Elevator brake with pressure sensor and method for monitoring braking force in real time

Abstract

The invention relates to the technical field of elevator monitoring, and discloses an elevator brake with a pressure sensor and a method for monitoring braking force in real time. The brake comprises a static block, a first movable block, a second movable block, a brake pad, the pressure sensor, a pre-tightening bolt, a connecting bolt, a brake spring, a coil, a brake release rod, a brake wheel and a control module; the middle of the pressure sensor is connected with the second moving block through a connecting bolt, the upper end and the lower end of the pressure sensor are connected with the first moving block through connecting bolts, and the pre-tightening bolt penetrates through the first moving block and the pressure sensor to be fixed to the second moving block. According to the monitoring method, the pre-tightening force F0 and the braking force normal value F1 are calibrated through the control module, the safety threshold value F2 is set, the pressure value F of the pressure sensor is collected in real time, and early warning or shutdown control is achieved according to comparison between the elevator operation time sequence and the set value. Real-time monitoring of the braking force is achieved, the problem that insufficient braking force cannot be found in time through existing regular detection is solved, collected signals are accurate, the structure is simple, debugging and maintenance are convenient, and the safety performance of an elevator is effectively improved.

Description

Technical Field

[0001] This invention relates to the field of elevator monitoring technology, specifically to an elevator brake with a pressure sensor and a method for real-time monitoring of braking force. Background Technology

[0002] The brake is a core safety component in the elevator drive system. The braking force applied to the brake wheel of the drive unit directly determines the elevator's braking performance and operational safety, serving as a crucial line of defense against unexpected car movement and ensuring passenger safety. TSGT7001-2023, the "Elevator Supervision and Periodic Inspection Rules," clearly stipulates that redundant brakes, as the stopping components of the car's unexpected movement protection device, must possess fault monitoring capabilities. When braking force is insufficient or mechanical action fails, they should be able to trigger the door system to close and the elevator's operation restriction mechanism. This places stringent requirements on the reliability and monitorability of the braking force.

[0003] Currently, the industry generally uses a periodic offline verification model for testing elevator braking force. This involves determining whether the braking force meets the standard through fixed-period special inspections, which has significant limitations. Due to the lack of real-time monitoring methods, the braking force may gradually decrease between inspections due to factors such as wear, spring fatigue, and mechanical jamming. These hidden dangers are difficult to detect in time, and once the braking force falls below the safety threshold, it can easily lead to serious safety accidents such as elevator runaway and brake failure. At the same time, existing testing methods cannot provide real-time feedback on the brake's operating status and cannot quickly identify abnormalities such as incomplete brake opening or jamming, making it difficult to meet the dynamic protection requirements for safe elevator operation. Summary of the Invention

[0004] The present invention aims to provide an elevator brake with a pressure sensor and a method for real-time monitoring of braking force, in order to address the problems of existing elevator braking force not being able to be monitored in real time and the difficulty in timely detection of potential faults.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: an elevator brake with a pressure sensor, comprising a stationary block, a first moving block, a second moving block, a brake pad, a pressure sensor, a preload bolt, a connecting bolt, a brake spring, a coil, a release lever, a brake wheel, and a control module; the brake pad is disposed at the contact section between the second moving block and the brake wheel; the middle of the pressure sensor is connected to the second moving block via a connecting bolt; the upper and lower ends of the pressure sensor are connected to the first moving block via a first bolt; the preload bolt passes through the first moving block and the pressure sensor is fixed to the second moving block; a stationary block is connected to the outside of the first moving block; multiple brake springs are connected inside the stationary block and connected to the second moving block; coils are connected to the upper and lower sides inside the stationary block; a release lever is connected to the middle of the outer side of the stationary block; and the pressure sensor is electrically connected to the control module.

[0006] Preferably, as an improvement, the preload bolt is used to apply preload to the pressure sensor to eliminate the influence of pressure sensor deformation on brake performance.

[0007] Preferably, as an improvement, the control module can acquire the pressure signal from the pressure sensor and send a warning signal, a fault signal, or an abnormal action feedback signal to the elevator control system.

[0008] A method for real-time monitoring of braking force based on any of the above-described brakes includes the following steps: S1. When the elevator installation and commissioning are completed and the brake performance is normal, the control module calibrates and records the preload force F0 when the brake is open, and calibrates and records the normal braking force value F1 when the brake is closed. S2. The control module calculates and sets the safety threshold F2; S3. During elevator operation, the control module collects the pressure value F from the pressure sensor in real time and compares it with F0, F1, and F2 according to the elevator operation sequence; S4. Based on the comparison results, the control module sends the corresponding signal to the elevator control system to realize braking force monitoring and elevator operation control.

