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

Abstract

This application discloses a mixed reality-based elevator drum brake disassembly and maintenance guidance method and device, relating to the field of elevator inspection and testing technology. The method comprises: analyzing the failure modes and causes of the elevator drum brake to establish a brake fault tree model; analyzing maintenance behaviors based on the brake fault tree model and the key failure factors of the elevator drum brake to establish a brake maintenance behavior tree model; building a 3D digital simulation model of the elevator drum brake based on the brake maintenance behavior tree model and performing lightweight processing; and creating a brake maintenance operation guidance process segment through virtual process simulation based on the lightweighted model; and accurately integrating the maintenance operation model animation with the elevator drum brake entity using a three-dimensional registration method combining manual identification and natural feature points to implement elevator drum brake disassembly and maintenance guidance. This application can help operators accurately understand the elevator drum brake maintenance process.

Description

Technical Field

[0001] The present application relates to the field of elevator inspection and testing technology, and in particular to a mixed reality-based elevator drum brake disassembly and maintenance guidance method and device. Background Art

[0002] Currently, the traditional elevator inspection training model combines theoretical knowledge training with practical operation training. This model has disadvantages: theoretical learning through books is relatively rigid, and many complex elevator industry regulations are difficult to understand. Elevator brakes have numerous parts and a complex maintenance process, resulting in poor learning outcomes and a long and time-consuming training process. Furthermore, during practical operation training, trainees are inexperienced and present certain risks. For novices, operating actual elevator brakes and other moving parts poses certain safety risks.

[0003] In recent years, international elevator companies have begun using MR technology for mixed-reality navigation applications in real-world work environments and on-the-job professional training. In 2016, Germany's ThyssenKrupp Elevator Company implemented Microsoft HoloLens mixed-reality glasses to enhance elevator maintenance. Maintenance technicians use HoloLens to simulate a 3D image of the elevator they are about to visit, allowing them to identify and visualize any problems before arriving on-site. Upon arrival, they can call an expert center, which uses the images in the glasses to illustrate the problem and provide assistance. This significantly reduces maintenance time and helps over 24,000 ThyssenKrupp technicians perform maintenance work more safely and efficiently. Otis Elevator Company in the United States is also exploring mixed-reality technology solutions that enable remote technicians to virtually collaborate with a second technician in the elevator to solve problems virtually. This will allow technicians in different locations to simultaneously view a blend of virtual and real images, expanding the range of technologies available to restore elevators to service. ThyssenKrupp Elevator Asia Pacific Training Academy integrates virtual reality technology (VR) into safety training. Through VR training, technical service personnel can handle maintenance issues that may be encountered in reality in the virtual reality world, such as pit component replacement, elevator emergency rescue, live working, and installing mobile platforms on the car roof. If the operation is improper, it can also simulate death experiences such as "electric shock" and "falling from a height", and can be practiced repeatedly without any personal danger.

[0004] However, existing technologies provide general guidance focused on overall elevator maintenance and are unable to address the specific disassembly and maintenance scenarios of elevator drum brakes. Therefore, designing a mixed reality-based guidance method and device for disassembly and maintenance of elevator drum brakes has become a pressing technical challenge in this field. Summary of the Invention

[0005] The purpose of this application is to provide a mixed reality-based elevator drum brake disassembly and maintenance guidance method and device, which can present a high-quality mixed reality maintenance operation guidance experience on the equipment, help operators accurately understand the elevator drum brake maintenance process, and greatly improve the accuracy and efficiency of maintenance operations. At the same time, it can be used for personnel operation training, which helps to speed up training and improve operation skills.

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

[0007] In a first aspect, the present application provides a mixed reality-based elevator drum brake disassembly and maintenance guidance method, the mixed reality-based elevator drum brake disassembly and maintenance guidance method comprising:

[0008] 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 the brake arm, brake lining, electromagnet, push rod, compression spring, and brake release push rod.

