Elevator drum brake disassembly and maintenance guiding method and device based on mixed reality

Abstract

The invention discloses an elevator drum brake disassembling and overhauling guiding method and device based on mixed reality, and relates to the technical field of elevator inspection and detection.The method comprises the steps that a failure mode and a failure reason of an elevator drum brake are analyzed, and a brake failure tree model is established; according to the brake fault tree model and the key failure factors of the elevator drum brake, maintenance behaviors are analyzed, and a brake maintenance behavior tree model is established; according to the brake maintenance behavior tree model, a 3D digital simulation model of the elevator drum brake is established and subjected to lightweight processing, and according to the model subjected to lightweight processing, brake maintenance operation guidance process fragments are created through process virtual simulation; and a three-dimensional registration method combining manual identification and natural feature points is adopted, accurate fusion of the overhaul operation model animation and the elevator drum brake entity is carried out, and elevator drum brake disassembly overhaul guidance is achieved. According to the invention, operators can be helped to accurately understand the maintenance process of the elevator drum brake.

Description

Technical Field

[0001] The present application relates to the technical field of elevator inspection and testing, and particularly to a method and device for disassembling, inspecting and repairing an elevator drum brake based on mixed reality. Background Art

[0002] Currently, the traditional elevator inspection training mode combines theoretical knowledge training and practical operation training. The disadvantages of this mode are that learning through theoretical knowledge in books is rather rigid, and it is not easy to understand many complex elevator industry standard knowledge. There are numerous parts in the elevator brake and the repair process is complex, resulting in poor learning effects, and it also takes a long time and effort. Moreover, during the practical operation training process, the trainees on-site have no experience and there is a certain degree of danger. For novices, operating moving parts such as actual elevator brakes has a certain safety risk.

[0003] In recent years, foreign elevator companies have begun to apply mixed reality operation navigation in the actual operation environment and on-the-job professional training through MR technology. In 2016, Thyssenkrupp Elevator Company in Germany used the Microsoft HoloLens mixed reality glasses device to enhance elevator maintenance. The maintenance technicians can simulate 3D pictures of the elevator to be visited with the help of the HoloLens glasses, and can discover and see the problems existing in the elevator before arriving at the scene. When arriving at the scene, they can call the expert center, and the expert center uses the drawings in the glasses to show the problems to the technicians, providing help for the maintenance personnel, thus greatly saving the maintenance time and helping more than 24,000 Thyssenkrupp technicians to carry out maintenance work more safely and efficiently. Otis Elevator Company in the United States is also exploring "mixed reality" technology solutions, enabling remote technicians to conduct virtual collaboration with a second technician inside the elevator to solve problems virtually, and will enable technicians in different locations to view the mixed virtual and real images simultaneously, expanding the scope of technologies that can be used to restore the elevator to service. The Thyssenkrupp Elevator Asia-Pacific Training Institute integrates virtual reality technology (VR) into safety training. Through VR training, technical service personnel can handle maintenance problems that may be encountered in reality in the virtual reality world, such as replacing components in the pit, elevator emergency rescue, live working, installing a mobile platform on the car top, etc. If the operation is improper, death experiences such as "electric shock" and "falling from a height" will be simulated, and repeated practice can be carried out without any personal danger.

[0004] However, the existing technology is a general guidance oriented towards overall elevator maintenance and cannot guide the disassembly and inspection scenarios of a specific device, namely the elevator drum brake. Therefore, how to design a method and device for disassembling, inspecting and repairing an elevator drum brake based on mixed reality has become an urgent technical problem in this field. Summary of the Invention

[0005] The purpose of this application is to provide a method and device for disassembling, inspecting, and maintaining an elevator drum brake based on mixed reality, which can present a high-quality mixed reality inspection and maintenance operation guidance experience on the device, help operators accurately understand the inspection and maintenance process of the elevator drum brake, greatly improve the accuracy and efficiency of inspection and maintenance operations, and can also be used for personnel operation training, helping to speed up the training speed and improve operation skills.

[0006] To achieve the above object, this application provides the following solutions:

[0007] In the first aspect, this application provides a method for disassembling, inspecting, and maintaining an elevator drum brake based on mixed reality. The method for disassembling, inspecting, and maintaining an elevator drum brake based on mixed reality includes:

[0008] Analyze the failure modes and fault causes of the elevator drum brake to establish a brake fault tree model; the failure modes include: brake failure and brake release failure; the fault causes are based on six functional structures: brake arm, brake lining, electromagnet, push rod, compression spring, and brake release ejector rod.

[0009] Analyze the maintenance behaviors according to the brake fault tree model and the key failure factors of the elevator drum brake to establish a brake maintenance behavior tree model; the key failure factors are factors obtained by calculating the risk priority numbers of the failure modes according to the influence degree, occurrence probability, and detectability of each failure mode in the fault tree, combined with the FMEA analysis results; the brake maintenance behavior tree model is used for the process of guiding the inspection and maintenance of the elevator drum brake.

[0010] Establish a 3D digital simulation model of the elevator drum brake according to the brake maintenance behavior tree model.

[0011] Perform lightweight processing on the 3D digital simulation model of the elevator drum brake to obtain a lightweight processed 3D digital simulation model of the elevator drum brake.

[0012] According to the lightweight processed 3D digital simulation model of the elevator drum brake, create a brake inspection operation guidance process segment through process virtual simulation; the brake inspection operation guidance process segment includes: disassembly steps of the elevator drum brake, component status inspection, simulation guidance content of fault location methods and maintenance steps, and specific operation processes of reassembly and function testing.

[0013] According to the brake inspection operation guidance process segment, adopt a three-dimensional registration method combining artificial marking and natural feature points to accurately fuse the inspection operation model animation with the elevator drum brake entity, and realize the disassembly, inspection, and maintenance guidance of the elevator drum brake; the inspection operation model animation is a dynamic visualization representation of the brake inspection operation guidance process segment.

