High-speed shaft locker testing device and use method thereof

Abstract

The invention relates to the field of high-speed shaft locker testing, in particular to a high-speed shaft locker testing device and a using method thereof.The high-speed shaft locker testing device comprises a motor speed reducer, an output shaft of the motor speed reducer is connected with a transmission shaft, a locker is installed on the transmission shaft, and the transmission shaft is rotationally arranged on a base; the motor speed reducer is mounted on the base; a proximity switch I and a proximity switch II which are used for monitoring the action of the piston are mounted on the locker; the first proximity switch, the second proximity switch and a hydraulic station externally connected with the locking device are all electrically connected to a controller. The motor reducer and the transmission shaft are stably supported through the base, the problem of transmission offset caused by vibration easily generated by temporary supporting is avoided, and it is ensured that the actual operation state of the high-speed shaft of the press can be accurately simulated; according to the application method, the test process can be traced, and the problems that the traditional test condition simulation is not real and the performance verification is not comprehensive are effectively solved.

Description

Technical Field

[0001] This invention relates to the field of high-speed shaft locking device testing, and in particular to a high-speed shaft locking device testing apparatus and its usage method. Background Technology

[0002] In the forging industry, presses are core processing equipment, and their operational stability and safety directly affect production efficiency and personnel safety. As presses develop towards higher speeds and greater precision, high-speed shaft locking devices, due to their high precision, fast response, and ability to lock at any position, have become crucial components for ensuring equipment safety. They must quickly lock the high-speed shaft during press start-up, shutdown, and emergency stops to prevent accidents caused by shaft inertial rotation; their reliability is paramount to the press's safety system.

[0003] The increasing safety standards for presses in the industry have made performance testing of high-speed shaft locking devices during factory shipment and maintenance increasingly urgent. Testing needs to simulate the actual operating conditions of the high-speed shaft (such as dynamic speed and random stop positions) to verify the locking device's response speed, locking effectiveness, and release smoothness. However, existing tests are mostly piecemeal checks of single performance characteristics, lacking dedicated equipment that can completely simulate real-world working conditions and integrate transmission, support, and monitoring functions, making it difficult to meet the needs of systematic verification.

[0004] The existing testing scheme has key flaws that lead to insufficient testing accuracy: First, the transmission components lack stable integrated support, and temporary supports are prone to vibration causing the transmission shaft to shift, making it impossible to accurately simulate actual operation; second, the locking / releasing action of the locking piston lacks real-time monitoring components, and relying solely on manual observation is prone to misjudgment; third, the motor reducer drive, hydraulic control, and action monitoring are not uniformly linked, making it difficult to achieve the timing coordination of "run-stop-lock-release," and making it impossible to accurately detect the locking performance at any position. This may lead to the use of unqualified locking devices, creating safety hazards for the press. Summary of the Invention

[0005] To address the problems of existing testing solutions, such as the lack of stable integrated support for transmission components, the absence of real-time monitoring components, and the lack of unified linkage between motor reducer drive, hydraulic control, and motion monitoring, this invention provides a high-speed shaft locking device testing device and its usage method.

[0006] To solve the above problems, the technical solution adopted by the present invention is as follows: A high-speed shaft locking device testing apparatus includes a motor reducer, an output shaft of which is connected to a drive shaft, and a locking device mounted on the drive shaft. The drive shaft is rotatably mounted on a base. The motor reducer is mounted on the base. Proximity switches one and two for monitoring piston movement are mounted on the locking device. Proximity switches one and two, and an external hydraulic station connected to the locking device, are all electrically connected to a controller. The base stably supports the motor reducer and drive shaft, avoiding transmission misalignment caused by vibrations from temporary supports, ensuring accurate simulation of the actual operating state of the high-speed shaft of the press. Proximity switches one and two monitor the locking and releasing actions of the locking device piston in real time, eliminating the risk of misjudgment of the action state. Simultaneously, the controller links the motor reducer, hydraulic station, and proximity switches to achieve sequential coordinated control of "simulated operation - arbitrary stop - locking - releasing," effectively solving the core problem of existing tests' difficulty in accurately detecting the locking performance of the locking device at any position, improving test accuracy and reliability, and providing stable and accurate test assurance for the performance verification of high-speed shaft locking devices.

