Mechanical brake position monitoring circuit and system

Abstract

The invention discloses a mechanical brake position monitoring circuit and system, which comprises a monitoring unit for monitoring the position and state of a simulation unit in real time, a control unit connected with the monitoring unit for receiving first data from the monitoring unit, and a simulation unit connected with the monitoring unit for receiving second data from the monitoring unit. Simulating the operation state and the motion characteristic of the mechanical brake according to the first instruction; the non-contact displacement sensor and the proximity switch are introduced, and the function of monitoring the position state and the action amount of the mechanical brake is achieved. A traditional contact type and single switching value signal monitoring mode is broken through, state monitoring reliability and data acquisition credibility are greatly improved, maloperation and refusal operation caused by a mechanical dead zone and an action dead zone existing in a contact type position switch are effectively avoided, the safety of equipment operation is greatly improved, and the service life of the equipment is prolonged. And the risks of misoperation of a mechanical brake and equipment damage are reduced.

Description

Technical Field

[0001] The invention relates to hydropower equipment state monitoring, in particular to a mechanical brake position monitoring circuit system. Background Art

[0002] In the field of hydropower generation, ensuring the stability and reliability of the generator braking system is crucial to the safe operation of the entire power plant. my country's hydropower generators usually use two braking methods: electrical braking and mechanical braking. Although electrical braking can reduce wear and pollution, its high cost and strict environmental requirements limit its application. Therefore, many hydropower plants tend to use pure mechanical braking or a combination of electrical and mechanical braking.

[0003] The entire braking system, including brakes, oil and air circuits, and manual and automatic control devices, is the core component of the hydro-generator set. Its role is not limited to rapid braking when the unit is shut down to avoid long-term low-speed operation, but also includes jacking up the rotor during installation or maintenance to prevent accidental rotation of the shut-down unit, and helping the plastic tile unit to re-establish the oil film.

[0004] However, if there is a false alarm in the monitoring of the mechanical brake damper, it may seriously affect the startup process of the unit, or even cause shutdown, causing huge economic losses to the power plant. The traditional domestic mechanical brake damper travel switch calibration method has obvious shortcomings, mainly relying on static calibration, and lacks full-stroke digital calibration of the entire system under dynamic conditions. This method cannot fully evaluate the system performance, and may cause accidents in actual operation due to the lack of dynamic simulation calibration of the sensor.

[0005] In addition, traditional verification methods fail to fully detect the performance of the travel switch and may not be able to detect damage to the body or nodes in time. The existence of mechanical dead zone may cause the travel switch to not operate properly, while the looseness or offset of the mounting bracket may affect the accuracy of the node signal. These problems may have a serious impact on the stability and reliability of the entire braking system, thereby posing a threat to the safe operation of the entire hydropower generation system. Therefore, improving the monitoring method and improving the overall performance of the system are of great significance to ensure the safe operation of the hydropower generator set. Summary of the invention

[0006] Therefore, the technical problem to be solved by the present invention is that the monitoring of the mechanical brake is inaccurate and the safety is low.

[0007] The above technical problem is solved by the following technical solution: The present invention proposes a mechanical brake position monitoring circuit, which includes a monitoring unit, a control unit and a simulation unit.

[0008] In a preferred embodiment of the mechanical brake position monitoring circuit of the present invention: the monitoring unit monitors the position and state of the simulation unit in real time, and summarizes the first data to be transmitted to the control unit;

[0009] a control unit connected to the monitoring unit, receiving first data from the monitoring unit, processing the first data to form a first instruction, and transmitting the first instruction to the simulation unit; and

[0010] The simulation unit is connected to the monitoring unit and simulates the operating state and motion characteristics of the mechanical brake according to the first instruction.

[0011] In a preferred embodiment of the mechanical brake position monitoring circuit of the present invention: a power unit is connected to the simulation unit to provide power support for the operation of the simulation unit, including a three-phase motor and a reducer, wherein the three-phase motor provides driving force for the simulation unit; the reducer is used to reduce the speed of the three-phase motor.