[0014] In a second aspect, the present application provides a disassembly and maintenance guidance device for an elevator drum brake based on mixed reality. The disassembly and maintenance guidance device for an elevator drum brake based on mixed reality is used to implement the disassembly and maintenance guidance method for an elevator drum brake based on mixed reality described above. The disassembly and maintenance guidance device for an elevator drum brake based on mixed reality includes:

[0015] A brake fault tree model establishment module, which is used to analyze the failure modes and fault causes of the elevator drum brake and establish a brake fault tree model; the failure modes include: brake failure and brake release failure; the fault causes are obtained based on six functional structures: the brake arm, brake lining, electromagnet, push rod, compression spring, and brake release ejector rod.

[0016] A brake maintenance behavior tree model establishment module, which is used to analyze maintenance behaviors according to the brake fault tree model and the key failure factors of the elevator drum brake, and establish a brake maintenance behavior tree model; the key failure factors are factors obtained by calculating the risk priority numbers of the failure modes according to the influence degree, occurrence probability, and detectability of each failure mode in the fault tree, combined with the FMEA analysis results; the brake maintenance behavior tree model is used for the process of guiding the maintenance of the elevator drum brake.

[0017] An elevator drum brake 3D digital simulation model establishment module, which is used to establish a 3D digital simulation model of the elevator drum brake according to the brake maintenance behavior tree model.

[0018] A lightweight processing module, which is used to perform lightweight processing on the 3D digital simulation model of the elevator drum brake to obtain a lightweight processed 3D digital simulation model of the elevator drum brake.

[0019] A brake maintenance operation guidance process segment creation module, which is used to create a brake maintenance operation guidance process segment through process virtual simulation according to the lightweight processed 3D digital simulation model of the elevator drum brake; the brake maintenance operation guidance process segment includes: disassembly steps of the elevator drum brake, inspection of component states, simulation guidance content of fault location methods and maintenance steps, and specific operation processes of reassembly and function testing.

[0020] A fusion module, which is used to accurately fuse the maintenance operation model animation with the elevator drum brake entity according to the brake maintenance operation guidance process segment by using a three-dimensional registration method combining artificial marking and natural feature points, so as to realize the disassembly and maintenance guidance of the elevator drum brake; the maintenance operation model animation is a dynamic visualization representation of the brake maintenance operation guidance process segment.

[0021] According to the specific embodiments provided by this application, the following technical effects are disclosed in this application:

[0022] This application provides a method and device for disassembling, inspecting and maintaining an elevator drum brake based on mixed reality. The method includes: analyzing the failure modes and causes of elevator drum brakes, and establishing a brake fault tree model; analyzing maintenance behaviors according to the brake fault tree model and the key failure factors of elevator drum brakes, and establishing a brake maintenance behavior tree model; establishing a 3D digital simulation model of an elevator drum brake according to the brake maintenance behavior tree model; performing lightweight processing on the 3D digital simulation model of the elevator drum brake, and creating a process virtual simulation to create a fragment of an inspection and maintenance operation guide process for the brake; according to the fragment of the inspection and maintenance operation guide process for the brake, using a three-dimensional registration method that combines artificial marking and natural feature points to accurately fuse the inspection and maintenance operation model animation with the entity of the elevator drum brake, and then the disassembly, inspection and maintenance guidance of the elevator drum brake can be realized. This application can present a high-quality mixed reality inspection and maintenance operation guidance experience on the device, help operators accurately understand the brake inspection and maintenance process, greatly improve the accuracy and efficiency of inspection and maintenance operations, and can also be used for personnel operation training, which helps to speed up the training speed and improve operation skills. It solves the problems such as the unintuitive acquisition of elevator drum brake inspection and maintenance guidance knowledge, the complexity of industry standard knowledge, and the insufficient knowledge reserve of operators. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the following will briefly introduce the drawings required to be used in the embodiments. Obviously, the following drawings are only some embodiments of this application. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0024] Figure 1 It is a schematic flowchart of a method for disassembling, inspecting and maintaining an elevator drum brake based on mixed reality provided by an embodiment of this application.

[0025] Figure 2 It is a composition diagram of the main components of an elevator drum brake provided by an embodiment of this application.

[0026] Figure 3 It is a schematic diagram of a brake fault tree model provided by an embodiment of this application.

[0027] Figure 4 It is a schematic diagram of the structure of the maintenance behavior of an elevator drum brake provided by an embodiment of this application.

[0028] Figure 5 It is a schematic diagram of a brake maintenance behavior tree model provided by an embodiment of this application.

[0029] Figure 6 Schematic diagram of the lightweight processing result of the elevator traction machine and cabinet brake 3D digital simulation model provided by an embodiment of the present application.

[0030] Figure 7 A screenshot in a fragment of the maintenance operation guidance process for the elevator drum brake provided by an embodiment of the present application.

[0031] Figure 8 Another screenshot in a fragment of the maintenance operation guidance process for the elevator drum brake provided by an embodiment of the present application.

[0032] Figure 9 A screenshot of the mixed reality maintenance operation guide for the elevator drum brake provided by an embodiment of the present application

[0033] Figure 10 Another screenshot of the mixed reality maintenance operation guide for the elevator drum brake provided by an embodiment of the present application.

[0034] Figure 11 Schematic diagram of the functional modules of a device for disassembling and overhauling an elevator drum brake based on mixed reality provided by an embodiment of the present application. Specific embodiments

[0035] Next, the technical solutions in the embodiments of the present application will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present application without creative efforts shall fall within the protection scope of the present application.

[0036] To make the above objects, features, and advantages of the present application more obvious and understandable, the present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0037] In an exemplary embodiment, as Figure 1 shown, a method for disassembling and overhauling an elevator drum brake based on mixed reality is provided. The method for disassembling and overhauling an elevator drum brake based on mixed reality includes:

[0038] S1: Analyze the failure modes and fault causes of the elevator drum brake, and establish a brake fault tree model; the failure modes include: brake failure and brake release failure; the fault causes are based on six functional structures: the brake arm, brake lining, electromagnet, push rod, compression spring, and brake release ejector rod.

[0039] S2: Analyze the maintenance behaviors based on the brake fault tree model and the key failure factors of the elevator drum brake, and establish a brake maintenance behavior tree model; the key failure factors are obtained by calculating the risk priority number (RPN) of the failure mode according to the influence degree, occurrence probability and detectability of each failure mode in the fault tree, combined with the analysis results of FMEA (Failure Mode and Effects Analysis); the brake maintenance behavior tree model is used for the process of guiding the inspection and repair of the elevator drum brake.