[0007] Preferably, the base includes two opposing mounting plates; the two mounting plates are connected by two upright plates; the upright plates are vertically connected to the side walls of the mounting plates; the drive shaft is rotatably mounted on the two mounting plates. This base, with the two upright plates vertically connected to the opposing mounting plates, forms a rigid and stable frame structure, effectively improving the overall load-bearing capacity and vibration resistance, and preventing transmission misalignment due to base deformation during testing. Simultaneously, the rotatable mounting of the drive shaft on the two mounting plates provides support at both ends of the drive shaft, reducing radial runout during operation and ensuring the coaxiality of the drive shaft with the motor reducer and locking device. This provides stable and reliable structural support for accurately simulating high-speed shaft operation and subsequent locking tests.

[0008] Preferably, the drive shaft includes a first connecting shaft and a second connecting shaft, coaxially connected by screws; the output shaft of the motor reducer is connected to the first connecting shaft; the locking device is mounted on the second connecting shaft; the first connecting shaft is rotatably mounted on one of the mounting plates, and the second connecting shaft is rotatably mounted on the other mounting plate. This drive shaft adopts a coaxial, screw-connected, and separate structure for the first and second connecting shafts, which facilitates alignment of the motor reducer output shaft and the locking device during assembly, and also facilitates subsequent individual disassembly, maintenance, or replacement of the corresponding shaft sections, reducing overall maintenance costs. Simultaneously, the first and second connecting shafts are rotatably mounted on two separate mounting plates, forming independent supports at both ends, effectively reducing radial runout during drive shaft operation, ensuring stable power transmission from the motor reducer to the locking device, and providing a reliable transmission foundation for accurately simulating high-speed shaft operation and locking performance testing.

[0009] Preferably, connecting shaft one is mounted on one of the mounting plates via bearing one, and connecting shaft two is mounted on the other mounting plate via bearing two. The locking device is mounted on the mounting plate with screws and also on connecting shaft two via a key. Connecting shaft one and connecting shaft two are mounted on the mounting plates via bearing one and bearing two, respectively. Bearing one and bearing two provide stable sliding support, which reduces frictional loss during shaft operation and accurately positions the radial position of the shaft to ensure coaxiality of the two shafts, avoiding transmission misalignment from affecting test accuracy. The locking device is fixed to the mounting plate with screws for a secure assembly, and at the same time, it cooperates with connecting shaft two via a key to ensure accurate relative position between the locking device and the shaft, so that the locking action can be accurately applied to connecting shaft two, and to transmit the torque during shaft operation. The overall structure ensures transmission stability and reliability of locking test, laying the foundation for accurate verification of locking device performance.

[0010] Preferably, the motor reducer is mounted on the mounting plate via a bracket. Mounting the motor reducer on the mounting plate via a bracket ensures a stable assembly of the motor reducer, guarantees the coaxiality of its output shaft and connecting shaft, prevents offset or vibration during power transmission, and provides reliable support for stable operation of the transmission shaft and the accuracy of subsequent testing.

[0011] A method for using a high-speed shaft locking device, applied to the aforementioned high-speed shaft locking device, includes the following steps: S1 System Preparation: Fix the base of the test device to the laboratory floor with expansion bolts; connect the hydraulic system and the locking device pipeline, ensuring that there is no leakage in the pipeline, and at the same time, electrically connect proximity switch one, proximity switch two and the hydraulic system to the controller respectively. S2 simulates high-speed shaft operation: The controller sends a start command to the motor reducer, which drives the motor reducer to rotate the connecting shaft one and the connecting shaft two synchronously, so that the speed of the connecting shaft two reaches the preset simulated speed, in order to simulate the actual operating state of the high-speed shaft of the press. S3 Arbitrary Position Stop and Locking Test: The controller sends a controlled stop command to the motor reducer, causing connecting shaft one and connecting shaft two to stop synchronously with the motor reducer to any preset angle; then the controller sends a locking command to the hydraulic system, and the hydraulic system supplies hydraulic oil to the locking device through pipelines, driving the piston and clutch ring inside the locking device to move, realizing the spline engagement of the clutch ring with the hub on connecting shaft two; after proximity switch one detects the locking device locking signal, it feeds the signal back to the controller, and the controller records the successful locking status and completes the count; if proximity switch one does not have a locking signal within 3 seconds, it will immediately determine failure and control the hydraulic system to cut off the oil; S4 Release Test: When connecting shaft two needs to be released, the controller sends a release command to the hydraulic system. The hydraulic system delivers hydraulic oil to the locking device through another independent pipeline, driving the piston and clutch ring to move in opposite directions, causing the clutch ring to disengage from the hub. After proximity switch two detects the release signal, it feeds the signal back to the controller, which records the release success status. S5 Cyclic Test and Data Processing: Repeat steps S2 to S4 to complete the preset number of "run-stop-lock-release" cyclic tests. The controller records the stopping angle, locking response time, release response time, and success / failure status of each test in real time. After the test is completed, the test data is exported and processed.