[0009] Preferably, as an improvement, in step S1, the calibration process is carried out under conditions where the elevator is unloaded and the operating environment is stable.

[0010] Preferably, as an improvement, in step S2, the safety threshold F2 is 60%-80% of the normal braking force value F1.

[0011] Preferably, as an improvement, in step S3, when the elevator stops and the brake is closed, if the pressure value F collected by the pressure sensor is lower than F1, the control module sends a warning signal and the elevator continues to run; if the pressure value F is lower than F2, the control module sends a fault signal and prohibits the elevator from starting and running normally.

[0012] Preferably, as an improvement, in step S3, when the elevator starts running, the brake opens, and the pressure value F collected by the pressure sensor is equal to F0, the elevator runs normally; when the pressure value F is greater than F0, the control module sends an action feedback abnormal signal to stop the elevator.

[0013] Advantages of this solution: It innovatively breaks through the traditional detection mode: Through the integrated design of pressure sensor and brake, it realizes real-time monitoring of braking force, accurately captures hidden faults such as braking force decay and mechanical jamming, meets the requirements of TSGT7001-2023 regulations, solves the core pain point that existing technologies cannot dynamically monitor, and is significantly innovative.

[0014] The structural design combines accuracy and reliability: 1. The pre-tightening bolt design eliminates sensor deformation interference and improves signal acquisition accuracy. The sensor is waterproof and dustproof and adaptable to complex working conditions. The structure is optimized rather than simply superimposed, reflecting a creative design concept.

[0015] 2. Hierarchical control enhances safety and practicality: The "early warning-shutdown" two-level control logic ensures normal elevator operation while preventing serious safety accidents, closely matching actual usage scenarios and making safety protection more flexible and efficient.

[0016] 3. High adaptability and easy industrialization: No need to modify the existing brake core structure, convenient installation and debugging, good compatibility with mainstream elevator host and control system, low maintenance cost, and has broad application prospects and practical value.

[0017] 4. Data traceability expands the value of technology: The control module can retain pressure data and alarm records, providing precise support for maintenance. Compared with a single monitoring solution, it has more comprehensive functions and enhances product competitiveness. Attached Figure Description

[0018] Figure 1 This is a block diagram of the monitoring and control logic in an embodiment of the present invention; Figure 2 This is a schematic diagram of the working process when the brake is opened according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the working process when the brake is closed according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the overall structure of the brake according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the connection structure between the pressure sensor and the moving block in an embodiment of the present invention.

[0019] The reference numerals in the accompanying drawings include: stationary block 1, moving block one 2, moving block two 3, brake pad 4, pressure sensor 5, preload bolt 6, connecting bolt 7, brake spring 8, coil 9, brake release lever 10, first bolt 11, and brake wheel 12. Detailed Implementation

[0020] The following detailed description illustrates the specific implementation method: The basic implementation examples are as follows: Figure 1-5As shown, this test was applied to a traction passenger elevator with a rated load capacity of 1000 kg and a rated speed of 1.75 m / s. The core purpose of the test was to verify the real-time monitoring accuracy of the elevator brake with pressure sensor 5 under no-load, full-load, and braking force decay conditions, as well as the effectiveness of the "early warning-stop" two-level control logic, providing practical application data support for the safety upgrade of the elevator brake. The test baseline conditions were set as follows: rated brake force 3500 N, preload calibration value F0 = 8 N, normal braking force value F1 = 3480 N, safety threshold F2 = 2436 N (70% of F1), simulating two fault scenarios: braking force decay to 2300 N (below F2) and brake mechanical jamming.

[0021] I. Details of the test apparatus configuration An elevator brake with a pressure sensor 5 is installed on the output shaft of the elevator drive unit. It includes a stationary block 1, a first moving block 2, a second moving block 3, a brake pad 4, a pressure sensor 5, a preload bolt 6, a connecting bolt 7, a brake spring 8, a coil 9, a release lever 10, a brake wheel 12, and a control module. The stationary block 1 is made of QT450 ductile iron; the first and second moving blocks 2 and 3 are forged from 45# steel; the brake wheel 12 is made of 40Cr alloy structural steel; the brake pad 4 is made of asbestos-free friction material; the brake spring 8 is made of 65Mn spring steel; the coil 9 is wound with oxygen-free copper enameled wire and wrapped with an epoxy resin insulation layer; the release lever 10 is a machined 45# steel part with a galvanized anti-rust treatment; the pressure sensor 5 is a JLBS-2 type strain gauge pressure sensor; and the control module is an industrial-grade PLC controller.