[0040] S3: Establish a 3D digital simulation model of the elevator drum brake according to the brake maintenance behavior tree model.

[0041] S4: Perform lightweight processing on the 3D digital simulation model of the elevator drum brake to obtain a lightweight processed 3D digital simulation model of the elevator drum brake.

[0042] S5: According to the lightweight processed 3D digital simulation model of the elevator drum brake, create a brake inspection operation guidance process segment through process virtual simulation; the brake inspection operation guidance process segment includes: the disassembly steps of the elevator drum brake, the inspection of component states, the simulation guidance content of the fault location method and the maintenance steps, as well as the specific operation processes of reassembly and function testing.

[0043] S6: According to the brake inspection operation guidance process segment, adopt a three-dimensional registration method combining artificial marking and natural feature points to accurately fuse the inspection operation model animation with the elevator drum brake entity, and realize the disassembly and inspection guidance of the elevator drum brake; the inspection operation model animation is a dynamic visualization of the brake inspection operation guidance process segment; that is, the inspection process steps (such as disassembly, inspection, maintenance and reassembly, etc.) are intuitively presented in the form of 3D animation, so that the operator can obtain clearer operation guidance in the mixed reality environment.

[0044] Implementing the above steps S1 to S6, the present application can present a high-quality mixed reality inspection operation guidance experience on the elevator drum brake, which can help the operator accurately understand the brake inspection and maintenance process, greatly improve the accuracy and efficiency of the inspection and maintenance operation, and at the same time can turn the brake inspection operation process into a highly immersive training experience, providing a more intuitive and effective learning tool for the maintenance personnel, improving their operation skills and safety awareness, and helping to speed up the training speed and improve the training effect.

[0045] In an exemplary embodiment, in step S1, it specifically includes:

[0046] S11: Analyze the failure modes and impacts of the elevator drum brake using the FMEA method based on functional analysis to obtain the failure modes of the elevator drum brake.

[0047] S12: Based on the failure modes, decompose the corresponding faults according to each functional structure to determine the locations and causes of the corresponding faults.

[0048] S13: Based on the locations and causes of the corresponding faults, establish a brake fault tree model.

[0049] As Figure 2 shown, the elevator drum brake can be disassembled into 6 parts by function: brake arm, brake lining, electromagnet, push rod, compression spring, and brake release push rod; among them, the brake arm consists of a connecting hinge, a support arm, and a fixed support; the brake lining is composed of friction material and a support base; the electromagnet consists of an end cover, a moving iron core, and a coil; the push rod consists of a body, connecting threads, and a limit circlip; the compression spring is a standard cylindrical helical spring; the brake release push rod consists of a push rod body and a return spring.

[0050] Analyze the failure modes and impacts of the elevator drum brake using the FMEA method based on functional analysis, obtain two common failure modes of the drum brake: brake holding failure and brake release failure, decompose the faults according to each functional structure, further analyze the locations and causes of the faults, and establish a brake fault tree model, as Figure 3 shown.

[0051] (1) Failure modes and fault causes: Based on the six - part structure of the elevator drum brake, the following two common fault modes and their corresponding fault causes are analyzed:

[0052] Brake holding failure:

[0053] ① Electromagnet: Coil short - circuit or open - circuit, moving iron core stuck.

[0054] ② Brake arm: Connecting hinge worn and loosened, support arm deformed or broken.

[0055] ③ Compression spring: Spring fatigue failure or breakage, resulting in insufficient brake holding force.

[0056] ④ Brake release push rod: Push rod stuck and unable to return.

[0057] Brake release failure:

[0058] ① Electromagnet: Coil overheating causes insulation failure, moving iron core offset.

[0059] ② Push rod: Limit circlip loose or push rod deformed.

[0060] ③ Brake lining: Friction material severely worn, resulting in insufficient braking force.

[0061] Specifically, the reasons for brake failure include: the brake not engaging and insufficient braking torque.

[0062] The reasons for the brake not engaging include: relay contact welding adhesion and brake jamming; the reasons for contact adhesion include: improper design and aging of the contact structure, and the reason for the aging of the contact structure is excessive environmental dust or high humidity; the reasons for brake jamming include: excessive electromagnetic force and armature jamming. The excessive electromagnetic force is due to excessive residual magnetism in the electromagnetic coil, resulting in the electromagnetic force not disappearing in time. The reasons for armature jamming include: excessive deviation in the installation angle of the guiding bolt, impurities in the guiding hole, or residual magnetism in the armature.

[0063] The reason for insufficient braking torque is the fatigue failure of the brake spring, oil stain on the braking surface, excessive working clearance of the brake, or elevator overload. The excessive working clearance of the brake is due to the long-term non-adjustment of the working clearance or wear of the brake shoe. The reasons for the wear of the brake shoe include excessive braking force, emergency braking, and insufficient opening voltage.

[0064] The reasons for release brake failure include: guiding component jamming, brake phase loss, and running with the brake engaged. Among them, brake phase loss means that the electromagnet does not obtain a complete three-phase power supply, resulting in insufficient electromagnetic force and unable to overcome the braking force. Running with the brake engaged is due to too small a working clearance, resulting in too small an armature stroke, or too large a brake spring force. In addition, demagnetization of the electromagnet or short circuit of the coil may also cause the electromagnetic force to be less than the braking force, thus causing the failure of running with the brake engaged.

[0065] (2) Establishment of the brake fault tree model: Combining the above six parts of the structure and their decomposed fault modes and reasons, establish a brake fault tree model. The following is the structural schematic of the fault tree:

[0066] Top event: Brake failure or release brake failure.

[0067] Intermediate events: Electromagnet failure (coil open circuit, short circuit, etc.), brake arm failure (hinge wear, support arm deformation, etc.), push rod failure (limit snap ring loosening, etc.), brake lining failure (friction material wear, etc.), compression spring failure (spring fatigue, fracture, etc.), release brake ejector rod failure (ejector rod jamming, etc.).

[0068] Basic events: Such as short circuit of the electromagnet coil, stuck moving iron core, fracture of the compression spring, etc.

[0069] In an exemplary embodiment, in step S2, it specifically includes:

[0070] S21: Analyze the virtual maintenance behavior and process of the elevator drum brake according to the brake fault tree model and the key failure factors of the elevator drum brake to obtain the analysis result.

