Brake system for pay-off rack

Abstract

The invention discloses a brake system for a pay-off rack. The brake system comprises a pay-off wheel, a support and brake systems which are symmetrically arranged. Wherein the brake system comprises a brake device and a brake device, and the brake device comprises a brake disc coaxial with the pay-off wheel, an electromagnetic speed reduction mechanism (an electromagnetic damping brake frame and a resistor) and a friction brake mechanism. The electromagnetic speed reduction mechanism adjusts current through a resistor to achieve stable speed reduction, and the friction braking mechanism is used for final braking. The system adopts a two-stage braking mode to cooperatively control electromagnetic and friction braking, solves the problems of large braking impact and poor stability in the prior art, improves the take-up and pay-off precision and test reliability of the wire body, and is suitable for production, construction and performance test scenes of wire bodies such as cables, ropes and the like.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of brake devices, in particular to a brake system for a pay-off stand. BACKGROUND

[0002] The pay-off stand is a core equipment in the production, construction and performance testing process of cables, ropes and other lines, and the stability of its brake system directly affects the precision of line winding and unwinding, the quality and safety of the line itself, and the reliability of the construction process. In high-precision testing scenarios, the speed control and emergency stopping effect of the pay-off wheel are key indicators of the performance of the pay-off stand, and the smoothness and response speed of the brake system are extremely high.

[0003] The brake system of the traditional pay-off stand mostly adopts a single friction braking mode, which generates resistance through the direct contact between the friction plate and the brake disc to achieve stopping. However, this mode has obvious defects: the impact generated by the instantaneous contact between the friction plate and the brake disc during braking is large, which easily leads to excessive stretching or even breaking of the line; the friction plate wears severely after long-term use, the braking effect gradually decreases, and the stability is difficult to guarantee; and the rotational speed of the pay-off wheel cannot be precisely controlled, making it difficult to meet the high-precision testing requirements of line extension performance and deformation capacity.

[0004] To solve the above problems, some technical solutions attempt to use a combination of electromagnetic braking and friction braking, but lack a reasonable cooperative control mechanism. For example, electromagnetic braking and friction braking often intervene at the same time, resulting in the electromagnetic damping not fully playing a role in smooth deceleration before being impacted by friction braking, or the friction braking intervention being delayed, leading to a long stopping time. In addition, the current regulation of electromagnetic braking lacks precise control means, and the damping force cannot be flexibly adjusted according to the working conditions, making it difficult to adapt to the needs of different line materials and working conditions.

[0005] The brake system of the pay-off stand has the problems of large braking impact, line damage, poor stability, and inability to precisely control the speed, and there is an urgent need for a brake system that can achieve smooth deceleration of electromagnetic damping and reliable stopping of friction braking in an orderly manner, and can flexibly adjust the damping force, to improve the performance and adaptability of the pay-off stand. SUMMARY

[0006] In view of the defects of the prior art, the present application proposes a brake system applied to a pay-off stand, which has the performance of smooth braking, can reduce the wear rate of traditional friction brake plates, and is convenient for mechanical testing of lines.

[0007] To achieve the above purpose, the present application adopts the following technical solutions: A brake system for a pay-off rack, comprising a pay-off wheel with two axial ends each provided with a support, and a brake system provided on the two sides of the support, characterized in that the brake system comprises a brake device and a braking device, wherein the brake device comprises a brake disc, an electromagnetic deceleration mechanism and a friction braking mechanism, the electromagnetic deceleration mechanism and the friction braking mechanism are respectively arranged on the left and right sides of the brake disc, the friction braking mechanism comprises a friction braking support, the electromagnetic deceleration mechanism comprises an electromagnetic damping support and a resistor, an external power source is electrically connected to the input end of the resistor, the output end of the resistor is electrically connected to the electromagnetic damping support, and the higher the current received by the electromagnetic damping support, the stronger the deceleration effect of the brake disc.

[0008] Preferably, the braking device comprises two driving mechanisms, and the resistor is a sliding rheostat, a driving mechanism I is arranged on one side of the resistor, and the driving mechanism I is used for adjusting the resistance value of the sliding rheostat, and a driving mechanism II is used for adjusting the distance between the friction braking support and the brake disc.

[0009] Preferably, the driving mechanism I comprises a hydraulic pipe, a sealing sliding plug is slidably connected in the hydraulic pipe, the sealing sliding plug is in transmission connection with the sliding contact of the resistor through a driving member, one side of the hydraulic pipe is provided with a driving pump station for storing hydraulic oil, the output end of the driving pump station is connected to the inner cavity of the hydraulic pipe through a liquid delivery pipe, and the output end of the driving pump station and the connection position of the hydraulic pipe are located on the two sides of the sealing sliding plug, respectively.

[0010] Preferably, the driving mechanism II is consistent with the driving mechanism I in structure, the driving mechanism II comprises a hydraulic pipe, a sealing sliding plug and a driving member, and the sealing sliding plug in the driving mechanism II is in transmission connection with the friction braking support through a corresponding driving member.

[0011] Preferably, the driving mechanism I and the driving mechanism II further comprise a sleeve pipe sleeved on the outer side of the hydraulic pipe, the corresponding sleeve pipe of the driving mechanism I is connected to the liquid inlet end of the corresponding hydraulic pipe of the driving mechanism II through a circulation pipe, the corresponding sleeve pipe of the driving mechanism II is connected to the liquid inlet of the driving pump station through a return pipe, the side end of each hydraulic pipe is provided with a flow channel, the flow channel and the corresponding sleeve pipe are in the same vertical plane, the projection of each sealing sliding plug in the vertical plane and the projection of the corresponding flow channel in the vertical plane overlap, and as the sealing sliding plug slides along the axial direction of the hydraulic pipe, the overlapping area of the sealing sliding plug and the flow channel changes, and each sealing sliding plug is coaxially provided with a tension spring on the side away from the corresponding driving member, and the tension spring is used for resetting the sealing sliding plug.