[0012] In a preferred implementation manner of the mechanical brake position monitoring circuit of the present invention: the control unit includes a programmable logic controller, an isolation transformer, a switching power supply and a frequency converter, the programmable logic controller is used to centrally process all control logics, receive data and output instructions; the isolation transformer is used to isolate the input and output circuits to prevent electromagnetic interference; the switching power supply is used to provide power for the programmable logic controller and the monitoring unit; the frequency converter is used to regulate the operating speed and direction of the three-phase motor.

[0013] In a preferred implementation of the mechanical brake position monitoring circuit of the present invention: an interactive unit is connected to the control unit and is used for user operation and display system feedback.

[0014] In a preferred implementation of the mechanical brake position monitoring circuit of the present invention: the interactive unit includes a touch screen for displaying real-time data and alarm information, and supporting parameter adjustment and analog control.

[0015] In a preferred implementation of the mechanical brake position monitoring circuit of the present invention: the interactive unit includes an indicator light and an operation button to provide an operating status indication to facilitate manual operation.

[0016] In a preferred embodiment of the mechanical brake position monitoring circuit of the present invention: the monitoring unit includes a proximity switch and a photoelectric sensor, the proximity switch detects the upper and lower limit states of the mechanical brake and provides a switch signal; the photoelectric sensor is used to accurately measure the brake displacement stroke and output an analog signal.

[0017] In a preferred embodiment of the mechanical brake position monitoring circuit of the present invention: the monitoring unit also includes a module, which is connected to the control unit and is used to collect the absolute encoder signal of the mechanical brake displacement stroke to provide a standard basis for the accuracy inspection of the photoelectric sensor.

[0018] In a preferred implementation of the mechanical brake position monitoring circuit of the present invention: the simulation unit includes a ball screw, a motor fixing bracket and a brake disc, the ball screw realizes linear motion to simulate the up and down displacement state of the mechanical brake; the motor fixing bracket stably supports the three-phase motor to avoid the influence of vibration during operation; the brake disc physically presents the motion state of the mechanical brake and transmits action information.

[0019] The present invention also provides a mechanical brake position monitoring system, which includes a monitoring unit, a control unit, a simulation unit, a power unit and an interaction unit.

[0020] In a preferred embodiment of the mechanical brake position monitoring circuit of the present invention: a monitoring unit monitors the position and state of the simulation unit in real time, and summarizes the first data to pass to the control unit; a control unit is connected to the monitoring unit, receives the first data from the monitoring unit, processes the first data to form a first instruction, and passes the first instruction to the simulation unit; a simulation unit is connected to the monitoring unit and the monitoring unit, and simulates the operating state and motion characteristics of the mechanical brake according to the first instruction; a power unit is connected to the simulation unit to provide power support for the operation of the simulation unit, including a three-phase motor and a reducer, the three-phase motor provides driving force for the simulation unit; the reducer is used to reduce the speed of the three-phase motor; an interactive unit is connected to the control unit for user operation and display system feedback.

[0021] The beneficial effects of the present invention are as follows: the present invention introduces a non-contact displacement sensor and a proximity switch to realize the function of monitoring the position state and the amount of movement of the mechanical brake. It breaks through the traditional contact-type, single switch signal monitoring method, greatly improves the reliability of state monitoring and the credibility of data acquisition, effectively avoids the mechanical dead zone and action dead zone of the contact position switch causing the malfunction and refusal to operate, greatly improves the safety of equipment operation, and reduces the risk of mechanical brake malfunction and equipment damage. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings of the embodiments of the present invention are briefly introduced below. Obviously, the drawings described below only relate to some embodiments of the present invention, but are not intended to limit the present invention. Among them:

[0023] Figure 1shows a schematic diagram of a mechanical brake position monitoring circuit;

[0024] Figure 2 shows a schematic diagram of a mechanical brake position monitoring system;

[0025] Figure 3 A schematic diagram of a mechanical brake simulation device of a mechanical brake position monitoring system is shown;

[0026] Figure 4 shows a power supply diagram for a mechanical brake position monitoring system;

[0027] Figure 5 A wiring diagram showing the PLC power module of a mechanical brake position monitoring system

[0028] Figure 6 The working power wiring diagram of the interactive unit of the mechanical brake position monitoring system is shown;

[0029] Figure 7 A three-phase motor control diagram of a mechanical brake position monitoring system is shown;

[0030] Figure 8 Shows the SSI signal input wiring diagram of the mechanical brake position monitoring system;

[0031] Fig. 9 shows the wiring diagram of the analog input of the mechanical brake position monitoring system;

[0032] Fig.10 shows the wiring diagram of the switch input of the mechanical brake position monitoring system;

[0033] Fig.11 A flow chart of a machinery brake position monitoring system is shown. DETAILED DESCRIPTION

[0034] In order to enable those skilled in the art to better understand the present invention, the present invention is further described in detail below in conjunction with specific implementation methods and drawings.

