Monorail crane driving and braking tribological characteristic testing system and using method thereof

Abstract

The invention discloses a monorail crane driving and braking tribological characteristic testing system and a using method thereof, and belongs to the technical field of monorail crane driving and braking tribological performance testing. A horizontal direction friction pair driving wheel mechanism, a horizontal direction friction pair test plate mechanism, a vertical direction driving friction pair mechanism and a vertical direction friction pair test plate mechanism are arranged on the bottom plate; the horizontal friction pair driving wheel mechanism is located at the top end of the bottom plate, the horizontal friction pair plate testing mechanism is located beside the horizontal friction pair driving wheel mechanism, and the vertical friction pair driving mechanism is located over the bottom plate. The complex working environment of mine monorail crane equipment can be accurately simulated, including various working conditions such as underground dust, oil film, moisture and water spraying, and a more real and reliable test platform is provided for researching the friction and wear characteristics of core part materials of a driving part and a braking part of a monorail crane in the actual underground environment.

Description

Technical Field

[0001] The present invention belongs to the technical field of monorail crane driving and braking tribological performance testing, and in particular relates to a monorail crane driving and braking tribological performance testing system and a use method thereof. Background Art

[0002] In the mining industry, monorail cranes serve as key equipment for underground auxiliary transportation, primarily used to transport personnel, equipment, and materials. Their operational reliability and safety are directly related to mine production efficiency and the safety of operators. The monorail crane's drive and braking systems are core components that ensure its proper operation. Both rely on the friction generated by the friction pair to achieve their drive and braking functions.

[0003] Monorail cranes face numerous challenges in real-world operation. Underground tunnels are cramped, with limited ventilation, large humidity and temperature fluctuations, and the presence of hazardous substances such as dust and various corrosive media. These factors significantly impact the tribological properties of the drive wheel and brake disc friction pairs, threatening the monorail crane's drive and braking stability. Furthermore, when traveling uphill or downhill at high speed and carrying heavy loads, the friction demand on the drive and brake systems increases significantly. This increases friction wear on the friction pairs, making friction stability difficult to maintain, making drive slippage and brake failure highly susceptible to accidents. Especially during heavy-loaded uphill or downhill travel, accidents such as slippage, loss of control, and crashes are highly likely to occur. In-depth research on the tribological properties of monorail crane drive and brake friction pairs under different operating conditions is crucial to ensuring the safe, reliable operation and stable, accurate control of monorail crane transportation systems. By establishing correlations between the interface characteristics and contact motion parameters of different friction pairs and the tribological characteristic parameters of the drive and brake systems, this research provides important fundamental data and theoretical support for the safe and stable operation, intelligent and precise control, and extended life of key drive and brake components of monorail cranes. This not only helps improve the operating efficiency and reliability of monorail cranes, but also reduces downtime caused by equipment failure and reduces operating costs, which is of great significance to the overall performance improvement of mine transportation systems.

[0004] Therefore, the present invention provides a monorail crane drive and brake tribological properties testing system and its use method. By establishing a correlation between the interface characteristics of different drive and brake friction pairs and the monorail crane system's drive and brake tribological performance, this system provides important basic data and theoretical support for safe and stable operation of the monorail crane, reliability research, and extending the life of key drive and brake components. Summary of the Invention

[0005] The embodiment of the present invention provides a monorail crane driving and braking tribological characteristics testing system and a use method thereof to solve the problems in the prior art.

[0006] An embodiment of the present invention adopts the following technical solution: a monorail crane drive and braking tribological characteristics testing system, comprising a support base and a base plate horizontally arranged on the support base, wherein the base plate is provided with a horizontal friction pair drive wheel mechanism, a horizontal friction pair test plate mechanism, a vertical drive friction pair mechanism and a vertical friction pair test plate mechanism; the horizontal friction pair drive wheel mechanism is located at the top end position of the base plate, the horizontal friction pair test plate mechanism is located beside the horizontal friction pair drive wheel mechanism to test the horizontal friction pair, the vertical drive friction pair mechanism is located directly above the base plate, and the vertical friction pair test plate mechanism is located below the vertical drive friction pair mechanism to test the vertical friction pair.

[0007] Furthermore, the horizontal friction pair drive wheel mechanism includes a drive motor, a reducer, a first coupling, a torque sensor, a reducer bracket, a torque sensor bracket, a drive wheel and a drive wheel shaft. The reducer bracket and the torque sensor bracket are arranged at intervals on the top of the base plate, and the reducer and the torque sensor are respectively installed on the reducer bracket and the torque sensor bracket. The drive motor is located on the base plate, and the torque sensor is connected to the drive motor through the reducer and the first coupling. A support is provided on the side of the torque sensor bracket, and the drive wheel shaft is horizontally connected to the support. A second coupling is provided on the drive wheel shaft, and one end of the drive wheel shaft is connected to the torque sensor through the second coupling. The drive wheel is located at the other end of the drive wheel shaft.

[0008] Furthermore, the horizontal friction pair test plate mechanism includes a horizontal electric push cylinder, an electric push cylinder rear fixing frame, a horizontal pressure sensor, a first bolt, a first nut, a connecting flange and a guide rail top plate. The horizontal electric push cylinder is fixed to the base plate through the electric push cylinder rear fixing frame. A guide flange is provided on the telescopic end of the horizontal electric push cylinder. The horizontal pressure sensor is connected to the horizontal electric push cylinder through the guide flange. The pressure sensor is connected to the guide rail top plate through the first bolt, the first nut and the connecting flange.