[0012] Preferably, a delay mechanism is connected to the middle section of the circulation pipe, the delay mechanism comprises a liquid storage tank and a three-way valve, and the three-way valve is connected to the circulation pipe and the liquid inlet of the liquid storage tank, respectively.

[0013] Preferably, the liquid outlet of the liquid storage tank is connected with a stop valve, and the liquid outlet of the stop valve is connected with the return pipe through a flow guide pipe.

[0014] Compared with the prior art, the application has the beneficial effects that: The technical scheme effectively solves the pain points of the traditional brake system: the electromagnetic deceleration mechanism uses a resistor to adjust the current to control the electromagnetic damping force, realizes the smooth deceleration of the pay-off wheel, and avoids the impact of single friction braking; the friction braking mechanism is used for final braking to make up for the low-speed efficiency attenuation of the electromagnetic braking; the two work together to ensure the stability and safety during emergency braking, meet the precise control requirements of the pay-off wheel speed during regular testing, effectively protect the wire body quality, improve the reliability of the construction and testing process, and are suitable for various complex working conditions. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 It is a schematic diagram of the overall structure of the application.

[0016] Figure 2 It is a schematic diagram of the position relationship between the friction braking frame and the electromagnetic damping braking frame.

[0017] Figure 3 It is a schematic diagram of the overall structure of the brake device.

[0018] Figure 4 It is a schematic diagram of the cooperation relationship between the driving mechanism I and the resistor.

[0019] Figure 5 It is a schematic diagram of the cooperation relationship between the driving mechanism II and the time delay mechanism.

[0020] Figure 6 It is a schematic diagram of the position relationship between the sleeve and the flow channel.

[0021] Figure 7 It is a schematic diagram of the overall structure of the time delay mechanism.

[0022] In the figure: 100, pay-off frame; 200, support; 300, brake device; 310, brake disc; 320, friction braking frame; 330, electromagnetic damping braking frame; 400, brake device; 410, driving pump station; 420, driving mechanism; 421, driving mechanism II; 422, driving mechanism I; 4201, hydraulic pipe; 4202, sleeve; 4203, driving piece; 4204, sealing sliding plug; 4205, flow channel; 4206, tension spring; 430, liquid delivery pipe; 440, circulation pipe; 450, resistor; 460, time delay mechanism; 461, liquid storage tank; 462, three-way valve; 463, stop valve; 464, flow guide pipe; 470, return pipe. DETAILED DESCRIPTION

[0023] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of the present application.

[0024] In the description of the present application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application.

[0025] Please refer to Figures 1-2 A brake system for a pay-off stand, in practice, the pay-off stand 100 as a cable, rope and other line production, construction and testing process in the core equipment, its brake system stability is directly related to the line body precision, line body quality and safety and reliability of the construction process.

[0026] In practical application, the pay-off stand 100 often faces different working condition requirements: both need to achieve fast and stable stop in emergency to avoid line body overstretching or breaking; also need to accurately control the rotation speed and resistance of the pay-off wheel in the conventional test scene to complete the detection of line body extension performance, deformation ability and other indicators.

[0027] However, in the prior art device, the brake system of the traditional pay-off stand 100 mostly adopts single friction braking mode, which has problems such as large braking impact, line body easy to be damaged, poor braking stability; some systems use electromagnetic and friction combined braking, but due to the lack of reasonable cooperative control mechanism, they cannot realize the orderly cooperation of the two braking modes, and are difficult to meet the use requirements under complex working conditions.

[0028] Based on this, the device optimizes the structural design of the brake system, constructs a two-stage braking mode of "electromagnetic damping deceleration + friction braking stop", and adds a separate electromagnetic damping adjustment mode, which realizes the stability of the braking process, the flexibility of the braking mode and the diversity of the test function. The specific embodiment will describe the overall structure of the system, the specific structure of each component, the assembly relationship and the working principle, which provides comprehensive technical guidance for the actual production, assembly and application of the system.

[0029] Please refer to Figure 1Similar to existing technology devices, this device also includes a wire feeding reel, a support 200, and a braking system, wherein the braking system is a key component for achieving the technical effect of this invention.

[0030] Please refer to Figure 1 , Figure 2 Specifically, a bracket 200 is fixedly installed at each of the two axial ends of the pay-off reel. The bracket 200 is integrally formed from high-strength alloy material, and its bottom is fixed to the ground by expansion bolts to ensure the stability of the pay-off reel during high-speed rotation and braking. A braking system is symmetrically installed on each of the two brackets 200. The two braking systems work synchronously to further improve the smoothness and reliability of braking.

[0031] Each braking system includes a braking device 300 and a braking device 400. The braking device 300 is used to directly decelerate and stop the wire feeding reel, while the braking device 400 is used to drive the braking device 300 to complete the corresponding action.

[0032] Specifically, the braking device 300 includes a brake disc 310, an electromagnetic reduction mechanism, and a friction braking mechanism. The brake disc 310 is coaxially and fixedly connected to the wire-laying reel, rotating synchronously with it. The electromagnetic reduction mechanism and the friction braking mechanism are respectively located on the left and right sides of the brake disc 310, with their braking ends facing the end face of the brake disc 310 to ensure precise braking action. The friction braking mechanism includes a friction brake frame 320, on which friction pads are mounted. The friction pads are made of a high-friction, high-temperature-resistant ceramic composite material to ensure braking effect and service life. The electromagnetic reduction mechanism includes an electromagnetic damping brake frame 330 and a resistor 450. An external power supply is electrically connected to the input terminal of the resistor 450, and the output terminal of the resistor 450 is electrically connected to the electromagnetic damping brake frame 330. By adjusting the resistance value of the resistor 450, the input current of the electromagnetic damping brake frame 330 can be changed, thereby adjusting its deceleration effect on the brake disc 310. The higher the current, the stronger the deceleration effect.