[0035] The terms used in the present invention are those general terms currently widely used in the art in consideration of the functions of the present invention, but these terms may vary according to the intention of a person of ordinary skill in the art, precedents, or new technologies in the art. In addition, specific terms may be selected by the applicant, and in this case, their detailed meanings will be described in the detailed description of the present invention. Therefore, the terms used in the specification should not be understood as simple names, but rather as a general description based on the meaning of the terms and the present invention.

[0036] Reference Figure 1This embodiment provides a mechanical brake position monitoring circuit, including a monitoring unit 200, a control unit 100 and a simulation unit 300.

[0037] The monitoring unit 200 monitors the position and state of the simulation unit 300 in real time, and summarizes it into first data, which is transmitted to the control unit 100; the monitoring unit 200 is responsible for real-time monitoring of the operating state and position change of the simulation unit 300, including but not limited to the displacement, speed and state information of the position. The monitoring unit 200 includes a proximity switch and a photoelectric sensor, which continuously collects the position data of the simulation unit 300, and according to the sampling frequency and monitoring rules set inside the monitoring unit 200, the monitoring unit 200 summarizes, processes and stores these real-time data to form first data. These data include the current state of the simulation unit, the historical record of position change, etc. Finally, the monitoring unit 200 transmits these first data to the control unit 100 so that the control unit 100 can generate the first instruction.

[0038] The control unit 100 is connected to the monitoring unit 200, receives the first data from the monitoring unit 200, processes the first data to form a first instruction, and passes the first instruction to the simulation unit 300; the core function of the control unit 100 is to perform real-time analysis and calculation on the first data input by the monitoring unit 200 to form a first instruction. Specifically, the control unit 100 will analyze whether the current operation meets expectations based on the current position, operating status and set target state of the simulation unit 300, and then generate a corresponding first instruction. These instructions will include operating requirements of the mechanical brake, such as starting, stopping, speed regulation or adjusting position. The generated first instruction is passed to the simulation unit 300 through the communication interface to adjust the action of the simulation unit.

[0039] The simulation unit 300 is connected to the monitoring unit 200 and the monitoring unit 200, and simulates the operating state and motion characteristics of the mechanical brake according to the first instruction. The simulation unit 300 not only includes the simulation of the motion process of the mechanical brake, but also involves the simulation of the changes in the motion characteristics of the mechanical brake, such as braking, starting, acceleration, speed, etc. during operation. The simulation process can help predict the performance of the mechanical brake under different working conditions, thereby providing a basis for the control and scheduling of actual equipment. Through this simulation operation, the control unit 100 can adjust the motion state of the simulation unit 300 in real time, simulate the operation process consistent with the actual brake, ensure accurate feedback and control in testing and actual operation, so that the entire system can form a closed-loop control, and improve the operating safety and accuracy of the mechanical brake.

[0040] As an optional embodiment, the power unit 400 is connected to the simulation unit 300 to provide power support for the operation of the simulation unit 300, including a three-phase motor and a reducer. The three-phase motor provides driving force for the simulation unit 300; the reducer is used to reduce the speed of the three-phase motor. The three-phase motor can provide a higher power output, which is suitable for simulation systems that require greater power support, such as hydropower equipment status monitoring, to ensure that the simulation unit 300 can accurately simulate the operating state of the mechanical brake. The reducer is connected to the three-phase motor to reduce the speed. Since the three-phase motor usually operates at a higher speed, and the simulation unit 300 requires a lower and more stable movement speed to accurately simulate the state of the mechanical brake, the use of a reducer can effectively slow down the speed of the three-phase motor, while increasing the output torque, to ensure that the simulation unit 300 can smoothly and accurately simulate the motion characteristics of the brake.