[0012] This method is highly compatible with the high-speed shaft locking device testing equipment. First, S1 ensures the device is securely assembled and the piping and circuit connections are reliable, laying a stable foundation for testing. Then, S2 accurately simulates the actual operating state of the high-speed shaft of the press. Combined with S3-S4, it achieves fully automated control of the entire process of "stop-lock-release at any position," relying on proximity switches to provide real-time feedback on the action status and the controller to synchronously record the results, avoiding misjudgments from manual observation. Finally, S5 performs a cyclical test covering multiple operating conditions, completely recording key data such as the stopping angle and response time. The overall process efficiently and accurately verifies the locking reliability and responsiveness of the locking device at any position, while also ensuring traceability of the testing process, effectively solving the problems of unrealistic simulation of operating conditions and incomplete performance verification in traditional testing methods.

[0013] Preferably, step S1 further includes: checking the hydraulic oil level and temperature in the hydraulic system to ensure the level is within the preset range and the oil temperature is 5-60℃; starting the hydraulic system under no-load operation, verifying the smooth operation of the hydraulic pump and control valve, and then adjusting the no-load pressure of the hydraulic system to 0.5-1MPa; manually triggering proximity switch one and proximity switch two to confirm that their signals can be transmitted normally to the controller. The supplementary operations in step S1 can eliminate potential problems in advance: checking the hydraulic oil level and temperature and adjusting the no-load pressure ensures the hydraulic system is in a stable working state, avoiding lock / release failure due to abnormal oil parameters or unstable pressure; manually verifying the proximity switch signal transmission confirms the normal function of the monitoring components in advance, preventing missed detection of the action status due to switch failure in subsequent tests. These operations further solidify the testing foundation, ensuring the accuracy and reliability of the subsequent "run-lock-release" full-process test, and avoiding test errors or interruptions caused by insufficient preparation in the early stages.

[0014] Preferably, step S2 further includes: the controller monitors the operating current of the motor reducer and the actual speed of the second connecting shaft in real time. If the deviation between the actual speed and the preset simulated speed exceeds ±5%, or the operating current exceeds 1.1 times the rated current of the drive motor, the controller immediately sends a speed reduction command to the drive motor and triggers an audible and visual alarm. After the fault is cleared, step S2 is re-executed. The supplementary operation of step S2 achieves dual protection by monitoring the speed and current in real time: firstly, by controlling the deviation between the actual speed of the second connecting shaft and the preset value to not exceed ±5%, the accuracy of the high-speed shaft operation state simulation is ensured, and the speed distortion is avoided from affecting the authenticity of the locking test; secondly, by limiting the motor current to not exceed 1.1 times the rated value, the motor reducer is prevented from being overloaded and damaged, protecting the equipment safety; and thirdly, the speed can be reduced and an alarm is triggered in time when there is an abnormality, which facilitates rapid troubleshooting and ensures that subsequent tests are carried out under normal operating conditions, further improving the stability of the test process and the accuracy of the results.

[0015] Preferably, step S3 further includes: after connecting shaft one and connecting shaft two stop rotating, the controller confirms the deviation between the stopping angle and the preset angle through the shaft angle detection component. If the deviation exceeds ±1°, the controller determines that the stopping has failed and re-executes steps S2 to S3; if proximity switch one does not provide a locking signal within the preset 3-second timeout threshold, the controller determines that the locking has failed, triggers an alarm, and cuts off the hydraulic system's oil supply to the locking device. The supplementary operation in step S3 can accurately control the key prerequisites and abnormal handling of the locking test: by confirming that the stopping angle deviation does not exceed ±1°, it ensures that "stopping at any position" is highly consistent with the actual working conditions of the press, avoiding distortion of the locking test results due to angle deviation; if proximity switch one does not provide a locking signal within 3 seconds, it promptly determines failure and cuts off the oil supply, which can quickly identify locking device action delay or failure problems, prevent invalid tests from continuing, and avoid damage to components due to excessive oil supply from the hydraulic system. The overall operation further improves the accuracy and safety of the locking test, ensuring that the test results can truly reflect the locking performance of the locking device at any position.