[0033] Specifically, the electromagnetic deceleration mechanism includes an electromagnetic damping brake bracket 330, a resistor 450, and related circuit components. The electromagnetic damping brake bracket 330 adopts a U-shaped structure design, with its open end facing one side of the brake disc 310. Electromagnetic coils are respectively installed at the two arms of the U-shaped structure. The electromagnetic coils are made of copper enameled wire, ensuring that a sufficiently strong electromagnetic field can be generated after a certain current is applied. The bottom of the electromagnetic damping brake bracket 330 is fixed to the bracket 200 by bolts, and its position can be finely adjusted by adjusting bolts to ensure that the gap between the electromagnetic coil and the end face of the brake disc 310 is controlled within the range of 0.5–1 mm. An excessively large gap will reduce the electromagnetic damping effect, while an excessively small gap may cause friction between the brake disc 310 and the electromagnetic coil during rotation.

[0034] Meanwhile, the friction braking mechanism includes a friction brake frame 320 and friction pads. The friction brake frame 320 adopts a double-arm lever structure design (this is existing technology and will not be described in detail here, nor is it shown in the figure). Alternatively, the friction brake frame 320 can slide with the bracket 200, etc., depending on the specific requirements. Its middle section is hinged to the bracket 200 via a pin, allowing the friction brake frame 320 to rotate around the pin, thus facilitating the contact and separation of the friction pads from the brake disc 310. The free end of the friction brake frame 320 has a friction pad mounting groove, and the friction pads are fixed in the groove by rivets. The size of the friction pads matches the end face size of the brake disc 310, ensuring that the friction pads fully cover the effective braking area of ​​the brake disc 310 during braking. The surface of the friction pads has anti-slip textures to further increase the coefficient of friction and enhance the braking effect.

[0035] It should be noted that the electromagnetic deceleration mechanism utilizes "eddy current braking" or "hysteresis braking" in practice. The rotating brake disc 310 (usually copper or aluminum) cuts the magnetic field of the electromagnetic damping brake frame 330, generating eddy currents in the disc. The eddy current magnetic field interacts with the original magnetic field, generating a resistance torque opposite to the direction of rotation. The greater the current in the coil of the electromagnetic damping brake frame 330, the greater the braking force, achieving smooth deceleration and speed maintenance.

[0036] It is particularly important to emphasize that the efficiency of eddy current braking drops sharply at low speeds. Therefore, this device uses an electromagnetic deceleration mechanism to decelerate the brake disc 310 and a traditional friction braking structure (friction brake frame 320) to achieve complete braking of the brake disc 310.

[0037] Please refer to Figure 1 , Figure 3 , Figure 4 , Figure 6 The braking device 400 includes two drive mechanisms 420, namely drive mechanism I 422 and drive mechanism II 421. Simultaneously, the resistor 450 is a sliding rheostat. Drive mechanism I 422 is used to adjust the resistance value of the sliding rheostat, and drive mechanism II 421 is used to adjust the distance between the friction brake frame 320 and the brake disc 310, thereby achieving coordinated control of electromagnetic damping braking and friction braking. The specific structure, assembly relationship, and working principle of each component will be described in detail below.

[0038] The drive mechanism I 422 includes a hydraulic pipe 4201, a sealing slide 4204, and a drive component 4203. A drive pump station 410 is also provided on one side of the drive mechanism I 422 (the drive pump station 410 uses a plunger-type hydraulic pump to provide stable hydraulic power to the drive mechanism I 422. The drive pump station 410 stores hydraulic oil internally. Its output end is connected to the inner cavity of the hydraulic pipe 4201 via a delivery pipe 430. The delivery pipe 430 is a high-pressure rubber hose, and its working pressure is not lower than the rated working pressure of the drive pump station 410. A flow regulating valve is installed on the delivery pipe 430 to regulate the injection speed of the hydraulic oil. The connection between the output end of the drive pump station 410 and the hydraulic pipe 4201, and the drive component 4203, are located on both sides of the sealing slide 4204, ensuring that the hydraulic oil can push the sealing slide 4204 towards the drive component 4203 when injected. The drive pump station 410 is a very mature existing technology device and will not be described in detail here). Therefore, one end of the hydraulic pipe 4201 is closed, and the other end is connected to the infusion pipe 430 of the drive pump station 410 through a flange. Furthermore, a sealing plug 4204 is provided in the inner cavity of the closed end of the hydraulic pipe 4201.

[0039] A sealing plug 4204 is disposed inside the hydraulic pipe 4201 and is slidably connected to the inner wall of the hydraulic pipe 4201. The sealing plug 4204 is made of rubber, and its outer diameter is interference-fitted with the inner diameter of the hydraulic pipe 4201 to ensure a sealing effect. A driving component 4203 is provided on one side of the sealing plug 4204.

[0040] It is particularly important to emphasize that the drive component 4203 can be a hydraulic or pneumatic assembly (the working principle of the hydraulic or pneumatic assembly is due to the volume change caused by the sliding of the sealing plug 4204 in the inner cavity of the hydraulic pipe 4201. This type of structure is existing technology and will not be described in detail here), or it can be a connecting rod structure (the connecting rod should protrude from the closed end of the hydraulic pipe 4201 and the connecting rod should be in a sealed sliding connection with the hydraulic pipe 4201).