[0009] Furthermore, two symmetrically arranged guide shafts are provided on the guide rail top plate, and two linear bearing seat box-type guide rail slides are provided on the bottom plate, and the two guide shafts slide on the two linear bearing seat box-type guide rail slides respectively.

[0010] Furthermore, the side walls of the guide rail top plate are connected to a vertical guide rail and two vertical sliders slidably connected to the vertical guide rail by screws, the two vertical sliders are connected to a mounting platform by screws, the mounting platform is connected to a test plate by screws, a sensor holder is provided on the guide rail top plate, a friction sensor is provided on the sensor holder, a connecting block is provided on the friction sensor, and the connecting block is connected to the mounting platform.

[0011] Furthermore, the vertical drive friction pair mechanism includes a gantry, a vertical electric push cylinder, a vertical pressure sensor, a second bolt, a second nut and a connecting plate. The gantry is vertically arranged on the top of the base plate, and the vertical electric push cylinder is fixed to the lower end of the top of the gantry by screws. The vertical pressure sensor is connected to the telescopic end of the vertical electric push cylinder, and the vertical pressure sensor is connected to the connecting plate by the second bolt and the second nut. Two symmetrically arranged T-shaped seats are provided at the bottom of the connecting plate, and a friction wheel shaft with a rotational connection is provided between the two T-shaped seats, and a friction wheel shaft is provided on the friction wheel shaft.

[0012] Furthermore, both ends of the friction wheel shaft are provided with limiting flanges, and the friction wheel shaft rotates on the limiting flanges. Each limiting flange is provided with a linear slider, and the side wall of the gantry is provided with a linear guide rail for the linear slider to slide.

[0013] Furthermore, the vertical friction pair test plate mechanism includes a horizontally movable linear module, and a test movable plate is provided on the movable end of the horizontally movable linear module.

[0014] Furthermore, it also includes an environmental module, in which a dust concentration regulating device, an oil film simulator and a humidity control system are provided.

[0015] A method for using a monorail crane drive and brake tribological characteristics testing system comprises the following steps:

[0016] S1: According to the test requirements, use the environmental module to simulate the environment required for the test, set the dust concentration, oil film thickness and ambient humidity, and make the friction test area reach the predetermined environmental conditions;

[0017] S2: Select the driving friction pair or brake friction pair to be studied, and adjust and install the test device. Select the friction pair material, prepare a specimen of standard size, and clean and pre-treat the specimen surface to ensure that it is free of oil, dust, and other impurities to ensure the accuracy of the test. Install and fix the material plate to be tested on the mounting platform, adjust the initial contact position and pressure, and ensure that the contact area between the test plate and the friction wheel or friction block is correctly connected.

[0018] S3: Under the set environmental conditions, the motor is turned on to drive the friction wheel or friction block to move; the drive motor speed is set to 1000r / min, and the electric push cylinder drives the test plate to move, causing relative motion between the friction pairs to simulate the friction process in actual working conditions. The friction force sensor and pressure sensor monitor and record key parameters such as friction force and contact pressure in real time. The data acquisition system collects data at a sampling frequency of 100Hz and transmits it to the computer control terminal. Each test lasts 30 minutes. Under the same environmental conditions, the test is repeated 3-5 times to ensure the reliability and repeatability of the data.

[0019] S4: The collected data is transmitted to the computer control terminal, and the computer control system pre-processes the collected data, including filtering, denoising, data smoothing and other operations, according to the friction formula F f =μF N Calculate the key indicators such as friction coefficient and save them according to the set data storage period; at the same time, the test personnel can view the change curve of the test data in real time through the monitoring interface to intuitively understand the dynamic change of friction coefficient (where: F f —Friction force, μ—Friction coefficient, F N — clamping force);

[0020] S5: Based on the calculated friction coefficient data, plot the curves showing how the friction coefficient changes with various environmental factors; plot the relationship between the friction coefficient and environmental factors such as dust concentration, oil thickness, and ambient humidity; these curves can intuitively show the changing trends of the friction coefficient under different environmental conditions. Statistical analysis methods can be used to evaluate the effects of different environmental factors on the friction coefficient and determine which factors have a more significant impact on the friction coefficient.

[0021] S6: Based on the test data, a friction coefficient proxy model is constructed. The test data is substituted into the model, and the model is fitted using the least squares method to obtain the estimated value of the regression coefficient. A quantitative relationship model between the friction coefficient and environmental factors is established and a sensitivity analysis is performed.

[0022] S7: During the test, key parameters such as friction coefficient, friction force, and contact pressure are monitored in real time, and these data are promptly fed back to the control system. The control system adjusts test conditions such as the drive motor speed and electric push cylinder pressure according to the set parameter range to ensure the stability of the test process and the accuracy of the data;

[0023] S8: After the test is completed, the collected data is sorted and analyzed, and the friction coefficient is presented in the form of graphs and charts, such as the curve of the change of friction coefficient over time and environmental factors, and the relationship between wear and test time. Based on the test data, a life prediction model is established, combining the friction coefficient and wear data to predict the service life of the material under different working conditions.

[0024] S9: Analyze the failure mode and cause of failure of the material by observing the failure form of the specimen and combining the data analysis results.