[0016] Preferably, an emergency shutdown procedure is also included: At any stage of steps S2 to S4, if the motor reducer current exceeds 1.5 times the rated current, the hydraulic system pressure exceeds 1.2 times the preset locking pressure, or the operator presses the emergency stop button, the controller immediately sends an emergency shutdown command to the motor reducer, cuts off the hydraulic system power supply, activates an audible and visual alarm, and records the cause and time of the emergency shutdown. This emergency shutdown procedure precisely covers key risk scenarios in the test. It achieves automatic emergency response to equipment abnormalities by monitoring motor reducer overcurrent (exceeding the rated current by 1.5 times) and hydraulic system overpressure (exceeding the preset locking pressure by 1.2 times), while also retaining a manual emergency stop operation channel. Upon triggering, it can immediately stop the machine and cut off the hydraulic power supply to quickly eliminate the risk source, preventing equipment overload damage or pressure runaway leading to safety accidents. Simultaneously, the audible and visual alarms can promptly remind on-site personnel, and recording the shutdown cause and time facilitates subsequent fault investigation, effectively ensuring the safety of equipment and personnel during the test and improving the overall risk control capability and problem traceability of the test.

[0017] As can be seen from the above technical solutions, the advantages of the present invention are: 1. The base provides stable support for the motor reducer and drive shaft, avoiding transmission misalignment caused by vibrations from temporary supports, ensuring accurate simulation of the actual operating state of the high-speed shaft of the press; proximity switches one and two monitor the locking and releasing actions of the locking piston in real time, eliminating the risk of misjudgment of the action state; at the same time, the controller links the motor reducer, hydraulic station, and proximity switches to achieve sequential coordinated control of "simulated operation - arbitrary stop - locking - releasing", effectively solving the core problem that existing tests cannot accurately detect the locking performance of the locking device at any position, improving the accuracy and reliability of the test, and providing a stable and accurate test guarantee for the performance verification of the high-speed shaft locking device.

[0018] 2. This method is highly compatible with the high-speed shaft locking device testing equipment. First, S1 ensures the device is securely assembled and the piping and circuit connections are reliable, laying a stable foundation for testing. Then, S2 accurately simulates the actual operating state of the press's high-speed shaft. Combined with S3-S4, it achieves fully automated control of the entire process of "stop-lock-release at any position," relying on proximity switches to provide real-time feedback on the action status and the controller to synchronously record the results, avoiding misjudgments from manual observation. Finally, S5 performs a cyclical test covering multiple operating conditions, completely recording key data such as the stopping angle and response time. The overall process efficiently and accurately verifies the locking reliability and responsiveness of the locking device at any position, while also ensuring traceability of the testing process, effectively solving the problems of unrealistic simulation of operating conditions and incomplete performance verification in traditional testing methods. Attached Figure Description

[0019] To more clearly illustrate the technical solution of the present invention, the accompanying drawings used in the description will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0021] Figure 2 This is a side view of the structure of the present invention.

[0022] Figure 3 This is a cross-sectional view of the proximity switch of the present invention.

[0023] Explanation of reference numerals in the attached drawings: 1-motor reducer, 2-bracket, 3-connecting shaft one, 4-connecting shaft two, 5-base, 6-key, 7-bearing bush one, 8-bearing bush two, 9-locking device, 10-proximity switch one, 11-proximity switch two; 501-mounting plate, 502-vertical plate. Detailed Implementation

[0024] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings of the specific embodiments. Obviously, the embodiments described below are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this patent, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this patent.

[0025] like Figure 1 and Figure 2 As shown, a high-speed shaft locking device testing device includes a motor reducer 1, the output shaft of the motor reducer 1 is connected to a transmission shaft, a locking device 9 is installed on the transmission shaft, and the transmission shaft is rotatably mounted on a base 5; the motor reducer 1 is mounted on the base 5; a proximity switch 10 and a proximity switch 11 for monitoring piston movement are installed on the locking device 9; the proximity switch 10, the proximity switch 11, and the hydraulic station external to the locking device 9 are all electrically connected to a controller.