[0041] In this device, the drive component 4203 is a push rod, which is a metal rod-shaped structure. One end of the push rod is fixedly connected to the sealing slide plug 4204 by a thread, and the other end passes through the through hole of the closed end of the hydraulic pipe 4201 and is fixedly connected to the sliding contact of the resistor 450. A sealing ring made of fluororubber is provided at the through hole to prevent hydraulic oil from leaking from the through hole.

[0042] In practice, the sliding contact of the sliding rheostat is connected to the drive mechanism I 422 via the drive component 4203 to achieve mechanical adjustment of the resistance value. An external power supply is electrically connected to the input terminal of the sliding rheostat via a wire, and the output terminal of the sliding rheostat is electrically connected to the electromagnetic coil of the electromagnetic damping brake frame 330 via a wire.

[0043] Please refer toFigure 1 , Figure 3 , Figure 5 The main structure of drive mechanism I 422 is the same as that of drive mechanism II 421, both consisting of hydraulic pipe 4201, sealing slide 4204, and drive component 4203. The difference is that the drive component 4203 of drive mechanism II 421 is connected to the drive end of friction brake frame 320 (if friction brake frame 320 and bracket 200 adopt the rotational connection method described above, then drive component 4203 also needs to be hinged to friction brake frame 320).

[0044] Correspondingly, the drive component 4203 in the drive mechanism II 421 can also be a hydraulic or pneumatic assembly, or a linkage structure.

[0045] In this device, the driving component 4203 of the drive mechanism II 421 adopts a hydraulic assembly, which includes a hydraulic cylinder and a piston rod. The hydraulic cylinder is fixed on the bracket 200, and one end of the piston rod is fixedly connected to the sealing slide 4204, while the other end is hinged to the driving end of the friction brake frame 320. When the sealing slide 4204 moves under the push of hydraulic oil, it can drive the piston rod to extend and retract, thereby pushing the friction brake frame 320 to rotate around the pin, realizing the contact and separation of the friction pad and the brake disc 310.

[0046] Furthermore, to ensure the sequential operation of the electromagnetic deceleration mechanism and the friction braking mechanism, and to closely match the actual working environment on site, this device has a sleeve 4202 sealed and fixedly connected to the outside of each hydraulic pipe 4201, forming an annular cavity between the sleeves.

[0047] Meanwhile, the device has a connecting groove through the side end of the hydraulic pipe 4201. The connecting groove and the sleeve 4202 (annular chamber) are on the same vertical plane, that is, the annular chamber is connected to the flow groove 4205, which is used to contain the hydraulic oil flowing out of the hydraulic pipe 4201.

[0048] Furthermore, the projection of the sealing plug 4204 on the vertical plane overlaps with the projection of the corresponding flow groove 4205 on the vertical plane. As the sealing plug 4204 slides along the axial direction of the hydraulic tank, the overlapping area of ​​the sealing plug 4204 and the flow groove 4205 changes accordingly. This causes the sealing plug 4204 in the drive mechanism I 422 to move after the drive pump station 410 fills the hydraulic pipe 4201 in the drive mechanism I 422 with hydraulic oil. Since the inflow is greater than the outflow, the sealing plug 4204 in the drive mechanism I 422 moves at this time, and the shielding effect of the sealing plug 4204 on the flow groove 4205 is weakened until the size of the sealing plug 4204 and the outlet of the hydraulic pipe 4201 are matched. This can be achieved by changing the output power of the drive pump station 410 to change the position of the sliding contact of the resistor 450.

[0049] Accordingly, this device has a liquid outlet on one side of the sleeve 4202. The liquid outlet is connected to the inlet of the hydraulic pipe 4201 of the drive mechanism II 421 through the circulation pipe 440, so as to realize the delivery of hydraulic oil from the drive mechanism I 422 to the drive mechanism II 421. In this process, the greater the output power of the drive pump station 410, the faster the braking speed, thus conforming to the braking control logic of the existing technology device, thereby reducing the need for additional training for workers.

[0050] Correspondingly, a flow groove 4205 is also provided on the side end of the hydraulic pipe 4201, forming an annular chamber with the sleeve 4202. The annular chamber is connected to the inlet of the circulating pump station through the return pipe 470 to realize the circulation and recovery of hydraulic oil.

[0051] In addition, to enhance the hydraulic oil return effect, a circulation pump station can be set up on one side of the drive pump station 410. The circulation pump station adopts a gear pump with the same rated working pressure as the drive pump station 410. It is used to draw the hydraulic oil in the return pipe 470 back to the drive pump station 410 to form a closed-loop circulation of hydraulic oil.

[0052] Furthermore, this device also includes a tension spring 4206 inside each hydraulic pipe 4201. The tension spring 4206 is coaxially disposed on the side of the sealing plug 4204 away from the drive component 4203. One end of the tension spring 4206 is fixed to the inner wall of the closed end of the hydraulic pipe 4201, and the other end is fixed to the end face of the sealing plug 4204. Under normal conditions, the tension spring 4206 is in a stretched state, and its tension pulls the sealing plug 4204 to its initial position.

[0053] Please refer to Figure 1 , Figure 5 , Figure 7 The device also has a delay mechanism 460 in the middle section of the circulation pipe 440. The main purpose of the delay mechanism 460 is to enable the electromagnetic deceleration mechanism to decelerate to the expected level first, and then drive the friction braking mechanism to stop the brake disc 310, so as to avoid the friction braking mechanism from actively intervening before the electromagnetic deceleration mechanism has fully played its role.