[0022] Brake pad 4 is located at the contact section between moving block 2 3 and brake wheel 12. The middle part of pressure sensor 5 is fixedly connected to moving block 2 3 by two connecting bolts 7. The upper and lower ends of pressure sensor 5 are fixedly connected to moving block 1 2 by first bolt 11. Pre-tightening bolt 6 passes through moving block 1 2 and pressure sensor 5 and is fixed on moving block 2 3. A stationary block 1 is fixedly connected to the outside of moving block 1 2. The inside of stationary block 1 has two slots. Two brake springs 8 are slidably connected in the two slots. The two brake springs 8 are slidably connected to moving block 2 3. The upper and lower sides of the inside of stationary block 1 are fixedly connected to coils 9. The middle of the outside of stationary block 1 is slidably connected to a release rod 10 in the direction of moving block 1 2. The left side of moving block 1 2 has a wide slot. A connecting plate is connected in the wide slot. The connecting plate is fixedly connected to the left end of release rod 10. An adjusting nut is connected to the right end of release rod 10. Pressure sensor 5 is electrically connected to control module.

[0023] II. Specific Steps of the Experimental Method S1. Magnetic field calibration: Fix the high-precision force gauge (measurement accuracy ±1N) between the brake wheel 12 and the brake pad 4 using a special clamp. Start the elevator brake to close and record the braking force displayed by the force gauge as 3480N. Simultaneously calibrate the normal braking force value F1=3480N of the control module. Then control the brake to open and record the real-time pressure value of the pressure sensor 5 as 8N. Set the preload force F0=8N. The safety threshold F2=3480N×70%=2436N is automatically calculated by the built-in algorithm of the control module. After calibration, remove the force gauge.

[0024] S2. Sample installation and circuit inspection: Confirm that all components of the brake are installed in place, the gap between the brake pad 4 and the brake wheel 12 is 0.3mm, and the pressure sensor 5 is connected to the moving block 2 and the moving block 3 without looseness; check the circuit connection between the control module and the elevator control system, the pressure sensor 5 and the temperature sensor to ensure that there are no short circuits or loose connections, and the insulation resistance is ≥200MΩ.

[0025] S3. Parameter Setting and Operating Condition Simulation: Select "Real-time Monitoring Mode" on the control module touch screen and enable the data recording function; simulate three test operating conditions in sequence: Operating Condition 1: No-load operation (no load in the elevator), control the elevator to run from the 1st floor to the 10th floor and then back to the 1st floor, and record the pressure value collected by pressure sensor 5 and the elevator operating status throughout the process; Operating Condition 2: Full-load operation (carrying 10 test personnel of standard weight (75kg / person), total load 750kg), repeat the operating process of Operating Condition 1 and record relevant data; Operating Condition 3: Fault simulation, by adjusting the adjusting nut, reduce the elasticity of brake spring 8, so that the braking force when the brake is closed is reduced to 2300N (lower than F2), and at the same time simulate the mechanical jamming of the brake (by setting a 0.5mm thick metal sheet between moving block 2 and stationary block 1), start the elevator operation command, and observe the response of the control module and the elevator operating status.

[0026] S4. Test Process Monitoring and Data Recording: During the test, the control module collects pressure and temperature data in real time, recording a set of data every 50ms. The touch screen synchronously displays the pressure curve and operating status. During operation in conditions 1 and 2, the braking force changes and temperature data are monitored in real time; in condition 3, the alarm signal output of the control module and the execution results of the elevator control system are recorded in detail.

[0027] III. Analysis of Experimental Results The key results are as follows: No-load condition (condition 1): When the elevator is running (brake open), the pressure value collected by pressure sensor 5 is stable at 8±0.2N, which is consistent with the preload F0. The elevator starts, runs and stops normally. When the brake is closed, the pressure value is stable at 3478-3482N, with a fluctuation range of ≤4N. The control module has no warning signal output, indicating that the braking force is stable under no-load conditions and the monitoring data is accurate.

[0028] Full load condition (condition 2): The pressure value of the elevator remains stable at 8±0.3N during operation. The braking force when the brake is closed is 3485-3490N, which is slightly higher than that when unloaded (due to the increase in the elevator load, the braking demand is slightly increased), but it is still within the normal range. The elevator runs smoothly without abnormal vibration, which verifies the adaptability of the device under full load conditions.