[0026] The device uses base 5 to stably support the motor reducer 1 and the drive shaft, avoiding transmission misalignment caused by vibrations from temporary supports, and ensuring accurate simulation of the actual operating state of the high-speed shaft of the press. It relies on proximity switches 10 and 2 to monitor the locking and releasing actions of the piston of the locking device 9 in real time, eliminating the risk of misjudgment of the action state. Simultaneously, through the controller linking the motor reducer 1, hydraulic station, and proximity switches, it achieves sequential coordinated control of "simulated operation - arbitrary stop - locking - releasing," effectively solving the core problem of existing tests' difficulty in accurately detecting the locking performance of the locking device 9 at any position, improving test accuracy and reliability, and providing stable and accurate test assurance for the performance verification of the high-speed shaft locking device 9.

[0027] In the above configuration, the base 5 includes two opposing mounting plates 501; the two mounting plates 501 are connected by two upright plates 502; the upright plates 502 are vertically connected to the side walls of the mounting plates 501; the drive shaft is rotatably mounted on the two mounting plates 501. The drive shaft includes a first connecting shaft 3 and a second connecting shaft 4, which are coaxially connected by screws; the output shaft of the motor reducer 1 is connected to the first connecting shaft 3; a locking device 9 is mounted on the second connecting shaft 4; the first connecting shaft 3 is rotatably mounted on one of the mounting plates 501, and the second connecting shaft 4 is rotatably mounted on the other mounting plate 501. The first connecting shaft 3 is mounted on one of the mounting plates 501 via a first bearing 7, and the second connecting shaft 4 is mounted on the other mounting plate 501 via a second bearing 8; the locking device 9 is mounted on the mounting plate 501 by screws, and the locking device 9 is mounted on the second connecting shaft 4 via a key 6. The motor reducer 1 is mounted on the mounting plate 501 via a bracket 2.

[0028] The base 5 is vertically connected to the opposing mounting plates 501 via two upright plates 502, forming a rigid and stable frame structure. This effectively improves the overall load-bearing capacity and vibration resistance, preventing transmission offset caused by deformation of the base 5 during testing. Simultaneously, the transmission shaft is rotatably mounted on the two mounting plates 501, providing support at both ends and reducing radial runout during operation. This ensures the coaxiality of the transmission shaft with the motor reducer 1 and the locking device 9, providing stable and reliable structural support for accurate simulation of high-speed shaft operation and subsequent locking tests. The transmission shaft adopts a coaxial and screw-connected split structure of connecting shaft 3 and connecting shaft 4. This facilitates alignment of the output shaft of the motor reducer 1 and the mounting position of the locking device 9 during assembly, and also allows for subsequent individual disassembly, maintenance, or replacement of the corresponding shaft sections, reducing overall maintenance costs. Furthermore, connecting shaft 3 and connecting shaft 4 are rotatably mounted on the two mounting plates 501, forming independent support at both ends. This effectively reduces radial runout during transmission shaft operation, ensuring stable power transmission from the motor reducer 1 to the locking device 9, and providing a reliable transmission foundation for accurate simulation of high-speed shaft operation and locking performance testing. Connecting shaft 3 and connecting shaft 4 are mounted on mounting plate 501 via bearing 7 and bearing 8, respectively. Bearing 7 and bearing 8 provide stable sliding support, reducing frictional loss during shaft operation and accurately positioning the radial position of the shafts to ensure coaxiality and prevent transmission misalignment from affecting test accuracy. Locking device 9 is securely mounted on mounting plate 501 with screws and engages with connecting shaft 4 via key 6, ensuring accurate relative positioning between locking device 9 and the shaft, allowing precise locking action on connecting shaft 4, and transmitting torque during shaft operation. The overall structure ensures transmission stability and reliable locking test, laying the foundation for accurate performance verification of locking device 9. Motor reducer 1 is mounted on mounting plate 501 via bracket 2, ensuring stable assembly of motor reducer 1 and guaranteeing coaxiality between its output shaft and connecting shaft 3. This prevents misalignment or vibration during power transmission, providing reliable support for stable operation of the transmission shaft and subsequent test accuracy.