[0054] The delay mechanism 460 includes a reservoir 461 and a three-way valve 462. The three ports of the three-way valve 462 are respectively connected to the input end of the circulation pipe 440, the output end of the circulation pipe 440, and the inlet of the reservoir 461. The reservoir 461 has a cylindrical structure, and its volume is determined according to the total oil volume of the hydraulic system, usually 1 / 3 to 1 / 2 of the total oil volume. It is used to temporarily store hydraulic oil to realize the delay function.

[0055] It is particularly important to emphasize that the top of the liquid storage tank 461 is equipped with an air vent valve (this is a conventional technology and is not shown in the figure) to release the air inside the tank and prevent air from affecting the working stability of the hydraulic system.

[0056] In practice, due to the characteristics of fluid flow, after the hydraulic oil flows out of the drive mechanism I 422, it must first be filled into the reservoir 461 to make it full before it can flow into the drive mechanism II 421 to overcome the elastic force brought by the tension spring 4206 inside the drive mechanism II 421, thus forming a delay effect.

[0057] Furthermore, for ease of testing, the delay mechanism 460 also includes a shut-off valve 463. The shut-off valve 463 is located at the outlet of the liquid storage tank 461. The shut-off valve 463 is an electromagnetic shut-off valve, and its outlet is connected to the return pipe 470 through a guide pipe 464. The control terminal of the shut-off valve 463 is electrically connected to the control system, which controls the opening and closing of the valve, thereby controlling the flow between the liquid storage tank 461 and the return pipe 470.

[0058] The core logic of this system's workflow relies on a coordinated linkage mechanism of "hydraulic drive - resistance adjustment - electromagnetic damping - friction braking." It achieves orderly switching between two operating modes by utilizing the restoring force of the tension spring 4206, the pressure difference of the hydraulic oil, the fluid storage buffer of the delay mechanism 460, and the on / off control of the shut-off valve 463. All processes are designed based on the principles of "fitting actual on-site working conditions, reducing manual training costs, and ensuring a smooth braking process," ensuring compatibility with existing braking control logic while resolving issues such as braking shock and poor coordination inherent in traditional devices.

[0059] I. Key Prerequisites: Under normal conditions, the tension spring 4206 provides a continuous reset force to the sealing slide 4204 of the drive mechanisms I 422 and 2 to ensure the stability of the initial state; The hydraulic system adopts a closed-loop circulation design. The drive pump station 410 undertakes the power output task, the circulation pump station is responsible for the recovery of hydraulic oil, and the flow regulating valve controls the injection speed. Electromagnetic damping braking is based on the principle of "eddy current braking". Its efficiency will decrease when running at low speeds, and it needs to be combined with friction braking to achieve complete stopping. The mode switching is triggered by the control system (PLC + touch screen), and the core control components are the three-way valve 462 and the shut-off valve 463. There is no mechanical jamming during the switching process.

[0060] II. Initial Normal State (Mode Not Activated) Under normal conditions, the system does not receive any braking or adjustment commands, and all components are in an initial standby state, as shown below: Status of drive mechanism 420: Drive pump station 410 and circulation pump station are not started, and there is no hydraulic oil pressure in hydraulic pipe 4201; Under the tension of the tension spring 4206, the sealing slide 4204 of the drive mechanism I 422 is in the initial position of the hydraulic pipe 4201 close to the drive pump station 410, completely blocking the flow groove 4205 at the side end of the hydraulic pipe 4201, thereby blocking the annular cavity passage between the hydraulic pipe 4201 and the sleeve 4202. The push rod of drive mechanism I422 is pulled to its maximum stroke due to the reset of the sealing slide 4204, which causes the sliding contact of the sliding rheostat to be at the position of maximum resistance. The sealing slide 4204 of the drive mechanism II 421 is also in the initial position under the tension of the tension spring 4206. The hydraulic components (hydraulic cylinder + piston rod) have no extension force. The friction brake bracket 320 maintains a 2-3mm gap with the brake disc 310 under the action of the return spring, and there is no contact friction phenomenon.

[0061] Electromagnetic deceleration mechanism status: The resistance of the sliding rheostat is at its maximum value. According to Ohm's law, the input current of the electromagnetic coil of the electromagnetic damping brake 330 approaches zero, and the electromagnetic field strength is extremely low. The gap between the electromagnetic coil and the end face of the brake disc 310 is maintained at 0.5-1mm, and no electromagnetic damping force is generated, so the brake disc 310 rotates freely with the wire feeding wheel.

[0062] Delay mechanism 460 status: The shut-off valve 463 is in the closed state by default, and the outlet of the liquid storage tank 461 is blocked; There is no hydraulic oil in the storage tank 461, and the top vent valve is in the normally open position to ensure that the air pressure inside the tank is balanced with the atmospheric pressure.

[0063] Overall effect: The pay-off wheel has no braking resistance, allowing for free winding or releasing of the yarn, making it suitable for scenarios where there is no braking requirement, such as yarn pre-winding and equipment debugging.

[0064] 3. Mode 1: Combined braking mode of "electromagnetic damping + friction braking" (emergency braking scenario) This mode is the core braking mode of the system. The triggering conditions are "the operator issues an emergency stop command through the touch screen" or "the speed of the wire feeding wheel exceeds the preset threshold (triggered by the speed sensor)". The core objective is to "achieve smooth deceleration first and then achieve rapid braking" in order to avoid the wire from stretching and breaking or generating braking impact.