[0025] The at least one technical solution adopted in the embodiment of the present invention can achieve the following beneficial effects:

[0026] 1. It can accurately simulate the tribological characteristics of monorail crane drive and brake in complex mining working environments, including dust, oil film, moisture, water and other working conditions. It provides a more realistic and reliable test platform for studying the friction and wear performance of key drive and brake components in actual mining environments, effectively solving the problem of existing test system devices being out of touch with actual working conditions.

[0027] 2. One friction wheel can be used to conduct multiple test groups, which improves test efficiency and reduces test simulation costs. The friction wheel can also be replaced with a friction block to change the friction pair form and conduct research on other friction tests, achieving multi-purpose use of one machine. This greatly enhances the versatility and flexibility of the test system and can simultaneously meet the scientific research needs of different operating conditions of the friction drive characteristics and friction braking characteristics of the monorail crane, reducing the cost of repeated equipment purchases.

[0028] 3. Equipped with high-precision sensors and advanced data acquisition and control systems, it can quickly and accurately obtain test data, providing detailed and reliable data support for the design, material selection, optimization and maintenance of mining monorail crane equipment, helping to improve the reliability and service life of mining machinery and reduce equipment failure rate and maintenance costs;

[0029] 4. The introduction of the control variable method and the construction of the friction coefficient proxy model can deeply analyze the impact of various environmental factors on the friction coefficient, provide a scientific basis for the reliability design of the monorail crane, combine the friction characteristics test results with the reliability evaluation method, and evaluate the stability and consistency of the material friction and wear performance through statistical analysis of data from multiple tests, which will help improve the reliability and service life of the monorail crane drive and braking, and reduce equipment failure rate and maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0031] Figure 1 It is a schematic diagram of the three-dimensional structure of the present invention;

[0032] Figure 2 Schematic diagram of the three-dimensional structure of the horizontal friction pair driving wheel mechanism of the present invention;

[0033] Figure 3Schematic diagram of the three-dimensional structure of the horizontal friction pair test plate mechanism of the present invention;

[0034] Figure 4 It is a side view of the horizontal friction pair test plate mechanism of the present invention;

[0035] Figure 5 Schematic diagram of the three-dimensional structure of the vertical guide rail and the vertical slider in the present invention;

[0036] Figure 6 Schematic diagram of the three-dimensional structure of the vertical direction driving friction pair mechanism of the present invention;

[0037] Figure 7 Schematic diagram of the three-dimensional structure of the vertical friction pair test plate mechanism of the present invention;

[0038] Figure 8 It is a schematic diagram of a partial three-dimensional structure of the vertical direction driving friction pair mechanism of the present invention;

[0039] Figure 9 Schematic diagram of the three-dimensional structure of the linear slider and the linear guide rail in the present invention;

[0040] Figure 10 It is a schematic diagram of the three-dimensional structure of replacing the friction block in the present invention;

[0041] Reference numerals:

[0042] Support base 1, bottom plate 11, horizontal friction pair drive wheel mechanism 2, drive motor 20, reducer 21, first coupling 22, torque sensor 23, reducer bracket 24, torque sensor bracket 25, drive wheel 26, drive wheel shaft 27, support 28, second coupling 29, horizontal friction pair test plate mechanism 3, horizontal electric push cylinder 30, electric push cylinder rear fixing bracket 31, horizontal pressure sensor 32, first bolt 33, first nut 34, connecting flange 35, guide rail top plate 36, guide flange 37, guide shaft 38, linear bearing seat box guide rail slide 39, vertical Straight guide rail 301, vertical slider 302, mounting platform 303, test plate 304, sensor support 305, friction sensor 306, connecting block 307, vertical drive friction pair mechanism 4, gantry 41, vertical electric push cylinder 42, vertical pressure sensor 43, second bolt 44, second nut 45, connecting plate 46, T-shaped seat 47, friction wheel shaft 48, friction wheel 49, friction block 491, limit flange 40, linear slider 401, linear guide rail 402, vertical friction pair test plate mechanism 5, horizontal moving linear module 51, test moving plate 52. DETAILED DESCRIPTION

[0043] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with specific embodiments of the present invention and corresponding drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0044] The following describes in detail, in conjunction with the accompanying drawings, various embodiments of the present invention provide a technical solution for a monorail crane drive and brake tribological characteristics testing system and a method for using the same.

[0045] Reference Figures 1 to 10 As shown, an embodiment of the present invention provides a monorail crane drive and braking tribological characteristics testing system, comprising a support base 1 and a base plate 11 horizontally arranged on the support base 1, wherein the base plate 11 is provided with a horizontal friction pair driving wheel mechanism 2, a horizontal friction pair testing plate mechanism 3, a vertical driving friction pair mechanism 4 and a vertical friction pair testing plate mechanism 5; the horizontal friction pair driving wheel mechanism 2 is located at the top end position of the base plate 11, the horizontal friction pair testing plate mechanism 3 is located beside the horizontal friction pair driving wheel mechanism 2 to test the horizontal friction pair, the vertical driving friction pair mechanism 4 is located directly above the base plate 11, and the vertical friction pair testing plate mechanism 5 is located below the vertical driving friction pair mechanism 4 to test the vertical friction pair.