[0009] Maintenance behavior is analyzed based on the brake fault tree model and the key failure factors of the elevator drum brake, and a brake maintenance behavior tree model is established; the key failure factors are factors obtained by calculating the risk priority number of the failure mode based on the impact, probability of occurrence and detectability of each failure mode in the fault tree, combined with the FMEA analysis results; the brake maintenance behavior tree model is used in the process of elevator drum brake maintenance guidance.

[0010] Based on the brake maintenance behavior tree model, a 3D digital simulation model of an elevator drum brake is established.

[0011] The 3D digital simulation model of the elevator drum brake is lightweighted to obtain the lightweighted 3D digital simulation model of the elevator drum brake.

[0012] Based on the 3D digital simulation model of the lightweight elevator drum brake, a brake maintenance operation instruction process fragment is created through process virtual simulation; the brake maintenance operation instruction process fragment includes: the elevator drum brake disassembly steps, component status inspection, fault location method and maintenance steps simulation guidance content, as well as the specific operation process of reassembly and functional testing.

[0013] Based on the brake maintenance operation guidance process fragment, a three-dimensional registration method combining manual identification 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.

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

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

[0016] A brake maintenance behavior tree model establishment module is used to analyze maintenance behavior 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 factors obtained by calculating the risk priority number of the failure mode based on the impact, probability of occurrence and detectability of each failure mode in the fault tree, combined with the FMEA analysis results; the brake maintenance behavior tree model is used in the process of elevator drum brake maintenance guidance.

[0017] The elevator drum brake 3D digital simulation model establishment module is used to establish the elevator drum brake 3D digital simulation model according to the brake maintenance behavior tree model.

[0018] The 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.

[0019] A brake maintenance operation instruction process fragment creation module is used to create a brake maintenance operation instruction 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 instruction 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, as well as the specific operation process of reassembly and functional testing.

[0020] 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 manual identification 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.

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

[0022] The present application provides a method and device for disassembly and maintenance guidance of an elevator drum brake based on mixed reality. The method comprises: analyzing the failure modes and causes of the elevator drum brake to establish a brake fault tree model; analyzing maintenance behaviors based on the brake fault tree model and the key failure factors of the elevator drum brake to establish a brake maintenance behavior tree model; establishing a 3D digital simulation model of the elevator drum brake based on the brake maintenance behavior tree model; lightweighting the 3D digital simulation model of the elevator drum brake and creating a brake maintenance operation guidance process segment through process virtual simulation; and accurately integrating the maintenance operation model animation with the elevator drum brake entity using a three-dimensional registration method combining manual identification and natural feature points based on the brake maintenance operation guidance process segment to implement elevator drum brake disassembly and maintenance guidance. The present application can present a high-quality mixed reality maintenance operation guidance experience on the device, helping operators to accurately understand the brake maintenance process, significantly improving the accuracy and efficiency of maintenance operations, and can also be used for personnel training, helping to accelerate training and improve operational skills. It solves the problems of non-intuitive acquisition of elevator drum brake inspection and maintenance guidance knowledge, complex industry standard knowledge and insufficient knowledge reserves of operators. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0024] Figure 1 A flowchart of a mixed reality-based elevator drum brake disassembly and maintenance guidance method provided in one embodiment of the present application.

[0025] Figure 2 This is a diagram showing the main components of an elevator drum brake provided in one embodiment of the present application.

[0026] Figure 3 A schematic diagram of a brake fault tree model provided in one embodiment of the present application.

[0027] Figure 4 A schematic diagram of the elevator drum brake maintenance behavior structure provided in one embodiment of the present application.

[0028] Figure 5 A schematic diagram of a brake maintenance behavior tree model provided in one embodiment of the present application.

[0029] Figure 6 A schematic diagram of the lightweight processing results of the 3D digital simulation model of the elevator traction machine and cabinet brake provided in one embodiment of the present application.

[0030] Figure 7 This is a screenshot of a process flow diagram of an elevator drum brake maintenance operation guide provided in one embodiment of the present application.

[0031] Figure 8 Another screenshot of the elevator drum brake maintenance operation instruction process fragment provided in one embodiment of the present application.