[0065] Phase 1: Start-up of pump station 410 and intervention of electromagnetic damping After receiving the braking command, the control system immediately starts the drive pump station 410, opens the flow regulating valve, and closes the exhaust valve of the liquid storage tank 461 (to prevent hydraulic oil leakage). The drive pump station 410 injects hydraulic oil into the hydraulic pipe 4201 of the drive mechanism I 422. The hydraulic oil acts on the side of the sealing slide 4204 away from the push rod, forming a pressure difference. In the initial stage, the oil injection volume of the drive pump station 410 is greater than the oil output volume of the flow channel 4205 (the sealing slide 4204 still partially covers the flow channel 4205), and the pressure in the hydraulic pipe 4201 gradually increases. When the pressure is greater than the tension of the tension spring 4206, the sealing slide 4204 slowly moves to the push rod side. The movement of the sealing plug 4204 drives the push rod to extend and retract synchronously, pushing the sliding contact of the sliding rheostat to move in the direction of decreasing resistance, and the resistance value connected to the circuit gradually decreases. The electromagnetic coil input current of the electromagnetic damping brake frame 330 increases as the resistance decreases, the electromagnetic field strength is enhanced, the rotating brake disc 310 (copper / aluminum material) cuts the magnetic field to generate eddy currents, the eddy currents interact with the electromagnetic field to form electromagnetic damping force, which hinders the rotation of the brake disc 310, and the wire feeding wheel begins to decelerate smoothly. Synchronization process: During the movement of the sealing plug 4204, the shielding effect on the flow groove 4205 gradually weakens, the effective flow area of ​​the flow groove 4205 increases, and the hydraulic oil in the hydraulic pipe 4201 of the drive mechanism I 422 flows into the annular chamber of the sleeve 4202 through the flow groove 4205, and then flows through the circulation pipe 440 to the delay mechanism 460. At this time, the shut-off valve 463 remains closed, and the three-way valve 462 maintains the connection between the circulation pipe 440 and the storage tank 461. Under these circumstances, hydraulic oil cannot flow to the drive mechanism II 421, but can only be injected into the storage tank 461 for storage, thereby initiating the buffer delay process.

[0066] Phase 2: Filling of storage tank 461 and continuous electromagnetic deceleration Hydraulic oil is continuously injected into the reservoir 461. During the initial filling process, air inside the reservoir is expelled through the vent valve. When the hydraulic oil level rises below the vent valve, the vent valve automatically closes to prevent hydraulic oil from overflowing.

[0067] During the filling process, the sealing slide 4204 inside the drive mechanism II 421 remains in its initial position under the action of the tension spring 4206, and the friction brake frame 320 does not move.

[0068] The electromagnetic damping brake continues to operate. As the drive pump station 410 continues to inject hydraulic oil, the sealing slide 4204 continues to move, the resistance of the sliding rheostat further decreases, the current of the electromagnetic coil increases, the electromagnetic damping force is enhanced, and the speed of the wire reel continues to decrease.

[0069] In terms of key control, the hydraulic oil injection speed is controlled by a flow regulating valve. The faster the injection speed, the faster the sealing slide 4204 moves, the faster the resistance decreases, the more rapidly the electromagnetic damping force increases, and the faster the wire feeding reel decelerates; conversely, the deceleration is more gradual. Operators can make flexible adjustments according to the material of the cable (e.g., fragile cables require slow deceleration).

[0070] Phase 3: Liquid storage tank 461 is filled and friction braking is activated. When the hydraulic oil in the reservoir 461 is full, the hydraulic oil can no longer be injected, and the pressure in the circulation pipe 440 rises sharply.

[0071] High-pressure hydraulic oil flows rapidly into the hydraulic pipe 4201 of the drive mechanism II 421 through the circulation pipe 440, acting on the side of the sealing slide 4204 away from the hydraulic components. As the pressure gradually increases and exceeds the tension of the tension spring 4206, the sealing slide 4204 moves towards the hydraulic components.

[0072] The movement of the sealing plug 4204 causes the piston rod of the hydraulic cylinder to extend and retract, and the piston rod pushes the friction brake bracket 320 to rotate around the pin (because the friction brake bracket 320 is hinged to the bracket 200, the rotation is smooth). The friction pads gradually approach the end face of the brake disc 310 and finally fit tightly together.

[0073] In terms of synchronization, the two sets of braking systems on both sides of the 200 are activated synchronously. The electromagnetic damping force and friction force are superimposed to ensure that the pay-off wheel has no sway or jamming, and there is no instantaneous tension peak at the line take-up and pay-off ends.

[0074] Phase 4: System Reset After the reel comes to a complete stop, the speed sensor detects that the rotation speed is zero and sends a reset signal to the controller, or the operator issues a reset command through the touch screen.

[0075] The controller stops the drive pump station 410 from working, closes the flow regulating valve, closes the three-way valve 462 and the shut-off valve 463, and opens the vent valve of the storage tank 461.

[0076] As the pressure in the hydraulic system gradually decreases, the sealing slide 4204 of drive mechanism I 422 and drive mechanism II 421 resets under the tension of the tension spring 4206, and the sealing slide 4204 re-covers the flow groove 4205.

[0077] The push rod of drive mechanism I422 is reset, the sliding rheostat contact returns to the position of maximum resistance, the electromagnetic coil current returns to near zero, and the electromagnetic damping force disappears.

[0078] The friction brake bracket 320 rotates and resets under the action of the return spring, separating the friction pads from the brake disc 310 and restoring the initial clearance.

[0079] When the circulating pump station starts, it draws the hydraulic oil from the return pipe 470, the annular chamber of the sleeve 4202, and the storage tank 461 back to the drive pump station 410, completing the closed-loop recovery of hydraulic oil. The system then returns to its normal initial state and awaits the next instruction.

[0080] Mode 2: "Individual Electromagnetic Damping" Adjustment Mode (Speed ​​Control / Line Testing Scenarios) The trigger condition for this mode is "the operator selects a separate electromagnetic damping mode via the touchscreen". The core objective is "precise control of the rotation speed and resistance of the pay-off reel". It is suitable for scenarios such as line elongation performance testing, deformation capacity testing, or routine line take-up and pay-off speed adjustment. The specific process is as follows: Phase 1: Mode Switching and Hydraulic System Start-up The operator inputs the "Individual Electromagnetic Damping Mode" command via the touchscreen and sets the target rotational speed (or resistance value). Upon receiving the command, the controller performs the following operations: Open the shut-off valve 463 to fully connect the outlet of the liquid storage tank 461 with the return pipe 470.