[0046] The friction testing system's flexible design allows for easy switching between drive and brake friction pairs to accommodate varying test requirements. Replacing the friction wheel 49 in the vertical drive friction pair mechanism 4 with a friction block 491 converts the drive friction pair into a brake friction pair. During replacement, the friction wheel 49, axle, sleeve, and other components are removed sequentially. The friction block 491 is then installed in its proper position and connected to the linear guide 402 slider and other components via a connecting plate 46 and screws. By replacing the friction block 491, its material, shape, and size can be easily adjusted to accommodate different types of friction pairs and test requirements, significantly enhancing the versatility and flexibility of the friction testing system and enabling switching between drive and brake modes.

[0047] Specifically, the horizontal friction pair drive wheel mechanism 2 includes a drive motor 20, a reducer 21, a first coupling 22, a torque sensor 23, a reducer bracket 24, a torque sensor bracket 25, a drive wheel 26 and a drive wheel shaft 27. The reducer bracket 24 and the torque sensor bracket 25 are arranged at intervals on the top of the base plate 11, and the reducer 21 and the torque sensor 23 are respectively installed on the reducer bracket 24 and the torque sensor bracket 25. The drive motor 20 is located on the base plate 11, and the torque sensor 23 is connected to the drive motor 20 through the reducer 21 and the first coupling 22. A support 28 is provided on the side of the torque sensor bracket 25. The drive wheel shaft 27 is horizontally rotatably connected to the support 28. A second coupling 29 is provided on the drive wheel shaft 27. One end of the drive wheel shaft 27 is connected to the torque sensor 23 through the second coupling 29, and the drive wheel 26 is located at the other end of the drive wheel shaft 27.

[0048] The model of the torque sensor 23 is MTA505.

[0049] Specifically, the horizontal friction pair test plate mechanism 3 includes a horizontal electric push cylinder 30, an electric push cylinder rear fixing frame 31, a horizontal pressure sensor 32, a first bolt 33, a first nut 34, a connecting flange 35 and a guide rail top plate 36. The horizontal electric push cylinder 30 is fixed to the base plate 11 through the electric push cylinder rear fixing frame 31. A guide flange 37 is provided on the telescopic end of the horizontal electric push cylinder 30. The horizontal pressure sensor 32 is connected to the horizontal electric push cylinder 30 through the guide flange 37. The horizontal pressure sensor 32 is connected to the guide rail top plate 36 through the first bolt 33, the first nut 34 and the connecting flange 35.

[0050] The model of the horizontal pressure sensor 32 is APT1000.

[0051] Specifically, two symmetrically arranged guide shafts 38 are provided on the guide rail top plate 36, and two linear bearing seat box-type guide rail slides 39 are provided on the bottom plate 11. The two guide shafts 38 slide on the two linear bearing seat box-type guide rail slides 39 respectively.

[0052] Specifically, the sidewalls of the guide rail top plate 36 are connected by screws to a vertical guide rail 301 and two vertical sliders 302 slidably connected to the vertical guide rail 301. A mounting platform 303 is screwed to the two vertical sliders 302, and a test plate 304 is screwed to the mounting platform 303. A sensor holder 305 is provided on the guide rail top plate 36, and a friction sensor 306 is provided on the sensor holder 305. The friction sensor 306 is provided with a connecting block 307, which is connected to the mounting platform 303. The model of the friction sensor 306 is MXD-01.

[0053] During the test, the horizontal electric push cylinder 30 drives the first bolt 33, the first nut 34 and the connecting flange 35 to make the guide rail top plate 36 move horizontally on the two linear bearing box guide rail slides 39 through the two guide shafts 38.

[0054] In the horizontal direction, the drive wheel 26 is driven by the drive motor 20 to rotate. The speed of the drive motor 20 can be adjusted within a certain range by the control system to achieve a friction process with different linear speeds. At the same time, the horizontal electric push cylinder 30 drives the test plate 304 to move longitudinally, so that the plate and the drive wheel 26 produce relative motion, simulating the friction conditions in actual working conditions. By adjusting the horizontal electric push cylinder 30, screw and other devices, the contact pressure between the friction pairs can be precisely controlled to meet the test requirements of different materials and working conditions.

[0055] Specifically, the vertical drive friction pair mechanism 4 includes a gantry 41, a vertical electric push cylinder 42, a vertical pressure sensor 43, a second bolt 44, a second nut 45, and a connecting plate 46. The gantry 41 is vertically arranged on top of the base plate 11. Made of a steel trough, it is fixed to the base plate 11 of the friction testing system device, forming the overall support framework for the friction pair mechanism of the vertical friction block 491, ensuring the stability and rigidity of the entire mechanism. The vertical electric push cylinder 42 is fixed to the lower end of the top of the gantry 41 by screws. The vertical pressure sensor 43 is connected to the telescopic end of the vertical electric push cylinder 42. The vertical pressure sensor 43 is connected to the connecting plate 46 via a second bolt 44 and a second nut 45. The bottom of the connecting plate 46 is provided with two symmetrically arranged T-shaped seats 47. A friction wheel shaft 48 is rotatably connected between the two T-shaped seats 47, and a friction wheel shaft 48 is provided on the friction wheel shaft 48. The vertical pressure sensor 43 is a German HBM U3 series model.

[0056] Specifically, both ends of the friction wheel shaft 48 are provided with limiting flanges 40, and the friction wheel shaft 48 rotates on the limiting flanges 40. Each limiting flange 40 is provided with a linear slider 401, and the side wall of the gantry 41 is provided with a linear guide rail 402 for the linear slider 401 to slide.