[0032] Figure 9 A screenshot of the mixed reality maintenance operation guide for elevator drum brakes provided in one embodiment of this application

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

[0034] Figure 11 A schematic diagram of the functional modules of a mixed reality-based elevator drum brake disassembly and maintenance guidance device provided in one embodiment of the present application. DETAILED DESCRIPTION

[0035] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0036] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the present application is further described in detail below with reference to the accompanying drawings and specific implementation methods.

[0037] In an exemplary embodiment, Figure 1 As shown, a mixed reality-based elevator drum brake disassembly and maintenance guidance method is provided, and the mixed reality-based elevator drum brake disassembly and maintenance guidance method includes:

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

[0039] S2: Analyze maintenance behaviors based on the brake fault tree model and 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 (RPN) of the failure mode based on the impact, probability of occurrence and detectability of each failure mode in the fault tree, combined with the results of FMEA (Failure Mode and Effects Analysis); the brake maintenance behavior tree model is used in the process of elevator drum brake maintenance guidance.

[0040] S3: Establishing a 3D digital simulation model of an elevator drum brake based on the brake maintenance behavior tree model.

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

[0042] S5: Based on the 3D digital simulation model of the elevator drum brake after lightweight processing, a brake maintenance operation instruction process segment is created through process virtual simulation; the brake maintenance operation instruction process segment includes: the elevator drum brake disassembly steps, component status inspection, fault location method and maintenance steps simulation guidance content, as well as the specific operation process of reassembly and functional testing.

[0043] S6: Based on the brake maintenance operation guidance process fragment, a three-dimensional registration method combining manual identification and natural feature points is adopted to accurately merge the maintenance operation model animation with the elevator drum brake entity, 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; that is, the maintenance process steps (such as disassembly, inspection, repair and reassembly, etc.) are intuitively presented through 3D animation, so that the operator can obtain clearer operation guidance in the mixed reality environment.

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

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

[0046] S11: The FMEA method based on functional analysis is used to analyze the failure modes and effects of the elevator drum brake and obtain the failure mode of the elevator drum brake.

[0047] S12: 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.

[0048] S13: Establishing a brake fault tree model based on the location and cause of the corresponding fault.

[0049] like Figure 2 As shown in the figure, the elevator drum brake can be divided into six parts according to its function, namely the brake arm, brake lining, electromagnet, push rod, compression spring and release push rod; among them, the brake arm is composed 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 is composed of an end cover, a moving iron core and a coil; the push rod is composed of a body, a connecting thread and a limit spring; the compression spring is a standard cylindrical coil spring; the release push rod is composed of a push rod body and a return spring.

[0050] The FMEA method based on functional analysis is used to analyze the failure modes and effects of elevator drum brakes. Two common failure modes of drum brake failure, brake failure and release failure, are obtained. The failure is decomposed according to each functional structure, and the location and cause of the failure are further analyzed. A brake fault tree model is established, such as Figure 3 shown.

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

[0052] Brake failure:

[0053] ① Electromagnet: The coil is short-circuited or open-circuited, and the moving iron core is stuck.

[0054] ②Brake arm: The connecting hinge is worn and loose, and the support arm is deformed or broken.

[0055] ③Compression spring: The spring fails due to fatigue or breaks, resulting in insufficient brake force.

[0056] ④ Release the push rod: the push rod is stuck and cannot be reset.

[0057] Brake release failure:

[0058] ① Electromagnet: Overheating of the coil causes insulation failure and displacement of the moving iron core.

[0059] ② Push rod: The limit spring is loose or the push rod is deformed.

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

[0061] Specifically, the causes of brake failure include: the brake not locking and insufficient braking torque.

[0062] The reasons why the brake does not engage include: welding and adhesion of the relay contact points and brake jamming; the reasons for contact point adhesion include: improper design and aging of the contact structure. The reason for aging of the contact structure is excessive dust or high humidity in the environment; the reasons for brake jamming include: excessive electromagnetic force and armature jamming. The excessive electromagnetic force is due to the excessive residual magnetism of the electromagnetic coil, which makes the electromagnetic force unable to disappear in time. The reasons for armature jamming include: excessive deviation of the guide bolt installation angle, impurities in the guide hole, or residual magnetism in the armature.