[0071] S22: According to the analysis results and the operation process of the elevator drum brake handled based on the behavior of the inspection and maintenance personnel in the virtual environment, construct a brake maintenance behavior tree model with branches expanding from the root node and unlimited expansion of sub-nodes; the operation process includes: disassembly, maintenance, and assembly.

[0072] Specifically, analyze the virtual inspection behavior and process of the elevator drum brake according to the key failure factors of the elevator drum brake, handle the disassembly and maintenance process of the brake according to the behavior of the inspection and maintenance personnel in the virtual environment, construct a behavior tree model with branches expanding from the root node and unlimited expansion of sub-nodes, and traverse the behavior tree top-down according to the maintenance behavior in different stages to find the unique leaf node (behavior node) and execute the maintenance action of the leaf node. Describe the internal behavior logic of the maintenance process through different behavior nodes, so that each independent state can be logically reused, including maintenance states such as releasing the brake spring, disassembling the brake arm, checking the wear of the brake lining and brake wheel, etc., to achieve modularization and standardization of the maintenance state.

[0073] Method for determining key failure factors:

[0074] 1. Theoretical basis: The identification of key failure factors is based on the FMEA method. This method identifies the failure modes that are most critical to the system function by analyzing the possible failure modes in the system and their impacts on the system performance.

[0075] 2. Specific analysis process:

[0076] Step ①: Function decomposition.

[0077] Decompose the elevator drum brake into multiple sub-components according to its functions and structures, including six parts: brake arm, brake lining, electromagnet, push rod, compression spring, and brake release rod, and further disassemble its sub-structures (for example, the electromagnet includes end cover, moving iron core, coil, etc.).

[0078] Step ②: List failure modes.

[0079] For each sub-component, list the possible failure modes based on the function analysis. For example:

[0080] Brake arm: Wear of connecting hinge, deformation of support arm, etc.

[0081] Brake lining: Wear of friction material, fracture of support base, etc.

[0082] Electromagnet: Coil short circuit, stuck moving iron core, lack of magnetism, etc.

[0083] Compression spring: Spring fatigue failure, fracture, etc.

[0084] Brake release rod: Stuck rod, unable to reset, etc.

[0085] Step ③: Evaluate the failure impact.

[0086] For each failure mode, evaluate from the following three dimensions:

[0087] Severity (S) of the failure: The degree of impact of the failure on the system function or safety.

[0088] Occurrence (O) of the failure: The likelihood of the failure occurring.

[0089] Detectability (D) of the failure: The ease of detecting the failure.

[0090] The scoring for each dimension uses a 5-level or 10-level system. The higher the score, the more significant the impact of that dimension.

[0091] Step ④: Calculate the Risk Priority Number (RPN).

[0092] Use the Risk Priority Number (RPN) to evaluate the importance of the failure mode:

[0093] RPN = S × O × D

[0094] Sort the RPN values of all failure modes. The failure mode with the highest RPN value is the critical failure factor of the system.

[0095] 3. Application in this application:

[0096] Based on the above analysis, combined with historical maintenance data and expert experience, the critical failure factors of the drum brake are determined to include:

[0097] Brake failure: Caused by brake spring fatigue, wear of the brake arm connection hinge, jamming of the electromagnet moving iron core, etc.

[0098] Release failure: Caused by demagnetization of the electromagnet, short circuit of the coil, too small working clearance, jamming of the push rod, etc.

[0099] Further combined with the brake maintenance behavior tree model in the virtual environment, use the critical failure factors as the root nodes of the behavior tree, decompose the maintenance actions and design the maintenance process, so as to achieve targeted maintenance guidance.

[0100] In an exemplary embodiment, the analysis of the maintenance behavior process is as Figure 4As shown, the maintenance behavior process elements of the brake maintenance behavior tree model include: interface UI, scene, maintenance object model, action, animation, event, and commentary; the interface UI includes: subject selection, task start, and end; the scene includes: elevator machine room, maintenance table, and maintenance workshop; the maintenance object model is each model involved in the brake maintenance behavior process; the action is the basic composition of the maintenance behavior; the animation is the performance triggered and executed during the maintenance behavior; the event is an operation that can be recognized by the system; the commentary is the voice operation prompt for the maintenance behavior.

[0101] In an exemplary embodiment, combining the brake maintenance behavior structure and the behavior tree theory, a brake maintenance behavior tree model is constructed that expands branches from the root node and has unlimited expansion of sub-nodes, as Figure 5 shown; among them, the brake maintenance behavior structure is based on the behavior analysis of inspection and maintenance personnel in the virtual environment for processes such as disassembling, maintaining, and assembling the brake, and logically divides, structurally organizes, and optimizes these behaviors to accurately handle complex operation processes such as brake disassembly and maintenance. The basic element of the brake maintenance behavior tree model is the task, including: 5 task nodes of disassembling the brake arm, disassembling the micro switch, disassembling the moving iron core, elevator drum brake iron core maintenance, and slack adjuster verification, and assembling the elevator drum brake and braking force verification. Each task also includes action tasks such as training start, voice prompt, tool selection, grasping the tool, animation playback, maintenance action start, putting down the tool, grasping the part, part placement, maintenance action end, and training end. The specific content of the 5 task nodes is as follows:

[0102] Task 1: Disassemble the brake arm.

[0103] (1) Start the task of disassembling parts; judge whether the user is holding the required tool. If not, play the voice prompt for picking up the tool, otherwise do not play.

[0104] (2) Measure and record the compression amount of the compression spring; judge whether the user is holding the required tool. If not, play the voice prompt for picking up the tool, otherwise do not play.

[0105] (3) Use an open-end wrench to loosen the nut and screw out the double-headed screw; if the user does not hold the required tool in the current task, play the voice prompt and operation animation for picking up the tool.

[0106] (4) Put down the brake arm together with the double-headed screw; play the voice prompt and operation animation for putting down this part.

[0107] Task 2: Disassemble the micro switch.

[0108] (1) Loosen the screws of the microswitch bracket with a screwdriver; if the user does not hold the required tool in the current task, play the voice prompt and operation animation for picking up the tool.