[0057] Specifically, the vertical friction pair test plate mechanism 5 includes a horizontally movable linear module 51 , and a test movable plate 52 is provided on the movable end of the horizontally movable linear module 51 . The vertical pressure sensor 43 can sense the downward pressure of the vertical electric push cylinder 42 .

[0058] During the vertical test, the vertical electric push cylinder 42 moves downward to drive the position of the vertical pressure sensor 43 to move downward so that the friction wheel 49 under the connecting plate 46 is located on the test movable plate 52. Then the horizontally movable linear module 51 works to drive the position of the test movable plate 52 to move horizontally, thereby causing the friction wheel 49 to rotate on the test movable plate 52. During the rotation process, the vertical electric push cylinder 42 moves downward to apply different pressures downward, thereby simulating the friction process of the monorail crane under different load conditions.

[0059] In the vertical direction, the friction wheel 49 can be replaced with a friction block 491. The motor drives the friction block 491 to move up and down in the vertical direction to achieve precise contact and separation with the test plate 304, which can simulate the friction conditions during the braking process.

[0060] Specifically, it also includes an environmental module, which is internally provided with a dust concentration regulating device, an oil film simulator and a humidity control system; its flexibility enables rapid adjustment of environmental parameters according to different test requirements, so as to accurately simulate the impact of the complex environment of a mine on the friction pair. The dust concentration regulating device is used to spray dust into the test area to simulate the dust conditions in a mine environment, and can accurately control the particle size distribution and spray concentration of the dust. The oil film smearing device is used to apply a uniform oil film to the surface of the friction pair, simulating the oil film conditions in mining machinery caused by poor lubrication or oil contamination. The humidifier controls the relative humidity of the test area to simulate the humid environment in a mine environment;

[0061] It should be noted that the drive motor 20 uses a high-precision servo motor as its driving source, enabling precise speed and position control, simulating the friction process in actual operating conditions. The drive motor 20 is connected to the friction wheel 49 or friction block 491 via a speed reducer 21 and a coupling, ensuring smooth power transmission. The speed reducer 21 reduces the speed and increases the torque to meet the friction requirements under different operating conditions. The coupling is used to connect the motor output shaft and the friction wheel shaft 48, ensuring coaxiality and transmission accuracy between the two.

[0062] A method for using a monorail crane drive and brake tribological characteristics testing system comprises the following steps:

[0063] S1: According to the test requirements, use the environmental module to simulate the environment required for the test, set the dust concentration, oil film thickness and ambient humidity, and make the friction test area reach the predetermined environmental conditions;

[0064] S2: Select the driving friction pair or brake friction pair to be studied, and adjust and install the test device; select the friction pair material, prepare a sample of standard size, clean and pre-treat the sample surface to ensure that the surface is free of oil, dust and other impurities to ensure the accuracy of the test; install and fix the material plate to be tested on the mounting platform 303, adjust the initial contact position and pressure, and ensure that the contact area between the test plate 304 and the friction wheel 49 or friction block 491 is correctly connected;

[0065] S3: Under the set environmental conditions, the motor is turned on to drive the friction wheel 49 or the friction block 491 to move; the motor speed is set to 1000 r / min, and the electric push cylinder drives the test plate 304 to move, so that relative motion occurs between the friction pairs, simulating the friction process in actual working conditions. The friction force sensor 306 and the horizontal pressure sensor 32 or the vertical pressure sensor 43 are used to monitor and record key parameters such as friction force and contact pressure in real time. The data acquisition system collects data at a sampling frequency of 100 Hz and transmits the data to the computer control terminal. Each test lasts 30 minutes. Under the same environmental conditions, the test is repeated 3-5 times to ensure the reliability and repeatability of the data.

[0066] S4: The collected data is transmitted to the computer control terminal, and the computer control system pre-processes the collected data, including filtering, denoising, data smoothing and other operations, according to the friction formula F f =μF N Calculate the key indicators such as friction coefficient and save them according to the set data storage period; at the same time, the test personnel can view the change curve of the test data in real time through the monitoring interface to intuitively understand the dynamic change of friction coefficient (where: F f —Friction force, μ—Friction coefficient, F N — clamping force);

[0067] S5: Based on the calculated friction coefficient data, plot the curves showing how the friction coefficient changes with various environmental factors; plot the relationship between the friction coefficient and environmental factors such as dust concentration, oil thickness, and ambient humidity; these curves can intuitively show the changing trends of the friction coefficient under different environmental conditions. Statistical analysis methods can be used to evaluate the effects of different environmental factors on the friction coefficient and determine which factors have a more significant impact on the friction coefficient.

[0068] S6: Based on the test data, a friction coefficient proxy model is constructed. The test data is substituted into the model, and the model is fitted using the least squares method to obtain the estimated value of the regression coefficient. A quantitative relationship model between the friction coefficient and environmental factors is established and a sensitivity analysis is performed.

[0069] S7: During the test, key parameters such as friction coefficient, friction force, and contact pressure are monitored in real time, and these data are promptly fed back to the control system. The control system adjusts test conditions such as motor speed and electric push cylinder pressure according to the set parameter range to ensure the stability of the test process and the accuracy of the data;

[0070] S8: After the test is completed, the collected data is sorted and analyzed, and the friction coefficient is presented in the form of graphs and charts, such as the curve of the change of friction coefficient over time and environmental factors, and the relationship between wear and test time. Based on the test data, a life prediction model is established, combining the friction coefficient and wear data to predict the service life of the material under different working conditions.