[0029] The method of using the above-mentioned high-speed shaft locking device includes the following steps: S1 System Preparation: Secure the base 5 of the test device to the laboratory floor using expansion bolts; connect the hydraulic system and the locking device 9 pipelines, ensuring no leaks; simultaneously, electrically connect proximity switch 10, proximity switch 21, and the hydraulic system to the controller; check the hydraulic oil level and temperature in the hydraulic system, ensuring the level is within the preset range and the oil temperature is 5-60℃; start the hydraulic system under no-load operation, verifying the smooth operation of the hydraulic pump and control valves, then adjust the no-load pressure of the hydraulic system to 0.5-1MPa; manually trigger proximity switches 10 and 21 to confirm that their signals can be transmitted normally to the controller. The supplementary operation in step S1 can eliminate potential problems in advance: checking the hydraulic oil level and temperature and adjusting the no-load pressure ensures the hydraulic system is in a stable working state, avoiding locking / releasing failure due to abnormal oil parameters or unstable pressure; manually verifying the proximity switch signal transmission confirms the normal function of the monitoring components in advance, preventing missed detection of the action status due to switch failure during subsequent testing. These operations further solidified the testing foundation, ensuring the accuracy and reliability of subsequent "run-lock-release" full-process testing, and avoiding test errors or interruptions caused by insufficient preparation in the early stages.

[0030] S2 Simulates High-Speed ​​Shaft Operation: The controller sends a start command to the motor reducer 1, which drives the motor reducer 1 to rotate the connecting shaft 3 and connecting shaft 4 synchronously, so that the speed of connecting shaft 4 reaches the preset simulated speed to simulate the actual operating state of the high-speed shaft of the press. The controller monitors the working current of the motor reducer 1 and the actual speed of connecting shaft 4 in real time. If the deviation between the actual speed and the preset simulated speed exceeds ±5%, or the working current exceeds 1.1 times the rated current of the drive motor, the controller immediately sends a speed reduction command to the drive motor and triggers an audible and visual alarm. After the fault is cleared, step S2 is executed again. The supplementary operation in step S2 provides dual protection through real-time monitoring of speed and current: firstly, by controlling the deviation between the actual speed of connecting shaft 2 4 and the preset value to be no more than ±5%, the accuracy of the high-speed shaft operation simulation is ensured, and speed distortion is avoided from affecting the authenticity of the locking test; secondly, by limiting the motor current to no more than 1.1 times the rated value, the motor reducer 1 is prevented from being overloaded and damaged, thus protecting the equipment safety; and thirdly, in case of abnormality, the speed can be reduced in time and an alarm can be triggered, which facilitates rapid troubleshooting and ensures that subsequent tests are carried out under normal operating conditions, further improving the stability of the test process and the accuracy of the results.

[0031] S3 Arbitrary Position Stop and Locking Test: The controller sends a controlled stop command to the motor reducer 1, causing connecting shaft 3 and connecting shaft 4 to stop synchronously with the motor reducer 1 to any preset angle; then the controller sends a locking command to the hydraulic system, which supplies hydraulic oil to the locking device 9 through pipelines, driving the piston and clutch ring inside the locking device 9 to move, realizing the engagement of the clutch ring with the spline 6 of the hub on the connecting shaft 4; after the proximity switch 10 detects the locking device 9 locking in place signal, it feeds the signal back to the controller, and the controller records the signal. The lock is successfully locked and the count is completed. If the proximity switch 10 does not provide a locking signal within 3 seconds, the lock is immediately deemed to have failed and the hydraulic system is shut off. After the connecting shaft 3 and connecting shaft 4 stop rotating, the controller uses the shaft angle detection component to confirm the deviation between the stopping angle and the preset angle. If the deviation exceeds ±1°, the controller determines that the stop has failed and repeats steps S2 to S3. If the proximity switch 10 does not provide a locking signal within the preset 3-second timeout threshold, the controller determines that the lock has failed, triggers an alarm, and cuts off the hydraulic system's oil supply to the locking device 9. The supplementary operation in step S3 can accurately control the six key prerequisites and abnormal handling of the locking test: by confirming that the stopping angle deviation does not exceed ±1°, it ensures that "stopping at any position" is highly consistent with the actual working conditions of the press, avoiding distortion of the locking test results due to angle deviation; if the proximity switch 10 does not provide a locking signal within 3 seconds, the lock is immediately deemed to have failed and the oil supply is cut off, which can quickly identify the locking device 9's action delay or failure, prevent invalid tests from continuing, and avoid damage to components from excessive hydraulic system oil supply. The overall operation further improves the accuracy and safety of the locking test, ensuring that the test results can truly reflect the locking performance of the locking device 9 in any position.