[0041] As an optional embodiment, the control unit 100 includes a programmable logic controller, an isolation transformer, a switching power supply and a frequency converter. The programmable logic controller is used to centrally process all control logics, receive data and output instructions; the isolation transformer is used to isolate the input and output circuits to prevent electromagnetic interference; the switching power supply is used to provide power for the programmable logic controller and the monitoring unit 200; the frequency converter is used to control the running speed and direction of the three-phase motor. The programmable logic controller is the core component of the control unit 100, which is responsible for centrally processing all control logics, receiving the first data from the monitoring unit 200 and outputting the first instruction to the simulation unit 300. Its function is to perform data analysis and logic judgment based on the received signal, control the working state of the simulation unit 300, and can also adjust the working state of the power unit 400. The programmable logic controller can adjust parameters and output control instructions according to different requirements, thereby realizing precise control of the mechanical brake position monitoring circuit. The isolation transformer is located in the control unit 100, mainly used to isolate the input and output circuits to prevent electromagnetic interference. Electromagnetic interference may cause signal distortion, control errors and even equipment damage, and the isolation transformer can ensure the stable operation of the system. The switching power supply provides reliable power support for the programmable logic controller and the monitoring unit 200. Through efficient conversion and voltage stabilization, the programmable logic controller and monitoring unit 200 can be ensured to operate continuously and stably under different loads and working conditions. Providing a stable DC power supply can also support fast response and high-efficiency power supply, which is the energy guarantee of the entire control system. The frequency converter is used to adjust the running speed and direction of the three-phase motor to meet the precise requirements of the simulation unit 300 for the driving rate. The frequency converter can adjust the working state of the three-phase motor according to the instructions output by the control unit 100, ensuring the smooth operation of the simulation unit 300 in different operating modes, and avoiding the influence of too high or too low speed on the simulation results.

[0042] As an optional embodiment, the interactive unit 500 is connected to the control unit 100 for user operation and display of system feedback. As an optional embodiment, the interactive unit 500 includes a touch screen for displaying real-time data and alarm information, and supports parameter adjustment and simulation control. Through the touch screen, the user can intuitively view key information such as the position, speed, and status of the mechanical brake, and promptly discover abnormal alarm information of the system when necessary. It can also support users to adjust parameters, such as setting working thresholds, adjusting working modes, and other functions. In addition, the touch screen also supports simulation control, allowing users to simulate different working scenarios through the touch interface, and test the system's response and performance under different conditions to ensure the stability and reliability of the equipment.

[0043] In some embodiments, the interactive unit 500 includes an indicator light and an operation button to provide an indication of the operating status for easy manual operation. The indicator light can clearly convey the operating status of the device, such as normal operation, standby, alarm or fault, through different colors or flashing modes. This intuitive status indication enables the operator to quickly understand the current working status of the system, detect abnormalities in a timely manner, and take appropriate measures. The operation button provides a simple and direct control method, which is convenient for the user to start and stop, switch modes or perform other operations when needed. Through the operation button, the operator can perform basic manual intervention on the system to ensure that the device can still work as expected under special circumstances.

[0044] As an optional embodiment, the monitoring unit 200 includes a proximity switch and a photoelectric sensor. The proximity switch is used to detect the upper and lower limit states of the mechanical brake. The proximity switch can accurately sense the position signal of the mechanical brake. When the brake reaches the set upper and lower limit positions, the proximity switch will trigger the switch signal and transmit it to the control unit 100 to determine whether the mechanical brake is already in the predetermined limit position, helping the system to monitor the brake's range of motion in real time, preventing the brake from exceeding the working limit, and ensuring the safety of the system. The photoelectric sensor is used to accurately measure the displacement stroke of the mechanical brake and convert the displacement data into an analog signal. The photoelectric sensor can provide high-precision displacement data by detecting the position change of the brake during movement. Through the measurement of the photoelectric sensor, the control unit 100 can obtain the displacement information of the brake in real time to help determine the movement state and performance of the brake.