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

[0064] Causes of brake release failure include: guide member obstruction, brake phase loss, and brake-operated operation. Brake phase loss refers to the electromagnet not receiving a complete three-phase power supply, resulting in insufficient electromagnetic force to overcome the braking force. Brake-operated operation is caused by a small working gap, resulting in insufficient armature travel, or excessive brake spring force. Furthermore, electromagnet magnetization loss or a coil short circuit can cause the electromagnetic force to be insufficient to overcome the braking force, leading to brake-operated operation failure.

[0065] (2) Establishment of brake fault tree model: Based on the above six-part structure and its decomposed fault modes and causes, a brake fault tree model is established. The following is a schematic diagram of the fault tree structure:

[0066] Top event: brake failure or brake release 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 retaining spring loose, etc.), brake lining failure (friction material wear, etc.), compression spring failure (spring fatigue, breakage, etc.), brake release push rod failure (pull rod stuck, etc.).

[0068] Basic events: such as short circuit of electromagnet coil, jamming of moving iron core, breakage of compression spring, etc.

[0069] In an exemplary embodiment, step S2 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 analysis results.

[0071] S22: Processing the operation process of the elevator drum brake based on the analysis results and the behavior of the maintenance personnel in the virtual environment, and constructing a brake maintenance behavior tree model with branches expanding from the root node and unlimited extension of child nodes; the operation process includes: disassembly, maintenance and assembly.

[0072] Specifically, the virtual inspection behavior and process of elevator drum brakes are analyzed according to the key failure factors of elevator drum brakes. The brake disassembly and maintenance process is processed according to the behavior of inspection and maintenance personnel in the virtual environment. A behavior tree model is constructed with branches expanding from the root node and child nodes expanding unlimitedly. The behavior tree is traversed from top to bottom according to the conditions according to the maintenance behaviors at different stages to find the unique leaf node (behavior node), and the maintenance action of the leaf node is executed. The behavioral logic within the maintenance process is described by 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, and checking the wear of the brake lining and brake wheel, thereby realizing 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 analyzes possible failure modes in the system and their impact on system performance to identify the failure modes that are most critical to system functions.

[0075] 2. Specific analysis process:

[0076] Step 1: Functional decomposition.

[0077] The elevator drum brake is decomposed into multiple sub-components according to its function and structure, including six parts: brake arm, brake lining, electromagnet, push rod, compression spring, release push rod, etc., and its sub-structures (such as the electromagnet including end cover, moving iron core, coil, etc.) are further disassembled.

[0078] Step ②: List the failure modes.

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

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

[0081] Brake lining: wear of friction material, breakage of support base, etc.

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

[0083] Compression spring: spring fatigue failure, breakage, etc.

[0084] Release the push rod: the push rod is stuck and cannot be reset, etc.

[0085] Step 3: Evaluate the impact of failure.

[0086] For each failure mode, an assessment is conducted along the following three dimensions:

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

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

[0089] Failure detectability (Detection, D): The ease with which a failure can be detected.

[0090] Each dimension is scored on a 5-point or 10-point scale, with higher scores indicating a more significant impact of the dimension.

[0091] Step ④: Calculate the criticality (RPN value).

[0092] Assess the importance of failure modes using the Risk Priority Number (RPN):

[0093] RPN=S×O×D

[0094] Sort the RPN values ​​of all failure modes, and the failure mode with the highest RPN value is the key 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 key failure factors of drum brakes were determined to be:

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

[0098] Brake release failure: caused by lack of magnetism in the electromagnet, short circuit of the coil, too small working gap, jamming of the push rod, etc.

[0099] Furthermore, combined with the brake maintenance behavior tree model in a virtual environment, the key failure factors are used as the root nodes of the behavior tree, the maintenance actions are decomposed and the maintenance process is designed, thereby achieving targeted maintenance guidance.