[0081] The three-way valve 462 is controlled to maintain the connection between the circulation pipe 440 and the storage tank 461, forming a hydraulic oil passage of "drive mechanism I 422 → circulation pipe 440 → storage tank 461 → shut-off valve 463 → return pipe 470 → circulation pump station → drive pump station 410".

[0082] Start the drive pump station 410 and the circulation pump station, open the flow regulating valve, and set the hydraulic oil injection speed (positively correlated with the target resistance).

[0083] Hydraulic oil is injected into the hydraulic pipe 4201 of the drive mechanism I 422 through the inlet pipe 430, and acts on the sealing slide 4204. When the pressure exceeds the tension of the tension spring 4206, the sealing slide 4204 moves to the push rod side, the shielding effect of the flow groove 4205 is weakened, and the hydraulic oil flows into the storage tank 461 through the flow groove 4205 and the circulation pipe 440, and is then recovered by the circulation pump station through the shut-off valve 463 and the return pipe 470, forming a continuous closed loop circulation.

[0084] Phase Two: Electromagnetic Damping Adjustment and Speed ​​Control The movement of the sealing slider 4204 drives the push rod to extend and retract, and the resistance value of the sliding rheostat changes with the displacement of the sealing slider 4204. The faster the injection speed, the greater the displacement of the sealing slider 4204, the smaller the resistance, the greater the current in the electromagnetic coil, and the stronger the electromagnetic damping force.

[0085] The electromagnetic damping force acts directly on the rotating brake disc 310, generating a resistance torque in the opposite direction of rotation, causing the rotational speed of the wire feeding wheel to gradually decrease to the target value.

[0086] A speed sensor detects the rotational speed of the wire-feeding reel in real time and feeds the signal back to the controller. The controller dynamically adjusts the injection rate of the hydraulic oil by regulating the opening of the flow control valve, thereby fine-tuning the electromagnetic damping force to achieve closed-loop speed control. Details are as follows: If the rotation speed is higher than the target value: increase the injection speed → decrease the resistance → increase the current → increase the damping force → decrease the rotation speed; If the rotational speed is lower than the target value: reduce the injection speed → increase the resistance → decrease the current → weaken the damping force → increase the rotational speed.

[0087] Critical condition: Due to the continuous recovery of hydraulic oil through the return pipe 470, the hydraulic pipe 4201 of the drive mechanism II 421 cannot build up sufficient pressure. The sealing plug 4204 is always in the initial position under the action of the tension spring 4206. The friction brake bracket 320 does not move, and only the electromagnetic damping force plays a role.

[0088] Phase 3: Line Testing and Adaptation When the system is used for testing the elongation performance and deformation capacity of lines, the process can be further adapted.

[0089] The test line is wound around the pay-off reel. The operator gradually increases the hydraulic oil injection speed via the touch screen, and the electromagnetic damping force increases simultaneously. The rotational resistance of the pay-off reel gradually increases, and the line is subjected to continuous tension.

[0090] The test is completed by recording the elongation and deformation of the thread under different resistances (tensions) using external testing equipment (such as tension sensors and length measuring instruments).

[0091] During the test, the injection speed can be adjusted in real time to simulate the working state of the line under dynamic tension, and the data stability is better than the traditional manual adjustment method.

[0092] Phase Four: Mode Exit and Reset After the speed control or test is completed, the operator issues a stop command, and the controller shuts down the drive pump station 410 and the circulation pump station, and closes the flow regulating valve and the shut-off valve 463.

[0093] The sealing slide 4204 of the drive mechanism I 422 is reset under the tension of the tension spring 4206, the resistance of the sliding rheostat returns to its maximum value, and the electromagnetic damping force disappears.

[0094] The residual hydraulic oil in the hydraulic system is recovered to the drive pump station 410 by the circulating pump station, and the system returns to its normal initial state. It can be switched to other modes or shut down.

[0095] Switching control logic between the two modes The core of the system's two-mode switching lies in the on / off state of the shut-off valve 463 and the connection direction of the three-way valve 462. The switching process is automatically executed by the control system without mechanical interference, and the switching response time is ≤0.5s. The specific switching logic is as follows: Switching from "Normal Initial State" to "Combined Braking Mode" Trigger signal: Emergency braking command (manual / automatic).

[0096] Controller actions: Close the shut-off valve 463 to block the passage between the liquid storage tank 461 and the return pipe 470; Three-way valve 462 keeps “circulation pipe 440-storage tank 461” connected → hydraulic oil is preferentially charged into storage tank 461; Start the drive pump station 410 → inject hydraulic oil into drive mechanism I 422 → electromagnetic damping engages → friction braking engages after the storage tank 461 is full.

[0097] Key to switching: Ensure the delay mechanism buffers 460 degrees first to prevent premature intervention of friction braking.

[0098] Switching from "normal initial state" to "independent electromagnetic damping mode" Trigger signal: Individual electromagnetic damping command (manual).

[0099] Controller actions: Open the shut-off valve 463 → open the passage between the liquid storage tank 461 and the return pipe 470; Three-way valve 462 keeps “circulation pipe 440-storage tank 461” connected → hydraulic oil forms a closed loop circulation; Synchronously start drive pump station 410 and circulation pump station → hydraulic oil injection drive mechanism I 422 → electromagnetic damping only intervenes.

