameters of the hydraulic oil circuit system connected to it, and add a timestamp to the data obtained by monitoring; The response recording unit is used to record the time point t0 when the control command is issued and the time point t0 when the brake responds to the control command and performs the action when the brake switches the working state of the brake to at least one braking working state in sequence according to the preset control command. z Recording and generating response record information; also used to determine the working condition change of the braking object according to the working condition information of the braking object, and extract the time line of the brake intervention or release of the braking object in combination with the corresponding attached timestamp, and then mark the braking state or release of the braking in it to generate the braking object state information recorded in time series; The data detection unit is used to obtain the state information of the braking object, and to make judgment and evaluation on one of the torque monitoring information, oil circuit monitoring information, noise monitoring information, vibration monitoring information, and response record information separately or on multiple combined judgment and evaluation, and then to collect the obtained judgment and evaluation results to generate the test results.

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