[0100] In an exemplary embodiment, the maintenance behavior process is analyzed as follows: 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 room, maintenance platform 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; and the commentary is the voice operation prompt of the maintenance behavior.

[0101] In an exemplary embodiment, a brake maintenance behavior tree model is constructed by combining the brake maintenance behavior structure and behavior tree theory, with branches expanding from a root node and child nodes expanding without limit, such as Figure 5 As shown; Among them, the brake maintenance behavior structure is based on the behavioral analysis of the inspection and maintenance personnel in the virtual environment on the processes of brake disassembly, maintenance and assembly, and these behaviors are logically divided, structured and optimized to accurately handle complex work processes such as brake disassembly and maintenance. The basic element of the brake maintenance behavior tree model is the task, including five task nodes: disassembling the brake arm, disassembling the micro switch, disassembling the moving iron core, elevator drum brake iron core maintenance and release rod verification, and assembly of elevator drum brake and braking force verification. Each task includes training start, voice prompts, tool selection, grabbing tools, animation playback, maintenance action start, putting down tools, grabbing parts, parts placement, maintenance action end, training end and other action tasks. The specific contents of the five task nodes are as follows:

[0102] Task 1: Remove the brake arm.

[0103] (1) Start the task of disassembling parts; determine whether the user is holding the required tools. If not, play the prompt voice to pick up the tools; otherwise, do not play.

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

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

[0106] (4) Lower the brake arm together with the double-headed screw; play the voice prompt and operation animation of lowering the component.

[0107] Task 2: Disassemble the micro switch.

[0108] (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.

[0109] (2) Remove the micro switch bracket; play the voice prompt and operation animation of removing the parts.

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

[0111] (1) Use an Allen wrench to loosen the four screws that secure the end cover. If the user does not have 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 core assembly; play the voice prompts and operation animations of the swinging parts.

[0113] (3) Remove the moving iron core assembly and separate the moving iron core and the end cover; play the voice prompts and operation animations for removing parts.

[0114] Task 4: Elevator drum brake core maintenance and brake release rod verification.

[0115] (1) Observe the internal situation of the moving iron core shell; play the voice prompt.

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

[0117] (3) Verify whether the disassembled release rod is made of magnetic material; play a voice prompt.

[0118] Task 5: Assemble elevator drum brake and verify braking force.

[0119] (1) Assemble the equipment and restore the spring compression to the initial distance; play the voice prompt of the assembly equipment 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.

[0120] (2) Measure the distance between the brake lining and the brake wheel; determine whether the user is holding the required tool. If not, play a voice prompt and operation animation to pick up the tool.

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

[0122] (4) Complete the brake disassembly and maintenance task; play a voice prompt.

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

[0124] The 3D digital simulation model of the elevator drum brake is lightweighted by using model face reduction, texture merging, physics-based model simplification or manifold learning-based model simplification to obtain the lightweighted 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 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 an elevator drum brake is established, and the model file is lightweighted. The number of polygons, texture quality, and material complexity of the model are optimized 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 the device, such as Figure 6 shown.

[0126] Model lightweighting can be achieved through model face reduction, texture merging, physics-based model simplification, manifold learning-based model simplification, etc. The physics-based model simplification method simplifies the physical entity hierarchy of the 3D digital simulation model of the elevator drum brake by reducing invisible parts, merging adjacent objects, etc. The model simplification method based on manifold learning converts the 3D model into a lower-dimensional manifold representation through a manifold learning algorithm, thereby reducing the complexity of the model. The physics-based model simplification method of the present 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 invisible parts of the brake, merging adjacent components, etc. The model simplification method based on manifold learning combines the geometric characteristics of the specific structure of the brake, and optimizes the model complexity through the corresponding dimensionality reduction algorithm, effectively reducing the model file size without sacrificing the details of the key maintenance components, 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 elevator drum brakes, extracting the tools required in the disassembly and maintenance process, such as wrenches, screwdrivers, measuring tools, etc. By extracting and displaying these tools, the elevator drum brake disassembly and maintenance operation process is transformed into an interactive model in a virtual reality environment. Through these models, trainers can simulate steps such as releasing the brake spring, removing the brake arm, and checking the wear of the brake lining and brake wheel in a virtual environment. Combining virtual reality technology and a physical simulation engine, the sorted operation process is transformed into a mixed reality simulation process. The screenshot of the elevator drum brake maintenance operation guidance process is shown below. Figure 7 and Figure 8 shown.