[0045] In some embodiments, the monitoring unit 200 also includes an SSI module, which is connected to the control unit 100 and is used to collect the SSI absolute encoder signal of the mechanical brake displacement stroke to provide a standard basis for the accuracy inspection of the photoelectric sensor. SSI is the abbreviation of Synchronous Serial Interface, which is a common communication protocol used for data transmission between a high-precision position encoder and a control system. In this embodiment, the SSI module obtains the precise position information of the brake in real time by connecting the absolute encoder of the mechanical brake. Through the high-precision encoder signal, the control system can accurately grasp the position of the brake and adjust or feedback related operations accordingly. In addition, the SSI module also provides a standard basis for the accuracy inspection of the photoelectric sensor. Although the photoelectric sensor can measure the displacement of the brake, its accuracy may be affected by various factors. By comparing with the absolute encoder signal collected by the SSI module, the system can calibrate and verify the measurement results of the photoelectric sensor to ensure the accuracy of the monitoring data.

[0046] As an optional embodiment, the simulation unit 300 includes a ball screw, a motor holder and a brake disc. The ball screw realizes linear motion and simulates the up and down displacement state of the mechanical brake; the motor holder stably supports the three-phase motor to avoid the vibration during operation; the brake disc physically presents the motion state of the mechanical brake and transmits the action information. The ball screw is used to realize linear motion and simulate the up and down displacement state of the mechanical brake. The ball screw reproduces the displacement process of the brake in the simulation system through its precise linear motion mechanism. In the actual work of the mechanical brake, the accuracy of the displacement is crucial to the braking effect. The ball screw can provide a smooth and efficient displacement simulation to ensure the accuracy of the simulation process. Since the high-speed rotation of the three-phase motor may cause vibration, the role of the motor holder is to ensure the stability of the three-phase motor during operation, reduce interference with other parts of the simulation system, and ensure the accuracy and stability of the simulation process. The brake disc physically presents the motion state of the mechanical brake and transmits the actual action information. The brake disc simulates the actual motion of the mechanical brake when it is working, and can accurately reflect the braking state and motion characteristics in the simulation system. Through the movement of the brake disc, the simulation unit 300 can provide the dynamic behavior of the mechanical brake, so that the control unit 100 can respond and make adjustments in real time.

[0047] Reference Figures 1-2This embodiment provides a mechanical brake position monitoring system, including a monitoring unit 200, a control unit 100, a simulation unit 300, a power unit 400 and an interaction unit 500. The monitoring unit 200 is used to monitor the position and state of the mechanical brake in real time, and summarize the data into first data and transmit it to the control unit 100; the control unit 100 is used to receive and process the first data from the monitoring unit 200, generate and transmit the first instruction to the simulation unit 300; the simulation unit 300 is used to simulate the operating state and motion characteristics of the mechanical brake according to the first instruction of the control unit 100; the power unit 400 is used to provide power support for the simulation unit 300 and drive the operation of the simulation unit; the interaction unit 500 is used to provide a user operation interface, display system feedback and data, and support parameter adjustment and simulation control.

[0048] Reference Figure 3 , is a schematic diagram of a mechanical brake simulation device, showing the connection relationship between the various components, where the DC24V power supply provides 24 volts of DC power for powering the PLC controller rack and touch screen. The AC220V power supply provides 220 volts of AC power for powering the inverter and possible other AC devices. The PLC controller rack contains multiple modules for controlling and monitoring the operation of the mechanical brake simulation device. The touch screen HMI01 is TPC7052Ni, which communicates with the PLC through the MODBUS / TCP protocol and uses the RJ45-1 interface. It is used for human-computer interaction, displaying status and real-time data, and setting system parameters. The printer is connected via the USB-A interface and is used to print report data and test results. The inverter UF01 is ATV320U02M2C, which communicates with the control unit 100 through the MODBUS-RTU protocol and uses the RJ45-2 interface.

[0049] Reference Figure 4 , is the power supply diagram of the system. The inverter main circuit power supply is provided by transformer T1, which is used to drive the inverter. The PLC power supply module is provided by the switching power supply G1, which powers the PLC-I / O module. The HMI working power supply is provided by the switching power supply G1, which powers HMI01. The displacement sensor power supply is provided by the switching power supply G1, which powers SP1. The panel / button indicator power supply is provided by the switching power supply G1, which powers HL1 / 2. In terms of control logic, the PLC-I / O module communicates with the PLC controller through the AI / SSI interface for data acquisition and control. HMI01 communicates with the PLC controller through 24V1+ and 0V for display and user input. SP1 communicates with the PLC controller through 24V1+ and 0V for position detection. HL1 / 2 communicates with the PLC controller through 24V1+ and 0V for status indication.