[0032] S4 Release Test: When the connecting shaft 2 4 needs to be released, the controller sends a release command to the hydraulic system. The hydraulic system delivers hydraulic oil to the locking device 9 through another independent pipeline, driving the piston and clutch ring to move in opposite directions, causing the clutch ring to disengage from the hub. After the proximity switch 2 11 detects the release signal, it feeds the signal back to the controller, and the controller records the release success status. S5 Cyclic Test and Data Processing: Repeat steps S2 to S4 to complete the preset number of "run-stop-lock-release" cyclic tests. The controller records the stopping angle, locking response time, release response time, and success / failure status of each test in real time. After the test is completed, the test data is exported and processed.

[0033] In any stage from S2 to S4, if the current of the motor reducer 1 exceeds 1.5 times the rated current, the hydraulic system pressure exceeds 1.2 times the preset locking pressure, or the operator presses the emergency stop button, the controller immediately sends an emergency stop command to the motor reducer 1, cuts off the power supply to the hydraulic system, activates an audible and visual alarm, and records the cause and time of the emergency stop. This emergency stop procedure precisely covers the six key risk scenarios in the test. It achieves automatic emergency response to equipment abnormalities by monitoring the overcurrent of the motor reducer 1 (exceeding the rated current by 1.5 times) and the overpressure of the hydraulic system (exceeding the preset locking pressure by 1.2 times), while also retaining the operation channel for manual emergency stop. After being triggered, it can immediately stop the machine and cut off the hydraulic power supply to quickly cut off the risk source, avoiding equipment overload damage or pressure runaway safety accidents. At the same time, the audible and visual alarm can promptly remind on-site personnel, and recording the cause and time of the stop facilitates subsequent fault investigation, effectively ensuring the safety of equipment and personnel during the test, and improving the overall risk prevention and control capabilities and problem traceability of the test.

[0034] This method is highly compatible with the high-speed shaft locking device testing equipment. First, S1 ensures the device is securely assembled and the piping and circuit connections are reliable, laying a stable foundation for testing. Then, S2 accurately simulates the actual operating state of the press's high-speed shaft. Combined with S3-S4, it achieves fully automated control of the "stop-lock-release at any position" process. Proximity switches provide real-time feedback on the action status, and the controller synchronously records the results, avoiding misjudgments from manual observation. Finally, S5 performs a cyclical test covering multiple operating conditions and fully records key data such as the stopping angle and response time. The overall process efficiently and accurately verifies the locking reliability and responsiveness of the locking device 9 at any position, while also ensuring traceability of the testing process, effectively solving the problems of unrealistic simulations and incomplete performance verification in traditional testing methods.

[0035] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A high-speed shaft locking device testing apparatus, comprising a motor reducer (1), wherein the output shaft of the motor reducer (1) is connected to a transmission shaft, and a locking device (9) is mounted on the transmission shaft, characterized in that, The drive shaft is rotatably mounted on the base (5); the motor reducer (1) is mounted on the base (5); the locking device (9) is equipped with proximity switch one (10) and proximity switch two (11) for monitoring piston action; the hydraulic system connected to proximity switch one (10), proximity switch two (11) and locking device (9) is electrically connected to the controller.

2. The high-speed shaft locking device testing device according to claim 1, characterized in that, The base (5) includes two mounting plates (501) arranged opposite to each other; the two mounting plates (501) are connected by two upright plates (502); the upright plates (502) are vertically connected to the side wall of the mounting plates (501); the drive shaft is rotatably arranged on the two mounting plates (501).

3. The high-speed shaft locking device testing device according to claim 2, characterized in that, The drive shaft includes a coaxially arranged connecting shaft one (3) and connecting shaft two (4) connected by screws; the output shaft of the motor reducer (1) is connected to connecting shaft one (3); the locking device (9) is installed on connecting shaft two (4); connecting shaft one (3) is rotatably installed on one of the mounting plates (501), and connecting shaft two (4) is rotatably installed on the other mounting plate (501).

4. The high-speed shaft locking device testing device according to claim 3, characterized in that, Connecting shaft one (3) is mounted on one of the mounting plates (501) via bearing one (7), and connecting shaft two (4) is mounted on another mounting plate (501) via bearing two (8); locking device (9) is mounted on the mounting plate (501) by screws, and locking device (9) is mounted on connecting shaft two (4) via key (6).

5. The high-speed shaft locking device testing device according to claim 4, characterized in that, The motor reducer (1) is mounted on the mounting plate (501) via the bracket (2).