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

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

[0130] S52: Based on the special requirements of the elevator drum brake maintenance process, an animation was created. A lightweight 3D digital simulation model of the elevator drum brake and physical simulation software were used to accurately reproduce the details of tool use and disassembly operations. A physical simulation engine was also introduced to simulate the interaction between tools and components during the maintenance process.

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

[0132] Specifically, these lightweight model files are used to create a mixed reality guidance process for brakes. The tools required for disassembly and maintenance (such as wrenches, screwdrivers, and steel rulers) are extracted and converted into an interactive model in a virtual reality environment, combining the specific operational steps and simulation requirements for brake disassembly and maintenance. Within the mixed reality simulation process, the present invention achieves personalized optimization for elevator drum brakes through the following steps:

[0133] (1) Based on 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 visualization and clarity of the key steps of the disassembly process.

[0134] (2) In combination with the special requirements of the brake maintenance process, animation is produced, and the lightweight 3D digital simulation model of the elevator drum brake and physical simulation software (such as 3DMax and Maya) are used to accurately restore the details of tool use and disassembly operations, and a physical simulation engine is introduced to simulate the interaction between tools and components during the maintenance process.

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

[0136] (4) Optimize the deployment of 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, step S6 specifically includes:

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

[0139] S62: Measure the real environment through the 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 3D digital simulation model, graphics, and animation of the lightweight elevator drum brake.

[0141] S64: According to the real-time change of 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.

[0142] Specifically, trainees can use head-mounted displays and handheld devices, a three-dimensional registration method that combines artificial markers and natural feature points, and obtain beacon positions through real-time scanning of beacons to achieve target recognition and tracking effects. They can also use depth cameras to measure the real environment and obtain the spatial position information of objects. Based on the tracked object, corresponding virtual information is superimposed on it, such as a lightweight 3D digital simulation model, graphics, and animations of an elevator drum brake, 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, graphics are used to mark the positions of key components or operating instructions, and animations are used to dynamically demonstrate maintenance operation steps and process fragments to achieve virtual-real fusion. According to the real-time changes in the object position, the virtual screen is updated to be consistent with the real environment, so as to achieve accurate fusion of the maintenance operation model animation and the brake entity, and present a high-quality mixed reality maintenance operation instruction experience on the equipment. The screenshot of the mixed reality maintenance operation instruction of the elevator drum brake is shown below. Figure 9 and Figure 10 shown.

[0143] In an exemplary embodiment, the mixed reality-based elevator drum brake disassembly and maintenance guidance method further 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.

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

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

[0146] (1) This application proposes a mixed reality-based precise operation guidance method for the disassembly and maintenance of elevator drum brakes. Compared to the existing general guidance oriented towards overall elevator maintenance, this application focuses more on the specific structure and maintenance complexity of the brake, a key component, and can provide technicians with more precise and targeted guidance.

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

[0148] (3) Compared with simply providing 3D models or remote collaboration functions, this application also combines a depth camera and a physical simulation engine to measure the spatial position of objects in real time to update virtual information, and achieves accurate integration of maintenance operation animations with actual equipment entities, allowing trainees to simultaneously observe virtual and real operation details in a mixed reality environment, significantly improving operation accuracy and efficiency.

[0149] (4) This application also incorporates a specific workflow for brake disassembly, using a step-by-step animation demonstration to specifically demonstrate the entire process of disassembly, inspection, and assembly, thereby overcoming the problem of insufficient maintenance guidance for specific key components in the prior art.