[0050] Reference Figure 5, is the wiring method of the programmable logic controller power module. The power enters the system through the circuit breaker QF1 to provide protection. The power supply is divided into two paths, one for the PLC power module and the other for other devices. The PLC power module converts the power into 24V DC and supplies it to the PLC and other devices. FG is used for grounding to ensure system safety.

[0051] Reference Figure 6 , is the wiring method of the interactive unit 500 working power supply. The power enters the system through the circuit breaker QF2 to provide protection. The power supply is divided into two paths, one of which supplies the HMI working power supply. The HMI working power supply converts the power supply into 24V DC and supplies it to the HMI device. FG is also used for grounding to ensure system safety.

[0052] Reference Figure 7 , is to control the start and stop of the three-phase motor and communicate with the programmable logic controller. The three-phase power is converted by transformer T1 to provide power for the motor and control circuit.

[0053] The start, stop and exit of the motor are controlled by buttons SB1, SB2 and SB3. The selector switch SW1 is used to select automatic or manual mode. The thermal relay RV1 provides overload protection to prevent the motor from being damaged due to overload. The MODBUS-RTU interface is used to communicate with the PLC for remote control and monitoring. The indicator lights HL1 and HL2 show the status of the motor, HL1 indicates ready and HL2 indicates running. Control the forward and reverse rotation, start and stop and speed adjustment of the motor.

[0054] Reference Figure 8 , is the wiring diagram of the SSI signal input module, which is used to connect the SSI module. The 24V DC power supply supplies power to the SSI encoder through the +24VDCO and OVDCO pins. The SSI encoder sends data and clock signals to the SSI module through the DATA2+ and DATA2- and CLK2+ and CLK2- pins. The SSI module receives signals from the encoder through the DATA1+ and DATA1- and CLK1+ and CLK1- pins. Signal conditioning is performed through CAP-IN0 and CAP-IN1 to ensure signal stability and accuracy. Aviation plug HT1 is used to connect the physical interface of the SSI module and the encoder to ensure reliable transmission of signals and power.

[0055] Reference Fig. 9, is the wiring diagram of analog input. Sensor signal: Each travel sensor 1# to 6# sends a 4~20mA current signal to the AI01 module through its corresponding analog input terminal AI02+, AI04+, AI06+, AI03+, AI05+. The switch signal of the sensor is sent to the AI01 module through the digital input terminals DI08, DI10, DI12, DI09, DI07, DI11 to indicate the status of the sensor. The system receives a 24V DC power supply through the 24V1+ and 0V terminals. The AI01 module receives and processes analog and digital signals from the sensor, and then converts these signals into a format that can be processed by the control system. The processed signal is transmitted to the programmable logic controller for generating the first instruction.

[0056] Reference Fig.10 , is the wiring diagram of the switch input. The system receives 24V DC power through the 24V1+ and 0V terminals. When the proximity switches are triggered, they send a signal to the module through the corresponding DI terminal. When the photoelectric sensors detect an object, they send a signal through the DI terminal. These sensors may be PNP type, which means that they provide a high level signal when not triggered and a low level signal when triggered. The module receives and processes the signals from the proximity switches and photoelectric sensors, and then converts these signals into a format that the control system can process. The processed signals are transmitted to the programmable logic controller for generating the first instruction.

[0057] Reference Fig.11 , is a flow chart of the mechanical brake position monitoring system, in which PLC is a programmable logic controller and HMI is an interactive unit. After the device is powered on, the communication connection between HMI and PLC is established first. If the detection is successful, it will proceed to the next step. If the detection fails, the HMI will alarm. Then the IO, inverter and external sensor are detected. The detection results are divided into success or failure. Failure also triggers the HMI alarm. After the detection is successful, the HMI inputs the detection parameters, and the user can choose manual or automatic mode. In manual mode, the user completes the detection by pressing the button. In automatic mode, the HMI starts the automatic detection process, and the brake cycles up and down. After the detection is completed, the HMI displays the detection parameters and updates the detection data, and saves the data to the SD card. If the automatic detection is interrupted, the HMI will alarm, and the user can reset the fault through the HMI to restore the normal state.