[0109] (2) Remove the microswitch bracket; play the voice prompt and operation animation for removing the component.

[0110] Task 3: Disassemble the moving iron core.

[0111] (1) Loosen the 4 screws fixing the end cover with an Allen wrench; if the user does not hold the required tool in the current task, play the voice prompt and operation animation for picking up the tool.

[0112] (2) Swing the brake release lever and eject the moving iron core assembly; play the voice prompt and operation animation for swinging the component.

[0113] (3) Remove the moving iron core assembly and separate the moving iron core and the end cover; play the voice prompt and operation animation for removing the component.

[0114] Task 4: Maintenance of the elevator drum brake iron core and verification of the brake release push rod.

[0115] (1) Observe the inside of the moving iron core housing; play the voice prompt.

[0116] (2) Clean and lubricate the surface of the brake iron core and the guide sleeve; play the voice prompt.

[0117] (3) Verify whether the disassembled brake release push rod is a magnetically conductive material; play the voice prompt.

[0118] Task 5: Assembly of the elevator drum brake and verification of the braking force.

[0119] (1) Assemble the equipment and restore the spring compression amount to the initial distance; play the voice prompt for assembling the equipment, judge whether the user holds the required measuring tool, and if not, play the voice prompt for picking up the tool to measure the spring compression amount.

[0120] (2) Measure the distance between the brake lining and the brake wheel; judge whether the user holds the required tool, and if not, play the voice prompt and operation animation for picking up the tool.

[0121] (3) Measure the braking performance and verify whether the braking force meets the requirements; play the voice prompt.

[0122] (4) End the brake disassembly and repair task; play the voice prompt.

[0123] In an exemplary embodiment, in step S4, it specifically includes:

[0124] The 3D digital simulation model of the elevator drum brake is lightweight processed by using model decimation, texture merging, physically-based model simplification, or manifold learning-based model simplification to obtain the lightweight processed 3D digital simulation model of the elevator drum brake; the physically-based model simplification simplifies the physical entity hierarchy of the 3D digital simulation model of the elevator drum brake by reducing the invisible parts of the elevator drum brake or merging adjacent objects; the manifold learning-based model converts the 3D digital simulation model of the elevator drum brake into a low-dimensional manifold representation through a manifold learning algorithm, thereby reducing the complexity of the model.

[0125] Specifically, a 3D digital simulation model of the elevator drum brake is established, and the model file is lightweight processed to optimize the polygon count, texture quality, and material complexity of the model, so as to reduce the size of the model file and improve its rendering performance on mobile devices. Without sacrificing visual quality, the volume of the model file is effectively reduced, making it more suitable for loading and displaying on devices, as Figure 6 shown.

[0126] Model lightweighting can be achieved through model decimation, texture merging, physically-based model simplification, manifold learning-based model simplification, etc. The physically-based model simplification method simplifies the physical entity hierarchy of the 3D digital simulation model of the elevator drum brake by reducing invisible parts and merging adjacent objects. The manifold learning-based model simplification method converts the 3D model into a lower-dimensional manifold representation through a manifold learning algorithm, thereby reducing the complexity of the model. The physically-based model simplification method of this application is aimed at the elevator brake maintenance scenario, and simplifies the physical entity hierarchy of the 3D digital simulation model of the elevator drum brake by reducing the invisible parts of the brake and merging adjacent components; the manifold learning-based model simplification method combines the geometric characteristics of the specific structure of the brake and optimizes the model complexity through the corresponding dimensionality reduction algorithm. Without sacrificing the details of key maintenance components, the volume of the model file is effectively reduced, making it more suitable for loading and running on mixed reality devices.

[0127] Furthermore, these lightweight model files are used to create a mixed reality guidance process for the elevator drum brake, and the tools required during disassembly and maintenance are extracted, such as wrenches, screwdrivers, measuring tools, etc. By extracting and displaying these tools, the disassembly and repair operation process of the elevator drum brake is transformed into an interactive model in a virtual reality environment. Through these models, trainers can simulate steps such as releasing the brake spring, disassembling the brake arm, and checking the wear of the brake lining and brake wheel in the virtual environment. Combining virtual reality technology and a physical simulation engine, the sorted operation process is transformed into a mixed reality simulation process. Screenshots of fragments of the elevator drum brake maintenance operation guidance process are as Figure 7 and Figure 8 shown.

[0128] In an exemplary embodiment, in step S5, it specifically includes:

[0129] S51: According to the elevator drum brake disassembly process video, mark the key disassembly components, and split the disassembly process video into independent segments to ensure the visual clarity of the key steps in the disassembly process;

[0130] S52: Combine the special requirements of the elevator drum brake maintenance process to create an animation. Use the lightweight 3D digital simulation model of the elevator drum brake and physical simulation software to accurately restore the details of tool use and disassembly operations, and introduce a physical simulation engine to simulate the interaction effect between the tool and the components during the maintenance process;

[0131] S53: Based on the corresponding mixed reality application requirements, design the interaction method between the user and the virtual tool, and develop a real-time maintenance progress prompt function to complete the creation of the brake maintenance operation guidance process segment.

[0132] Specifically, use these lightweight model files to create a mixed reality guidance process for the brake. Extract the required tools (such as wrenches, screwdrivers, steel straightedges, etc.) for the disassembly and maintenance process, and combine with the specific operation steps and simulation requirements of the brake disassembly and maintenance to convert them into interactive models in the virtual reality environment. In the mixed reality simulation process, the present invention realizes the personalized optimization for the elevator drum brake through the following steps:

[0133] (1) According to the elevator drum brake disassembly process video, mark the key disassembly components (such as brake springs and brake arms), and split the process video into independent segments to ensure the visual clarity of the key steps in the disassembly process.

[0134] (2) Combine the special requirements of the brake maintenance process to create an animation. Use the lightweight 3D digital simulation model of the elevator drum brake and physical simulation software (such as 3DMax, Maya) to accurately restore the details of tool use and disassembly operations, and introduce a physical simulation engine to simulate the interaction effect between the tool and the components during the maintenance process.

[0135] (3) Based on specific mixed reality application requirements, design the interaction method between the user and the virtual tool (such as operating the tool through gestures or rays), and develop a real-time maintenance progress prompt function.