[0150] Based on the same inventive concept, embodiments of the present application also provide a guidance device for implementing the aforementioned mixed reality-based elevator drum brake disassembly and maintenance guidance method. The solution provided by this device is similar to the solution described in the aforementioned method. Therefore, the specific limitations of one or more embodiments of the mixed reality-based elevator drum brake disassembly and maintenance guidance device provided below can be found in the limitations of the mixed reality-based elevator drum brake disassembly and maintenance guidance method described above and will not be further elaborated here.

[0151] In an exemplary embodiment, Figure 11 As shown, a mixed reality-based elevator drum brake disassembly and maintenance guidance device is provided, and the mixed reality-based elevator drum brake disassembly and maintenance guidance device includes:

[0152] The brake fault tree model establishment module M1 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 based on the six functional structures of the brake arm, brake lining, electromagnet, push rod, compression spring and brake release push rod.

[0153] The brake maintenance behavior tree model establishment module M2 is used to analyze maintenance behavior 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 factors obtained by calculating the risk priority number of the failure mode based on the impact, probability of occurrence and detectability of each failure mode in the fault tree, combined with the FMEA analysis results; the brake maintenance behavior tree model is used in the process of elevator drum brake maintenance guidance.

[0154] The elevator drum brake 3D digital simulation model establishment module M3 is used to establish the elevator drum brake 3D digital simulation model 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 the 3D digital simulation model of the elevator drum brake after lightweight processing.

[0156] The brake maintenance operation instruction process fragment creation module M5 is used to create a brake maintenance operation instruction 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 instruction 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, as well as the specific operation process 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 based on the brake maintenance operation guidance process fragment, using a three-dimensional registration method that combines manual identification 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.

[0158] The technical features of the above embodiments can be combined arbitrarily. To make the description concise, 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, they should be considered to be within the scope of this specification.

[0159] This document uses specific examples to illustrate the principles and implementation methods of this application. The description of the above examples is only intended to help understand the method and core concept of this application. At the same time, for those skilled in the art, based on the concept of this application, there may be changes in the specific implementation methods and application scope. In summary, the content of this specification should not be understood as limiting this application.

Claims

1. A mixed reality-based elevator drum brake disassembly and maintenance guidance method, 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 were analyzed, and a brake fault tree model was established. The failure modes included brake failure and brake release failure. The failure causes were derived from the six functional structures of the brake arm, brake lining, electromagnet, push rod, compression spring, and brake release push rod. The maintenance behavior is analyzed based on the brake fault tree model and the key failure factors of the elevator drum brake, and a brake maintenance behavior tree model is established. The key failure factors are factors obtained by calculating the risk priority number of each failure mode in the fault tree based on the impact, probability of occurrence, and detectability of each failure mode, combined with the FMEA analysis results. The brake maintenance behavior tree model is used in the process of guiding elevator drum brake maintenance. Establishing a 3D digital simulation model of an elevator drum brake based on the brake maintenance behavior tree model; Lightweighting the 3D digital simulation model of the elevator drum brake to obtain the lightweighted 3D digital simulation model of the elevator drum brake; Based on the lightweight 3D digital simulation model of the elevator drum brake, a brake maintenance operation instruction process segment is created through process virtual simulation. The brake maintenance operation instruction process segment includes: elevator drum brake disassembly steps, component status inspection, fault location method and maintenance steps, as well as the specific operation process of reassembly and functional testing; Based on the brake maintenance operation guidance process fragment, a three-dimensional registration method combining manual identification 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 were analyzed, and a brake fault tree model was 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 is 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 analysis results; Based on the analysis results and the behavior of 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 expanding from a root node and child nodes expanding unlimitedly; 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 is 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 room, maintenance platform 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: disassembly of the brake arm, disassembly of the micro switch, disassembly of the moving iron core, maintenance of the elevator drum brake iron core and verification of the release push rod, and assembly of the elevator drum brake and verification of the braking force; Among them, the task nodes for disassembling the brake arm specifically include: (1) Start the task of disassembling parts; determine whether the user is holding the required tools. If not, play the prompt voice to pick up the tools; 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 the 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, play a voice prompt and operation animation to pick up the tool; (4) Lower the brake arm together with the double-headed screw; play the voice prompt and operation animation of lowering the component; The task nodes for disassembling the micro switch specifically include: (1) Loosen the screws of the micro switch bracket with a screwdriver; if the user does not have 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 dismantling the moving iron core specifically include: (1) Use an Allen wrench to loosen the four screws securing the end cap. If the user is not holding 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 the 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 release rod is made of magnetic material; play a voice prompt; The specific task nodes for assembling elevator drum brakes and verifying braking force include: (1) Assemble the device and restore the spring compression to the initial distance; play the assembly device voice prompt to determine whether the user is holding the required measuring tool. If not, play the voice prompt to pick up the tool and measure the spring compression; (2) Measure the distance between the brake lining and the brake wheel; determine whether the user is holding the required tool. If not, play a voice prompt and operation animation to pick 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 lightweighted 3D digital simulation model of the elevator drum brake, which specifically includes: The 3D digital simulation model of the elevator drum brake is lightweighted by using model face reduction, texture merging, physics-based model simplification or manifold learning-based model simplification to obtain the lightweighted 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 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.