[0100] Key switching point: Ensure that the drive mechanism II 421 is pressure-free and the friction brake bracket 320 does not operate.

[0101] Switching from "Independent Electromagnetic Damping Mode" to "Combined Braking Mode" Triggering scenario: An emergency occurs during line testing, requiring immediate cessation of operations.

[0102] Controller actions: Close the shut-off valve 463 to cut off the passage between the liquid storage tank 461 and the return pipe 470; Keep the drive pump station 410 running (no need to stop it), and keep the hydraulic oil injection volume unchanged or increase it; The reservoir 461 begins to fill with liquid, and the original circulating hydraulic oil gradually accumulates. After the reservoir 461 is full, the three-way valve 462 switches to "circulation pipe 440 - drive mechanism II 421" and friction braking engages.

[0103] Switching advantages: No need to interrupt electromagnetic damping, directly superimposed friction braking, faster braking, no secondary impact on the line.

[0104] Switching from "Combined Braking Mode" to "Individual Electromagnetic Damping Mode" Triggering scenario: After an emergency stop, the pay-off reel needs to be restarted for rotation to conduct line testing; The controller performs the corresponding action: First, perform a combined braking mode reset operation (drive pump station 410 stops running → sealing slide 4204 resets → electromagnetic damping disappears). Open the shut-off valve 463 → Start the drive pump station 410 and the circulation pump station → Achieve closed-loop circulation of hydraulic oil → Introduce electromagnetic damping; Precautions during switching: Always perform the switching operation only after completing the reset operation to avoid damage to components due to the superposition of hydraulic system pressure.

[0105] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A braking system for a wire feeding frame, comprising a wire feeding wheel with a bracket (200) respectively disposed at each of its two axial ends, and a braking system disposed on each of the two side brackets (200), characterized in that: The braking system includes a braking device (300) and a braking device (400), wherein the braking device (300) includes a brake disc (310), an electromagnetic deceleration mechanism and a friction braking mechanism. The electromagnetic deceleration mechanism and the friction braking mechanism are respectively disposed on the left and right sides of the brake disc (310), and the friction braking mechanism includes a friction brake frame (320); The electromagnetic deceleration mechanism includes an electromagnetic damping brake frame (330) and a resistor (450). An external power source is electrically connected to the input terminal of the resistor (450), and the output terminal of the resistor (450) is electrically connected to the electromagnetic damping brake frame (330). The higher the current received by the electromagnetic damping brake frame (330), the stronger its deceleration effect on the brake disc (310).

2. The braking system for a wire feeding frame according to claim 1, characterized in that: The braking device (400) includes two driving mechanisms (420), and the resistor (450) is a sliding rheostat. The driving mechanism (420) located on one side of the resistor (450) is driving mechanism I (422). Driving mechanism I (422) is used to adjust the resistance value of the sliding rheostat. At the same time, driving mechanism II (421) is used to adjust the distance between the friction brake frame (320) and the brake disc (310).

3. A braking system for a wire-feeding frame according to claim 2, characterized in that: The drive mechanism I (422) includes a hydraulic pipe (4201), and a sealing plug (4204) is slidably connected inside the hydraulic pipe (4201). The sealing plug (4204) is connected to the sliding contact of the resistor (450) through the drive member (4203). A drive pump station (410) for storing hydraulic oil is provided on one side of the hydraulic pipe (4201). The output end of the drive pump station (410) is connected to the inner cavity of the hydraulic pipe (4201) through the infusion pipe (430). The connection position between the output end of the drive pump station (410) and the hydraulic pipe (4201) and the drive component (4203) are located on both sides of the sealing slide (4204).

4. A braking system for a wire feeding frame according to claim 3, characterized in that: The drive mechanism II (421) has the same structure as the drive mechanism I (422). The drive mechanism II (421) includes a hydraulic pipe (4201), a sealing slide (4204), and a drive component (4203). The sealing slide (4204) in the drive mechanism II (421) is connected to the friction brake frame (320) through the corresponding drive component (4203).

5. A braking system for a wire feeding frame according to claim 4, characterized in that: The drive mechanism I (422) and drive mechanism II (421) also include a sleeve (4202) sleeved on the outside of the hydraulic pipe (4201). The sleeve (4202) corresponding to drive mechanism I (422) is connected to the inlet end of the hydraulic pipe (4201) corresponding to drive mechanism II (421) through a circulation pipe (440). The sleeve (4202) corresponding to drive mechanism II (421) is connected to the inlet of drive pump station (410) through a return pipe (470). Each of the hydraulic pipes (4201) has a flow groove (4205) extending through its side end. The flow groove (4205) and the corresponding sleeve (4202) are on the same vertical plane. At the same time, the projection of each sealing plug (4204) on the vertical plane overlaps with the projection of the corresponding flow groove (4205) on the vertical plane. As the sealing plug (4204) slides along the axial direction of the hydraulic pipe (4201), the overlap area between the sealing plug (4204) and the flow groove (4205) changes accordingly. Each of the sealing slides (4204) is coaxially provided with a tension spring (4206) on the side away from the corresponding drive member (4203), and the tension spring (4206) is used to reset the sealing slide (4204).

6. A braking system for a wire feeding frame according to claim 5, characterized in that: The circulation pipe (440) is connected to a delay mechanism (460) in the middle section. The delay mechanism (460) includes a liquid storage tank (461) and a three-way valve (462). The three-way valve (462) is connected to the inlet of the circulation pipe (440) and the liquid storage tank (461) respectively.

7. A braking system for a wire feeding frame according to claim 6, characterized in that: The outlet of the storage tank (461) is connected to a shut-off valve (463), and the outlet of the shut-off valve (463) is connected to the return pipe (470) through a guide pipe (464).

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