[0136] (4) Optimize and deploy the mixed reality system on the target device to ensure the efficient loading and smooth operation of the elevator drum brake maintenance simulation model.

[0137] In an exemplary embodiment, in step S6, it specifically includes:

[0138] S61: A three-dimensional registration method combining artificial identification and natural feature points is adopted to achieve target recognition and tracking effects by obtaining the beacon position through real-time scanning of beacons.

[0139] S62: Measure the real environment through a depth camera to obtain the spatial position information of the tracked object.

[0140] S63: Based on the tracked object, corresponding virtual information is superimposed on the tracked object to achieve virtual-real fusion; the virtual information includes: a lightweight 3D digital simulation model of an elevator drum brake, graphics, and animations.

[0141] S64: According to the real-time change of the position of the tracked object, update the virtual screen to be consistent with the real environment, and accurately fuse the maintenance operation model animation with the elevator drum brake entity to achieve the disassembly and maintenance guidance of the elevator drum brake.

[0142] Specifically, the trainer can use a head-mounted display and a handheld device to achieve target recognition and tracking effects by obtaining the beacon position through real-time scanning of beacons with a three-dimensional registration method combining artificial identification and natural feature points, and measure the real environment through a depth camera to obtain the spatial position information of the object; based on the tracked object, corresponding virtual information such as a lightweight 3D digital simulation model of an elevator drum brake, graphics, animations, etc. is superimposed on it to achieve virtual-real fusion; the lightweight 3D digital simulation model of the elevator drum brake is used to display the structural details of the brake disassembly or assembly, the graphics are used to mark the positions of key components or operation guides, and the animations are used to dynamically demonstrate the maintenance operation steps and process segments to achieve virtual-real fusion; according to the real-time change of the object position, update the virtual screen to be consistent with the real environment, and accurately fuse the maintenance operation model animation with the brake entity to present a high-quality mixed reality maintenance operation guidance experience on the device. Screenshots of the mixed reality maintenance operation guidance of the elevator drum brake are as Figure 9 and Figure 10 shown.

[0143] In an exemplary embodiment, the method for guiding the disassembly and maintenance of an elevator drum brake based on mixed reality further includes: adding more teaching elements to the mixed reality simulation process with the help of intelligent auxiliary functions; the intelligent auxiliary functions include: voice prompts, animation demonstrations, and operation guides.

[0144] Specifically, intelligent auxiliary functions can be used to add more teaching elements to the mixed reality simulation process, such as voice prompts, animation demonstrations, operation guides, etc. This will make the training experience more vivid and help improve the training effect and learning outcome.

[0145] In summary, compared with the prior art, the innovation points and advantages of this application are:

[0146] (1) For the disassembly and maintenance scenario of the elevator drum brake, a precise operation guidance method based on mixed reality is proposed in this application. Compared with the general guidance of the existing technology oriented to the overall elevator maintenance, this application pays more attention to the special structure and maintenance complexity of the key component of the brake, and can provide more accurate and targeted guidance for technicians.

[0147] (2) This application integrates a three-dimensional registration method combining artificial markers and natural feature points, and a model lightweight optimization technology based on manifold learning, enabling the brake disassembly process to run on the mixed reality device in an efficient and low-latency manner, thus overcoming the performance bottleneck problem caused by complex model rendering in the existing technology.

[0148] (3) Compared with simply providing a 3D model or remote collaboration function, this application also combines a depth camera and a physical simulation engine to measure the spatial position of the object in real time to update the virtual information, and realizes the precise fusion of the maintenance operation animation and the actual device entity, enabling the training personnel to synchronously observe the operation details of the virtual and the real in the mixed reality environment, significantly improving the operation accuracy and efficiency.

[0149] (4) This application also combines the specific workflow of the brake disassembly, and shows the whole process of disassembly, inspection, assembly, etc. in the form of step-by-step animation demonstrations, overcoming the problem of insufficient maintenance guidance for specific key components in the existing technology.

[0150] Based on the same inventive concept, the embodiment of this application also provides a guidance device for implementing the above-mentioned method for guiding the disassembly and maintenance of the elevator drum brake based on mixed reality. The implementation solution provided by this device to solve the problem is similar to the implementation solution described in the above method. Therefore, the specific limitations in one or more embodiments of the guidance device for guiding the disassembly and maintenance of the elevator drum brake based on mixed reality provided below can refer to the limitations on the method for guiding the disassembly and maintenance of the elevator drum brake based on mixed reality in the above text, and will not be repeated here.

[0151] In an exemplary embodiment, as Figure 11 shown, a guidance device for guiding the disassembly and maintenance of the elevator drum brake based on mixed reality is provided. The guidance device for guiding the disassembly and maintenance of the elevator drum brake based on mixed reality includes:

[0152] A brake fault tree model establishment module M1, which is used to analyze the failure modes and fault causes of the elevator drum brake and establish a brake fault tree model; the failure modes include: brake failure and brake release failure; the fault causes are the causes obtained based on six functional structures of the brake arm, brake lining, electromagnet, push rod, compression spring, and brake release ejector rod.

[0153] The brake maintenance behavior tree model establishment module M2 is used to analyze maintenance behaviors according to the brake fault tree model and the key failure factors of the elevator drum brake, and establish a brake maintenance behavior tree model; the key failure factors are factors obtained by calculating the risk priority numbers of failure modes according to the influence degree, occurrence probability and detectability of each failure mode in the fault tree, combined with the FMEA analysis results; the brake maintenance behavior tree model is used for the process of guiding the inspection and maintenance of elevator drum brakes.

[0154] The elevator drum brake 3D digital simulation model establishment module M3 is used to establish a 3D digital simulation model of the elevator drum brake according to the brake maintenance behavior tree model.

[0155] The lightweight processing module M4 is used to perform lightweight processing on the 3D digital simulation model of the elevator drum brake to obtain a lightweight processed 3D digital simulation model of the elevator drum brake.

[0156] The brake maintenance operation guidance process segment creation module M5 is used to create a brake maintenance operation guidance process segment through process virtual simulation according to the lightweight processed 3D digital simulation model of the elevator drum brake; the brake maintenance operation guidance process segment includes: disassembly steps of the elevator drum brake, component status inspection, simulation guidance content of fault location methods and maintenance steps, as well as specific operation processes of reassembly and functional testing.