[0071] S9: Analyze the failure mode and cause of failure of the material by observing the failure form of the specimen and combining the data analysis results.

[0072] The friction test system's control system features advanced variable frequency speed regulation, enabling stepless motor speed control. By adjusting the motor's input frequency and voltage, the motor's speed can be precisely controlled, enabling the friction wheel 49 or friction block 491 to move at varying speeds. The control system also supports forward and reverse rotation, enabling the friction wheel 49 or friction block 491 to move in different directions and adjust the angle to simulate forward and reverse friction processes.

[0073] The friction test system's various motion functions adapt to different types of friction pairs and test requirements. For the drive friction pair, the motor speed and electric cylinder thrust can be adjusted to simulate the drive friction process under different operating conditions. For the brake friction pair, the motor speed and the installation position of friction block 491 can be adjusted to simulate the friction process under different braking conditions. This flexibility enables the friction test system to adapt to various test requirements, improving test efficiency and equipment utilization.

[0074] Experimental data collection and analysis function:

[0075] The friction test system is equipped with high-precision sensors and data acquisition systems, which can monitor and record key parameters such as friction force and contact pressure in real time;

[0076] Friction sensor 306 is mounted between mounting platform 303 of test plate 304 and friction wheel 49 or friction block 491. Its upper end is bolted to mounting platform 303, and its lower end is bolted to connecting block 307, which is fixed to mounting platform 303. This mounting method ensures that friction sensor 306 can directly sense friction changes in the contact area of ​​the friction pair, while also ensuring the sensor's stability and measurement accuracy. The voltage signal output by friction sensor 306 is amplified and filtered by a signal conditioning module and transmitted to the computer control terminal via a data acquisition card.

[0077] The horizontal pressure sensor 3 is installed between the horizontal electric push cylinder 30 and the guide rail top plate 36. One end is connected to the horizontal electric push cylinder 30 via a guide flange 37, and the other end is connected to the guide rail top plate 36 via a first bolt 33, a first nut 34, and a connecting flange 35. This ensures the stability of the sensor and the accuracy of the measurement. The voltage signal output by the horizontal pressure sensor 32 is processed and transmitted to the computer control terminal.

[0078] The data acquisition system is mainly composed of a data acquisition card, a signal conditioning module, a data acquisition controller, etc. The main function is to process and analyze the collected data such as friction force and contact pressure in real time, including data storage, organization, chart generation, etc., in order to accurately evaluate the tribological characteristics. First, the system filters and denoises the data to improve the accuracy of the data. Then, key indicators such as friction coefficient and wear rate are calculated, and corresponding charts and reports are generated. Test personnel can view data changes in real time through the software interface, detect abnormal data in time and process them to ensure the reliability of the test results;

[0079] Reliability analysis method:

[0080] The friction testing system device is used to deeply study the influence of various environmental factors on the friction coefficient, and further carry out reliability analysis research of monorail crane.

[0081] Qualitatively study the effect of environmental factors on the friction coefficient by setting parameters such as dust concentration (C), oil thickness (h) and ambient humidity (H). Use a dust injection device to spray dust of a specific particle size into the test area to simulate the dust conditions in a mining environment. The dust concentration range can be 10-100mg / m 3 Internal adjustment, set C1 = 10mg / m 3 C2=30mg / m 3 C3=50mg / m 3 C4 = 70 mg / m 3Different levels of dust concentration are controlled. An oil film is applied to the friction pair surfaces using an oil film applicator to simulate the oil film conditions caused by poor lubrication or oil contamination in mining machinery. The oil film thickness can be adjusted between 0.01 and 0.2 mm, with settings such as h1 = 0.01 mm, h2 = 0.05 mm, h3 = 0.1 mm, and h4 = 0.15 mm. A humidifier and dehumidifier are used to adjust the test environment's humidity, simulating a relative humidity range of 30% to 90% RH, with settings such as H1 = 30% RH, H2 = 50% RH, H3 = 70% RH, and H4 = 90% RH. Based on the actual load conditions of the monorail crane during operation, the contact pressure between the friction pairs is precisely controlled by adjusting devices such as the electric push cylinder or screw, allowing for different contact loads to be set. For light load conditions, the load can be set to 500 N; for medium load conditions, to 1000 N; and for heavy load conditions, to 2000 N. Simulate the friction process of the monorail crane at different operating speeds. The motor drives the friction wheel 49 or the friction block 491 to achieve different speeds. The speed range is adjustable between 0.1-3.0m / s. Set the low speed condition to 0.1m / s, the medium speed condition to 1.0m / s, and the high speed condition to 3.0m / s.