[0058] Finally, it should be pointed out that the methods and devices described in detail above are only embodiments, and those skilled in the art can modify these embodiments in different ways without departing from the scope of the present invention.

Claims

1. A mechanical brake position monitoring circuit, characterized in that: include, The monitoring unit (200) monitors the position and state of the simulation unit (300) in real time, summarizes the first data, and transmits it to the control unit (100); A control unit (100) is connected to the monitoring unit (200), receives first data from the monitoring unit (200), processes the first data to form a first instruction, and transmits the first instruction to the simulation unit (300); as well as, The simulation unit (300) is connected to the monitoring unit (200) and simulates the operating state and motion characteristics of the mechanical brake according to the first instruction.

2. The mechanical brake position monitoring circuit according to claim 1, characterized in that: Also includes, The power unit (400) is connected to the simulation unit (300) to provide power support for the operation of the simulation unit (300), and comprises a three-phase motor and a reducer. The three-phase motor provides driving force for the simulation unit (300); and the reducer is used to reduce the rotation speed of the three-phase motor.

3. The mechanical brake position monitoring circuit according to claim 2, characterized in that: The control unit (100) comprises a programmable logic controller, an isolation transformer, a switching power supply and a frequency converter. The programmable logic controller is used to centrally process all control logics, receive data and output instructions; the isolation transformer is used to isolate input and output circuits to prevent electromagnetic interference; the switching power supply is used to provide power for the programmable logic controller and the monitoring unit (200); and the frequency converter is used to control the running speed and direction of the three-phase motor.

4. The mechanical brake position monitoring circuit according to claim 3, characterized in that: Also includes, The interaction unit (500) is connected to the control unit (100) and is used for user operation and display system feedback.

5. The mechanical brake position monitoring circuit according to claim 4, characterized in that: The interactive unit (500) comprises a touch screen for displaying real-time data and alarm information, and supporting parameter adjustment and analog control.

6. The mechanical brake position monitoring circuit according to claim 4, characterized in that: The interactive unit (500) comprises an indicator light and an operation button, providing an operating status indication to facilitate manual operation.

7. The mechanical brake position monitoring circuit according to claim 4 or 6, characterized in that: The monitoring unit (200) comprises a proximity switch and a photoelectric sensor, wherein the proximity switch detects the upper and lower limit states of the mechanical brake and provides a switch signal; and the photoelectric sensor is used to accurately measure the brake displacement stroke and output an analog signal.

8. The mechanical brake position monitoring circuit according to claim 7, characterized in that: The monitoring unit (200) also includes an SSI module connected to the control unit (100) and used to collect an SSI absolute encoder signal of the mechanical brake displacement stroke, thereby providing a standard basis for the accuracy inspection of the photoelectric sensor.

9. The mechanical brake position monitoring circuit according to claim 8, characterized in that: The simulation unit (300) comprises a ball screw, a motor fixing frame and a brake disc, wherein the ball screw realizes linear motion to simulate the up and down displacement state of the mechanical brake; the motor fixing frame stably supports the three-phase motor to avoid vibration during operation; and the brake disc physically presents the motion state of the mechanical brake to transmit action information.

10. A mechanical brake position monitoring system, characterized in that: include, The monitoring unit (200) monitors the position and state of the simulation unit (300) in real time, summarizes the first data, and transmits it to the control unit (100); A control unit (100) is connected to the monitoring unit (200), receives first data from the monitoring unit (200), processes the first data to form a first instruction, and transmits the first instruction to the simulation unit (300); A simulation unit (300) connected to the monitoring unit (200) and simulating the operating state and motion characteristics of the mechanical brake according to the first instruction; A power unit (400) is connected to the simulation unit (300) to provide power support for the operation of the simulation unit (300), and comprises a three-phase motor and a reducer, wherein the three-phase motor provides driving force for the simulation unit (300); The reducer is used to reduce the speed of the three-phase motor; and The interaction unit (500) is connected to the control unit (100) and is used for user operation and display system feedback.

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