[0157] The fusion module M6 is used to accurately fuse the maintenance operation model animation with the elevator drum brake entity by using a three-dimensional registration method combining artificial marking and natural feature points according to the brake maintenance operation guidance process segment, so as to realize the disassembly and maintenance guidance of the elevator drum brake; the maintenance operation model animation is a dynamic visualization representation of the brake maintenance operation guidance process segment.

[0158] The technical features of the above embodiments can be combined arbitrarily. For the sake of brevity of description, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, it should be considered as the scope recorded in this specification.

[0159] In this article, specific examples are used to elaborate on the principles and implementation methods of this application. The descriptions of the above embodiments are only used to help understand the method and its core idea of this application; at the same time, for those of ordinary skill in the art, according to the idea of this application, there will be changes in the specific implementation methods and application scopes. In summary, the content of this specification should not be construed as a limitation to this application.

Claims

1. A method for disassembly and maintenance guidance of elevator drum brake based on mixed reality, characterized in that: The elevator drum brake disassembly and maintenance guidance method based on mixed reality includes: The failure modes and causes of elevator drum brakes are analyzed, and a brake fault tree model is established; the failure modes include: brake failure and brake release failure; the failure causes are based on the six functional structures of brake arm, brake lining, electromagnet, push rod, compression spring and brake release push rod; According to the brake fault tree model and the key failure factors of the elevator drum brake, the maintenance behavior is analyzed to establish a brake maintenance behavior tree model; the key failure factors are factors obtained by calculating the risk priority number of the failure mode based on the influence degree, occurrence probability and detectability of each failure mode in the fault tree, combined with the FMEA analysis results; the brake maintenance behavior tree model is used for the process of elevator drum brake maintenance guidance; According to the brake maintenance behavior tree model, a 3D digital simulation model of an elevator drum brake is established; Performing lightweight processing on the 3D digital simulation model of the elevator drum brake to obtain the lightweight 3D digital simulation model of the elevator drum brake; According to the 3D digital simulation model of the elevator drum brake after the lightweight treatment, a brake maintenance operation guidance process fragment is created through process virtual simulation; the brake maintenance operation guidance process fragment includes: the disassembly steps of the elevator drum brake, the component status inspection, the fault location method and the simulation guidance content of the maintenance steps, and the specific operation process of reassembly and function testing; According to the brake maintenance operation guidance process fragment, a three-dimensional registration method combining artificial markings and natural feature points is adopted to accurately merge the maintenance operation model animation with the elevator drum brake entity, thereby realizing the elevator drum brake disassembly and maintenance guidance; the maintenance operation model animation is a dynamic visualization of the brake maintenance operation guidance process fragment.

2. The elevator drum brake disassembly and maintenance guidance method based on mixed reality according to claim 1 is characterized in that: The failure modes and causes of elevator drum brakes are analyzed, and a brake fault tree model is established, including: The FMEA method based on functional analysis is used to analyze the failure modes and effects of elevator drum brakes, and the failure modes of elevator drum brakes are obtained; Based on the failure mode, the corresponding fault is decomposed according to each functional structure to determine the location and cause of the corresponding fault; A brake fault tree model is established based on the location and cause of the corresponding fault.

3. The elevator drum brake disassembly and maintenance guidance method based on mixed reality according to claim 1, characterized in that: According to the brake fault tree model and the key failure factors of the elevator drum brake, the maintenance behavior is analyzed and a brake maintenance behavior tree model is established, which specifically includes: According to the brake fault tree model and the key failure factors of the elevator drum brake, the virtual maintenance behavior and process of the elevator drum brake are analyzed to obtain the analysis results; According to the analysis results and the behaviors of the maintenance personnel in the virtual environment, the operation process of the elevator drum brake is processed, and a brake maintenance behavior tree model is constructed with branches expanded from the root node and unlimited extension of child nodes; the operation process includes: disassembly, maintenance and assembly.

4. The elevator drum brake disassembly and maintenance guidance method based on mixed reality according to claim 1, characterized in that: The maintenance behavior process elements of the brake maintenance behavior tree model include: interface UI, scene, maintenance object model, action, animation, event and commentary; the interface UI includes: subject selection, task start and end; the scene includes: elevator machine room, maintenance station and maintenance workshop; the maintenance object model is the various models involved in the brake maintenance behavior process; the action is the basic structure of the maintenance behavior; the animation is the performance of triggering execution in the maintenance behavior; the event is an operation that can be recognized by the system; the commentary is the voice operation prompt of the maintenance behavior.

5. The elevator drum brake disassembly and maintenance guidance method based on mixed reality according to claim 1, characterized in that: The brake maintenance behavior tree model includes five task nodes, namely: disassembly of brake arm, disassembly of micro switch, disassembly of moving iron core, maintenance of elevator drum brake iron core and verification of release push rod, and assembly of elevator drum brake and verification of braking force; Among them, the task nodes of disassembling the brake arm specifically include: (1) Start the task of disassembling parts; determine whether the user is holding the required tool. If not, play the prompt voice to pick up the tool; otherwise, do not play; (2) Measure and record the compression amount of the compression spring; determine whether the user is holding the required tool. If not, play a prompt voice to pick up the tool; otherwise, do not play; (3) Use an open-end wrench to loosen nuts and unscrew double-ended screws. If the user does not have the required tool in the current task, a voice prompt and operation animation for picking up the tool will be played. (4) Lower the brake arm together with the double-ended screw; play the voice prompt and operation animation of lowering the component; The task nodes for disassembling the micro switch include: (1) Use a screwdriver to loosen the screws of the micro switch bracket; if the user does not hold the required tool in the current task, play the voice prompt and operation animation of picking up the tool; (2) Remove the micro switch bracket; play the voice prompt and operation animation of removing the parts; The task nodes for disassembling the moving iron core specifically include: (1) Use an Allen wrench to loosen the four screws that secure the end cover. If the user does not hold the required tool in the current task, play the voice prompt and operation animation for picking up the tool. (2) Swing the brake release lever and eject the core assembly; play voice prompts and operation animations of the swinging parts; (3) Remove the moving iron core assembly and separate the moving iron core and the end cover; play the voice prompt and operation animation for removing the parts; The elevator drum brake core maintenance and brake release rod verification task nodes specifically include: (1) Observe the internal situation of the moving iron core shell; play voice prompts; (2) Clean and lubricate the brake core surface and guide sleeve; play voice prompts; (3) Verify whether the disassembled brake release rod is made of magnetic conductive material; play a voice prompt; The specific task nodes of assembling elevator drum brakes and verifying braking force include: (1) Assemble the device and restore the spring compression to the initial distance; play the voice prompt of the assembly device to determine whether the user is holding the required measuring tool. If not, play the voice prompt of picking up the tool to measure the spring compression; (2) measuring the distance between the brake lining and the brake wheel; determining whether the user is holding the required tool, and if not, playing a voice prompt and operation animation for picking up the tool; (3) Measure braking performance and verify whether the braking force meets the requirements; play voice prompts; (4) Complete the brake disassembly and maintenance task; play a voice prompt.