[0029] Fault simulation condition (condition 3): When the braking force drops to 2300N, the control module immediately issues a "insufficient braking force" fault signal. After receiving the signal, the elevator control system prohibits the elevator from starting, and the touch screen displays the fault code and real-time pressure value. After removing the metal sheet, the brake spring 8 is adjusted to restore the braking force to 3480N, the fault signal is eliminated, and the elevator can operate normally. When simulating mechanical jamming, after the brake opening command is issued, the pressure sensor 5 collects a pressure value of 12N (greater than F0=8N). The control module immediately outputs a "brake action feedback abnormal" signal, the elevator stops running and issues an audible and visual alarm, verifying the effectiveness of safety control under fault conditions.

[0030] Temperature and stability: Throughout the test, the highest temperature near the brake coil 9 and the spring was 58℃, which did not exceed the warning threshold of 80℃. The pressure sensor 5 collected stable data without drift. The control module communicated normally with the elevator control system without signal loss.

[0031] In summary, the pressure sensor 5 of this device collects accurate data, the hierarchical control logic of the control module is reliable, and it can monitor the braking force and action status of the elevator brake in real time. In the event of a fault, it can promptly issue an alarm signal and control the elevator to stop running, effectively ensuring the safety of elevator operation. The device is easy to install, has good compatibility with existing elevator systems, and the testing process has verified its stability and practicality under different working conditions, meeting the actual needs of safe elevator operation.

[0032] The above descriptions are merely embodiments of the present invention, and common knowledge such as specific technical solutions and / or characteristics are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. An elevator brake with a pressure sensor, characterized in that: The system includes a stationary block, a first moving block, a second moving block, a brake pad, a pressure sensor, a preload bolt, a connecting bolt, a brake spring, a coil, a release lever, a brake wheel, and a control module. The brake pad is located at the contact section between the second moving block and the brake wheel. The middle of the pressure sensor is connected to the second moving block via a connecting bolt. The upper and lower ends of the pressure sensor are connected to the first moving block via a first bolt. The preload bolt passes through the first moving block and the pressure sensor is fixed to the second moving block. A stationary block is connected to the outside of the first moving block. Multiple brake springs are connected inside the stationary block and are connected to the second moving block. Coils are connected to the upper and lower sides inside the stationary block. A release lever is connected through the middle of the outer side of the stationary block towards the first moving block and is connected to the first moving block. The pressure sensor is electrically connected to the control module.

2. An elevator brake with a pressure sensor according to claim 1, characterized in that: The preload bolt is used to apply preload to the pressure sensor to eliminate the influence of pressure sensor deformation on brake performance.

3. An elevator brake with a pressure sensor according to claim 2, characterized in that: The control module can collect pressure signals from the pressure sensor and send warning signals, fault signals, or abnormal action feedback signals to the elevator control system.

4. A method for real-time monitoring of braking force based on any one of the brakes described in claims 1-3, characterized in that, Includes the following steps: S1. When the elevator installation and commissioning are completed and the brake performance is normal, the control module calibrates and records the preload force F0 when the brake is open, and calibrates and records the normal braking force value F1 when the brake is closed. S2. The control module calculates and sets the safety threshold F2; S3. During elevator operation, the control module collects the pressure value F from the pressure sensor in real time and compares it with F0, F1, and F2 according to the elevator operation sequence; S4. Based on the comparison results, the control module sends the corresponding signal to the elevator control system to realize braking force monitoring and elevator operation control.

5. The method for real-time monitoring of braking force according to claim 4, characterized in that: In step S1, the calibration process is carried out under conditions of no load on the elevator and a stable operating environment.

6. The method for real-time monitoring of braking force according to claim 5, characterized in that: In step S2, the safety threshold F2 is 60%-80% of the normal braking force value F1.

7. The method for real-time monitoring of braking force according to claim 6, characterized in that: In step S3, when the elevator stops, the brake closes. If the pressure value F collected by the pressure sensor is lower than F1, the control module sends a warning signal and the elevator continues to run. If the pressure value F is lower than F2, the control module sends a fault signal and prohibits the elevator from starting and running normally.

8. The method for real-time monitoring of braking force according to claim 7, characterized in that: In step S3, when the elevator starts running, the brake opens and the pressure value F collected by the pressure sensor is equal to F0, the elevator runs normally; when the pressure value F is greater than F0, the control module sends an action feedback abnormal signal to stop the elevator.

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