[0082] According to the test plan, the required environmental conditions are set using the environmental module of the friction test system device, representative friction pair materials are selected, and the sample is installed on the friction test system device to ensure that the contact part of the sample and the friction wheel 49 or friction block 491 is correctly docked. Under the set environmental conditions, the motor is turned on to drive the friction wheel 49 or friction block 491 to move, simulating the friction process in actual working conditions. During the test, key parameters such as friction and contact pressure are monitored and recorded in real time by the friction force sensor 306 and the horizontal pressure sensor 32 or the vertical pressure sensor 43. Each group of tests lasts for a certain period of time, and the test is repeated 3-5 times under the same environmental conditions to ensure the reliability and repeatability of the data. After the test, the collected data will be backed up and saved, including information such as friction, contact pressure, time, etc., for subsequent data processing and analysis. The appearance of the sample after the test is observed, and the wear of the sample is recorded, such as the wear shape, wear amount, etc.;

[0083] The collected friction and contact pressure data are transmitted to the computer control terminal through the data acquisition card for analysis and calculation. According to the friction formula F f =μF N , the friction coefficient μ can be expressed as: μ = F f / F N, use data analysis software to calculate the friction coefficient under each set of test conditions, and draw a curve of the friction coefficient changing with time to observe the dynamic change process of the friction coefficient. According to the obtained friction coefficient data, draw a curve of the friction coefficient changing with various environmental factors to help analyze the influence of environmental factors on the friction coefficient (where: F f —Friction force, μ—Friction coefficient, F N — clamping force);

[0084] The reliability of monorail crane drive braking is affected by the friction coefficient. Based on the friction coefficient proxy model, combined with the actual working conditions and design parameters of the monorail crane, a reliability model of the monorail crane can be established. This model comprehensively considers the influence of environmental factors such as dust concentration and oil stain thickness on the friction coefficient, thereby indirectly evaluating the impact of these factors on the reliability of the monorail crane. Based on the test data, a friction coefficient proxy model is constructed. The multivariate linear regression model is selected: μ = β0 + β1C + β2h + β3H + ε, where μ is the friction coefficient, C, h, and H are dust concentration, oil stain thickness, and ambient humidity, respectively, β0, β1, β2, and β3 are regression coefficients, and ε is the error term. Substitute the test data into the model, and use the least squares method to fit the model to obtain the estimated value of the regression coefficient, thereby establishing a quantitative relationship model between the friction coefficient and environmental factors. Analyze the sensitivity of environmental factors such as dust concentration and oil stain thickness to the reliability indicators of the monorail crane, and determine which factors have a greater impact on reliability.

[0085] The foregoing is merely an embodiment of the present invention and is not intended to limit the present invention. It will be apparent to those skilled in the art that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention are intended to be included within the scope of the claims of the present invention.

Claims

1. A monorail crane drive and brake tribological characteristics testing system, characterized in that: The invention comprises a support base (1) and a bottom plate (11) horizontally arranged on the support base (1); the bottom plate (11) is provided with a horizontal friction pair driving wheel mechanism (2), a horizontal friction pair testing plate mechanism (3), a vertical friction pair driving mechanism (4) and a vertical friction pair testing plate mechanism (5); the horizontal friction pair driving wheel mechanism (2) is located at the top end of the bottom plate (11); the horizontal friction pair testing plate mechanism (3) is located beside the horizontal friction pair driving wheel mechanism (2) to test the horizontal friction pair; the vertical friction pair driving mechanism (4) is located directly above the bottom plate (11); and the vertical friction pair testing plate mechanism (5) is located below the vertical friction pair driving mechanism (4) to test the vertical friction pair.

2. A monorail crane drive and brake tribological characteristics testing system according to claim 1, characterized in that: The horizontal friction pair drive wheel mechanism (2) comprises a drive motor (20), a reducer (21), a first coupling (22), a torque sensor (23), a reducer bracket (24), a torque sensor bracket (25), a drive wheel (26) and a drive wheel shaft (27), wherein the reducer bracket (24) and the torque sensor bracket (25) are arranged at intervals on the top of the base plate (11), the reducer (21) and the torque sensor (23) are respectively mounted on the reducer bracket (24) and the torque sensor bracket (25), and the drive motor ( 20) is located on the base plate (11), the torque sensor (23) is connected to the drive motor (20) through a reducer (21) and a first coupling (22), a support (28) is provided on the side of the torque sensor bracket (25), the driving wheel shaft (27) is horizontally rotatably connected to the support (28), a second coupling (29) is provided on the driving wheel shaft (27), one end of the driving wheel shaft (27) is connected to the torque sensor (23) through the second coupling (29), and the driving wheel (26) is located at the other end of the driving wheel shaft (27).

3. The monorail crane drive and brake tribological characteristics testing system according to claim 2, characterized in that: The horizontal direction friction pair test plate mechanism (3) comprises a horizontal electric push cylinder (30), an electric push cylinder rear fixing frame (31), a horizontal pressure sensor (32), a first bolt (33), a first nut (34), a connecting flange (35) and a guide rail top plate (36); the horizontal electric push cylinder (30) is fixed to the base plate (11) via the electric push cylinder rear fixing frame (31); a guide flange (37) is provided on the telescopic end of the horizontal electric push cylinder (30); the horizontal pressure sensor (32) is connected to the horizontal electric push cylinder (30) via the guide flange (37); and the horizontal pressure sensor (32) is connected to the guide rail top plate (36) via the first bolt (33), the first nut (34) and the connecting flange (35).

4. A monorail crane drive and brake tribological characteristics testing system according to claim 3, characterized in that: Two symmetrically arranged guide shafts (38) are provided on the guide rail top plate (36), and two linear bearing seat box-type guide rail slides (39) are provided on the bottom plate (11). The two guide shafts (38) slide on the two linear bearing seat box-type guide rail slides (39) respectively.