6. The elevator drum brake disassembly and maintenance guidance method based on mixed reality according to claim 1, characterized in that: The 3D digital simulation model of the elevator drum brake is lightweighted to obtain the 3D digital simulation model of the elevator drum brake after lightweighting, which specifically includes: The 3D digital simulation model of the elevator drum brake is lightweighted by model face reduction, texture merging, physics-based model simplification or manifold learning-based model simplification to obtain the lightweight 3D digital simulation model of the elevator drum brake; the physics-based model simplification simplifies the physical entity hierarchy of the 3D digital simulation model of the elevator drum brake by reducing the invisible part of the elevator drum brake or merging adjacent objects; the manifold learning-based model converts the 3D digital simulation model of the elevator drum brake into a low-dimensional manifold representation through a manifold learning algorithm, thereby reducing the complexity of the model.

7. The elevator drum brake disassembly and maintenance guidance method based on mixed reality according to claim 1, characterized in that: According to the 3D digital simulation model of the elevator drum brake after lightweight processing, a brake maintenance operation guidance process segment is created through process virtual simulation, which specifically includes: According to the elevator drum brake disassembly process video, mark the key disassembly components and split the disassembly process video into independent clips to ensure the visualization and clarity of the key steps of the disassembly process; In combination with the special needs of the elevator drum brake maintenance process, animations were produced, using a lightweight 3D digital simulation model of the elevator drum brake and physical simulation software to accurately restore the details of tool use and disassembly operations, and a physical simulation engine was introduced to simulate the interaction between tools and components during the maintenance process; Based on the corresponding mixed reality application requirements, the interaction method between users and virtual tools is designed, and a real-time maintenance progress prompt function is developed to complete the creation of brake maintenance operation guidance process fragments.

8. The elevator drum brake disassembly and maintenance guidance method based on mixed reality according to claim 1, characterized in that: According to the brake maintenance operation guidance process fragment, a 3D registration method combining artificial marking and natural feature points is used to accurately integrate the maintenance operation model animation with the elevator drum brake entity, and realize the elevator drum brake disassembly and maintenance guidance, which specifically includes: A three-dimensional registration method combining artificial identification and natural feature points is used to obtain the beacon position through real-time scanning of beacons to achieve target recognition and tracking effects; The real environment is measured by a depth camera to obtain the spatial position information of the tracked object; Based on the tracked object, corresponding virtual information is superimposed on the tracked object to achieve virtual-real fusion; the virtual information includes: a 3D digital simulation model, graphics and animation of the elevator drum brake after lightweight processing; According to the real-time changes in the position of the tracked object, the virtual image is updated to be consistent with the real environment, and the maintenance operation model animation is accurately integrated with the elevator drum brake entity to realize the elevator drum brake disassembly and maintenance guidance.

9. The elevator drum brake disassembly and maintenance guidance method based on mixed reality according to claim 1, characterized in that: The mixed reality-based elevator drum brake disassembly and maintenance guidance method also includes: adding more teaching elements to the mixed reality simulation process with the help of intelligent assistance functions; the intelligent assistance functions include: voice prompts, animation demonstrations and operation guidance.

10. A mixed reality-based elevator drum brake disassembly and maintenance guidance device, the mixed reality-based elevator drum brake disassembly and maintenance guidance device is used to implement the mixed reality-based elevator drum brake disassembly and maintenance guidance method according to any one of claims 1 to 9, characterized in that: The elevator drum brake disassembly and maintenance guidance device based on mixed reality includes: The brake fault tree model building module is used to analyze the failure mode and fault cause of the elevator drum brake and build a brake fault tree model; the failure mode includes: brake failure and brake release failure; the fault cause is based on the six functional structures of the brake arm, brake lining, electromagnet, push rod, compression spring and brake release push rod; A brake maintenance behavior tree model establishment module is used to analyze maintenance behavior according to the brake fault tree model and the key failure factors of the elevator drum brake, and establish a brake maintenance behavior tree model; the key failure factors are factors obtained by calculating the risk priority number of the failure mode based on the impact degree, occurrence probability and detectability of each failure mode in the fault tree, combined with the FMEA analysis results; the brake maintenance behavior tree model is used for the process of elevator drum brake maintenance guidance; An elevator drum brake 3D digital simulation model building module is used to build an elevator drum brake 3D digital simulation model according to the brake maintenance behavior tree model; A lightweight processing module is used to perform lightweight processing on the 3D digital simulation model of the elevator drum brake to obtain the 3D digital simulation model of the elevator drum brake after lightweight processing; A brake maintenance operation guidance process fragment creation module is used to create a brake maintenance operation guidance process fragment through process virtual simulation based on the 3D digital simulation model of the elevator drum brake after lightweight processing; the brake maintenance operation guidance process fragment includes: the disassembly steps of the elevator drum brake, the component status inspection, the fault location method and the simulation guidance content of the maintenance steps, and the specific operation process of reassembly and function testing; A fusion module is used to accurately fuse the maintenance operation model animation with the elevator drum brake entity based on the brake maintenance operation guidance process fragment, using a three-dimensional registration method that combines artificial markings and natural feature points, so as to realize the elevator drum brake disassembly and maintenance guidance; the maintenance operation model animation is a dynamic visualization of the brake maintenance operation guidance process fragment.

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