7. The elevator drum brake disassembly and maintenance guidance method based on mixed reality according to claim 1, characterized in that: Based on the 3D digital simulation model of the lightweight elevator drum brake, a brake maintenance operation instruction process segment is created through process virtual simulation, specifically including: Based on the elevator drum brake disassembly process video, key disassembly components are marked and the disassembly process video is split into independent segments to ensure the visualization and clarity of the key steps of the disassembly process; Based on the special requirements of the elevator drum brake maintenance process, an animation was created. A lightweight 3D digital simulation model of the elevator drum brake and physical simulation software were used to accurately reproduce the details of tool use and disassembly operations. A physical simulation engine was also introduced to simulate the interaction between tools and components during the maintenance process. Based on the corresponding mixed reality application requirements, the user interaction method between the virtual tool is designed, and a real-time maintenance progress prompt function is developed to complete the creation of the brake maintenance operation guidance process fragment.

8. The elevator drum brake disassembly and maintenance guidance method based on mixed reality according to claim 1, characterized in that: Based on the brake maintenance operation guidance process fragment, a 3D registration method combining manual identification and natural feature points is used to accurately integrate the maintenance operation model animation with the elevator drum brake entity, thus realizing the elevator drum brake disassembly and maintenance guidance, which specifically includes: A 3D registration method combining artificial markers and natural feature points is used to obtain beacon positions through real-time scanning of beacons to achieve target recognition and tracking effects. Use the depth camera to measure the real environment and 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 a lightweight elevator drum brake; According to the real-time changes in the position of the tracked object, the virtual screen 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: using intelligent assistance functions to add more teaching elements to the mixed reality simulation process; 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 being 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 modes and causes of elevator drum brakes and establish a brake fault tree model. The failure modes include brake failure and brake release failure. The failure causes are derived from 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 based on the brake fault tree model and key failure factors of elevator drum brakes, and establish a brake maintenance behavior tree model. The key failure factors are factors obtained by calculating the risk priority number of each failure mode in the fault tree based on the impact, probability of occurrence, and detectability of each failure mode, combined with the results of FMEA analysis. The brake maintenance behavior tree model is used to guide the process of elevator drum brake maintenance. An elevator drum brake 3D digital simulation model building module, used to build an elevator drum brake 3D digital simulation model based on 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 instruction process segment creation module is used to create a brake maintenance operation instruction process segment through process virtual simulation based on the 3D digital simulation model of the lightweight elevator drum brake. The brake maintenance operation instruction process segment includes: elevator drum brake disassembly steps, component status inspection, fault location method and maintenance steps simulation guidance content, as well as specific operation procedures for reassembly and functional 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 manual identification 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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