6. A method of using a high-speed shaft locking device for testing, characterized in that, The high-speed shaft locking device as described in claim 5 is applied to the following steps: S1 System Preparation: Fix the base (5) of the test device to the laboratory floor with expansion bolts; connect the pipeline of the hydraulic system and the locking device (9) to ensure that there is no leakage in the pipeline, and at the same time, electrically connect the proximity switch one (10), proximity switch two (11) and the hydraulic system to the controller respectively; S2 simulates high-speed shaft operation: The controller sends a start command to the motor reducer (1), which drives the motor reducer (1) to drive the connecting shaft one (3) and connecting shaft two (4) to rotate synchronously, so that the speed of connecting shaft two (4) reaches the preset simulated speed, in order to simulate the actual operating state of the high-speed shaft of the press. S3 Arbitrary Position Stop and Locking Test: The controller sends a controlled stop command to the motor reducer (1), causing the connecting shaft 1 (3) and connecting shaft 2 (4) to stop synchronously with the motor reducer (1) to any preset angle; then the controller sends a locking command to the hydraulic system, and the hydraulic system delivers hydraulic oil to the locking device (9) through the pipeline, driving the piston and clutch ring inside the locking device (9) to move, so that the clutch ring and the spline (6) of the wheel hub on the connecting shaft 2 (4) are engaged; after the proximity switch 1 (10) detects the locking signal of the locking device (9) in place, it feeds the signal back to the controller, and the controller records the successful locking status and completes the counting; if the proximity switch 1 (10) does not have a locking signal within 3 seconds, it will promptly determine the failure and control the hydraulic system to cut off the oil; S4 Release Test: When the connecting shaft 2 (4) needs to be released, the controller sends a release command to the hydraulic system. The hydraulic system delivers hydraulic oil to the locking device (9) through another independent pipeline, driving the piston and clutch ring to move in opposite directions, so that the clutch ring is disengaged from the hub. After the proximity switch 2 (11) detects the release signal, it feeds the signal back to the controller, and the controller records the release success status. S5 Cyclic Test and Data Processing: Repeat steps S2 to S4 to complete the preset number of "run-stop-lock-release" cyclic tests. The controller records the stopping angle, locking response time, release response time, and success / failure status of each test in real time. After the test is completed, the test data is exported and processed.

7. The method of using the high-speed shaft locking device according to claim 6, characterized in that, Step S1 also includes: checking the level and temperature of the hydraulic oil in the hydraulic system to ensure that the level is within the preset scale range and the oil temperature is 5-60℃; starting the hydraulic system under no-load operation, verifying that the hydraulic pump and control valve operate smoothly, and then adjusting the no-load pressure of the hydraulic system to 0.5-1MPa; manually triggering proximity switch one (10) and proximity switch two (11) to confirm that their signals can be transmitted normally to the controller.

8. The method of using the high-speed shaft locking device according to claim 6, characterized in that, Step S2 also includes: the controller monitors the working current of the motor reducer (1) and the actual speed of the connecting shaft (4) in real time. If the deviation between the actual speed and the preset simulated speed exceeds ±5%, or the working current exceeds 1.1 times the rated current of the drive motor, the controller immediately sends a speed reduction command to the drive motor and triggers an audible and visual alarm. Step S2 is executed again after the fault is cleared.

9. The method of using the high-speed shaft locking device according to claim 6, characterized in that, Step S3 also includes: after connecting shaft one (3) and connecting shaft two (4) stop rotating, the controller confirms the deviation between the stopping angle and the preset angle through the shaft angle detection component. If the deviation exceeds ±1°, the controller determines that the stopping has failed and re-executes steps S2 to S3. If the proximity switch one (10) does not provide a locking signal within the preset 3s timeout threshold, the controller determines that the locking has failed, triggers an alarm and cuts off the hydraulic system's oil supply to the locking device (9).

10. The method of using the high-speed shaft locking device according to claim 6, characterized in that, It also includes an emergency shutdown procedure: In any stage from step S2 to S4, if the current of the motor reducer (1) exceeds 1.5 times the rated current, the hydraulic system pressure exceeds 1.2 times the preset locking pressure, or the operator presses the emergency stop button, the controller immediately sends an emergency shutdown command to the motor reducer (1), cuts off the power supply to the hydraulic system, and simultaneously activates the audible and visual alarm and records the cause and time of the emergency shutdown.

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