5. The monorail crane drive and brake tribological characteristics testing system according to claim 4, characterized in that: The side wall of the guide rail top plate (36) is connected to a vertical guide rail (301) and two vertical sliders (302) slidably connected to the vertical guide rail (301) by screws, the two vertical sliders (302) are connected to a mounting platform (303) by screws, the mounting platform (303) is connected to a test plate (304) by screws, the guide rail top plate (36) is provided with a sensor support (305), the sensor support (305) is provided with a friction sensor (306), the friction sensor (306) is provided with a connecting block (307), and the connecting block (307) is connected to the mounting platform (303).

6. The monorail crane drive and brake tribological characteristics testing system according to claim 1, characterized in that: The vertical direction driving friction pair mechanism (4) includes a gantry (41), a vertical electric push cylinder (42), a vertical pressure sensor (43), a second bolt (44), a second nut (45) and a connecting plate (46). The gantry (41) is vertically arranged on the top of the base plate (11). The vertical electric push cylinder (42) is fixed to the lower end of the top of the gantry (41) by screws. The vertical pressure sensor (43) is connected to the telescopic end of the vertical electric push cylinder (42). The vertical pressure sensor (43) is connected to the connecting plate (46) by the second bolt (44) and the second nut (45). The bottom of the connecting plate (46) is provided with two symmetrically arranged T-shaped seats (47). A friction wheel shaft (48) is provided between the two T-shaped seats (47) for rotation connection. A friction wheel shaft (49) is provided on the friction wheel shaft (48).

7. The monorail crane drive and brake tribological characteristics testing system according to claim 6, characterized in that: Limiting flanges (40) are provided at both ends of the friction wheel shaft (48), and the friction wheel shaft (48) rotates on the limiting flanges (40). A linear slider (401) is provided on each limiting flange (40), and a linear guide rail (402) for the linear slider (401) to slide is provided on the side wall of the gantry (41).

8. The monorail crane drive and brake tribological characteristics testing system according to claim 1, characterized in that: The vertical friction pair test plate mechanism (5) comprises a horizontally movable linear module (51), and a test movable plate (52) is provided on the movable end of the horizontally movable linear module (51).

9. The monorail crane drive and brake tribological characteristics testing system according to claim 1, characterized in that: It also includes an environmental module, which is internally provided with a dust concentration regulating device, an oil film simulator and a humidity control system.

10. A method for using a monorail crane drive and brake tribological characteristics testing system according to any one of claims 1 to 9, characterized in that: The following steps are involved: S1: According to the test requirements, use the environmental module to simulate the environment required for the test, set the dust concentration, oil film thickness and ambient humidity, and make the friction test area reach the predetermined environmental conditions; S2: Select the driving friction pair or the braking friction pair of the research object, adjust and install the test device; select the friction pair material, prepare a sample of standard size, clean and pre-treat the sample surface to ensure that the surface is free of oil, dust and other impurities to ensure the accuracy of the test; install and fix the material plate to be tested on the installation platform (303), adjust the initial contact position and pressure, and ensure that the contact part of the test plate (304) and the friction wheel (49) or the friction block (491) is correctly connected; S3: Under the set environmental conditions, the motor is turned on to drive the friction wheel (49) or the friction block (491) to move; the motor speed is set to 1000 r / min, and the electric push cylinder drives the test plate (304) to move, so that relative movement occurs between the friction pairs, simulating the friction process in actual working conditions. The friction force sensor (306) and the pressure sensor are used to monitor and record key parameters such as friction force and contact pressure in real time. The data acquisition system collects data at a sampling frequency of 100 Hz and transmits the data to the computer control terminal. Each test lasts 30 minutes. Under the same environmental conditions, the test is repeated 3-5 times to ensure the reliability and repeatability of the data. S4: The collected data is transmitted to the computer control terminal, and the computer control system pre-processes the collected data, including filtering, denoising, data smoothing and other operations, according to the friction formula F f =μF N Calculate the key indicators such as friction coefficient and save them according to the set data storage period; at the same time, the test personnel can view the change curve of the test data in real time through the monitoring interface to intuitively understand the dynamic change of friction coefficient (where: F f —Friction force, μ—Friction coefficient, F N — clamping force); S5: Based on the calculated friction coefficient data, plot the curves showing how the friction coefficient changes with various environmental factors; plot the relationship between the friction coefficient and environmental factors such as dust concentration, oil thickness, and ambient humidity; these curves can intuitively show the changing trends of the friction coefficient under different environmental conditions. Statistical analysis methods can be used to evaluate the effects of different environmental factors on the friction coefficient and determine which factors have a more significant impact on the friction coefficient. S6: Based on the test data, a friction coefficient proxy model is constructed. The test data is substituted into the model, and the model is fitted using the least squares method to obtain the estimated value of the regression coefficient. A quantitative relationship model between the friction coefficient and environmental factors is established and a sensitivity analysis is performed. S7: During the test, key parameters such as friction coefficient, friction force, and contact pressure are monitored in real time, and these data are promptly fed back to the control system. The control system adjusts test conditions such as motor speed and electric push cylinder pressure according to the set parameter range to ensure the stability of the test process and the accuracy of the data; S8: After the test is completed, the collected data is sorted and analyzed, and the friction coefficient is presented in the form of graphs and charts, such as the curve of the change of friction coefficient over time and environmental factors, and the relationship between wear and test time. Based on the test data, a life prediction model is established, combining the friction coefficient and wear data to predict the service life of the material under different working conditions. S9: Analyze the failure mode and cause of failure of the material by observing the failure form of the specimen and combining the data analysis results.

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