Brake actuator fault detection device and detection method

Abstract

The invention discloses a fault detection device and method for a brake actuator, and belongs to the technical field of fault detection, and the fault detection device comprises a torque sensor, a coupler, a support, a brake controller and an industrial personal computer. The torque sensor is connected with a motor output shaft of the brake actuator through a coupler, fixed to an actuator shell through a support and used for monitoring the output torque of the motor in real time. During detection, an instruction is sent to a brake controller through an industrial personal computer, a closed-loop control mode and an open-loop control mode are adopted respectively, and whether a fault is originated from a motor or a transmission system is accurately positioned by analyzing a corresponding change relation between a torque value and a motor control duty ratio in a specific mode. The method effectively solves the problem that the traditional method cannot detect the small-amplitude accumulated change of the pressure signal and the inconsistency fault of the output torque during the small-duty-ratio stalling of the motor, and realizes the accurate diagnosis and positioning of the fault of the brake actuator.

Description

Technical Field

[0001] This invention belongs to the field of brake actuator fault detection technology, specifically relating to a brake actuator fault detection device and method. Background Technology

[0002] Brake actuators are devices used to provide braking force for aircraft or automobiles. Currently, traditional brake actuator fault detection methods primarily rely on the control system to manage the brake actuator motor and collect the system's brake pressure signal to diagnose the fault. However, this method can only identify obvious faults such as pressure sensor malfunctions and motor failure. For small, cumulative changes in the pressure signal, especially when the motor is in a low duty cycle stall state and the output torque is inconsistent, traditional methods struggle to accurately pinpoint the cause of the fault, failing to meet the fault detection requirements of brake actuators in practical applications. Summary of the Invention

[0003] This invention addresses the shortcomings of existing technologies by providing a brake actuator fault detection device and method. This solves the problem that traditional methods cannot effectively identify faults such as small-amplitude cumulative changes in pressure signals and inconsistent output torque when the motor is stalled at a low duty cycle. These types of faults are common in brake electromechanical actuators and significantly impact their long-term service life; therefore, a detection solution capable of precise fault location is urgently needed.

[0004] The invention content of the brake actuator fault detection device is explained as follows:

[0005] A brake actuator fault detection device, the device comprising:

[0006] A torque sensor, used to detect torque signals;

[0007] The coupling has a motor connection hole at one end, which has two key mounting slots for connecting to the brake actuator motor via a key; and a torque sensor connection hole at the other end, which has four key mounting slots for connecting to the torque sensor input shaft via a key.

[0008] The bracket has a torque sensor connection hole, which is also designed with four flat key mounting slots for connecting to the torque sensor output shaft via flat keys; the bracket also has a bracket fixing slot for connecting the bracket to the brake actuator housing.

[0009] Preferably, the device further includes a brake actuator controller, which can acquire torque sensor signals and calculate and output the motor control duty cycle through a PID control algorithm to achieve closed-loop control; at the same time, the controller can also output a fixed duty cycle for open-loop control.

[0010] Preferably, it also includes an industrial control computer and testing software. The industrial control computer sends a target torque control command to the brake controller for closed-loop control, or sends a motor duty cycle control command for open-loop control through the testing software. The industrial control computer can also display the current torque value of the torque sensor and the current motor control duty cycle output by the brake controller in real time.

[0011] Preferably, the input end of the torque sensor is connected to the output shaft of the brake actuator motor via the coupling, and the output end is connected to the bracket and fixed to the brake actuator housing via the bracket;

[0012] Preferably, the brake actuator has two sets of actuators, namely actuator I and actuator II, each actuator including a motor and a transmission mechanism; the bracket fixing slot on the bracket can adjust the relative position of the bracket and the brake actuator housing, thereby ensuring that the torque sensor can be connected to the motor of actuator I and the motor of actuator II respectively, so as to realize the fault detection of the two actuators;

[0013] Preferably, the torque sensor is capable of monitoring the output torque of the brake actuator motor in real time;

[0014] Preferably, both the sensor input connection hole (torque sensor connection hole) of the coupling and the sensor output connection hole (torque sensor connection hole) of the bracket are designed with four flat key mounting slots to allow for angle adjustment of the torque sensor.

[0015] The above describes the invention content of the brake actuator fault detection device. This invention also provides a brake actuator fault detection method. When the brake actuator experiences a small cumulative change in pressure signal or inconsistent output torque due to motor stall at a low duty cycle, this fault detection device can be used to detect and locate the brake actuator fault, including:

[0016] The torque sensor is connected in series between the brake actuator motor and the housing to be tested via a coupling and a bracket.

[0017] The industrial control computer sends control commands to the brake controller and records the torque value fed back by the torque sensor and the motor control duty cycle output by the brake controller.

[0018] Based on the relationship between the torque value and the motor control duty cycle, the fault is determined to be located in the motor or the transmission system.

[0019] Preferably, the fault determination based on the relationship between the torque value and the motor control duty cycle specifically includes a closed-loop control determination mode:

[0020] The brake controller is controlled to enter a closed-loop control mode to maintain a constant target torque. If the motor control duty cycle continues to increase, it indicates that the motor's output torque capability decreases under low duty cycle conditions, and the motor is determined to be faulty.

[0021] Preferably, the fault determination based on the relationship between the torque value and the motor control duty cycle specifically includes an open-loop control determination mode:

[0022] The brake controller is controlled to enter open-loop control mode to maintain a fixed duty cycle output.

[0023] If the torque value continues to decrease, it is determined to be a motor malfunction;

[0024] If the torque value remains stable, the motor output is normal, and the problem is determined to be a fault in the actuator transmission system.

[0025] Preferably, the brake actuator contains two independent actuators. By adjusting the mounting position of the bracket on the brake actuator housing, each actuator can be independently detected and located using this method, thus completing the fault detection of both actuators of the brake actuator.

[0026] This invention provides a brake actuator fault detection device and method. Its advantages lie in the following: the device connects one end of a torque sensor to the output shaft of the brake actuator motor, and the other end is fixed to the actuator housing via a bracket, thereby monitoring the motor's output torque in real time. By combining a test industrial control computer and a brake controller, closed-loop and open-loop control are implemented on the two sets of actuator mechanisms inside the actuator, respectively. Based on the recorded torque and duty cycle changes, the device accurately determines whether a fault exists in the motor or transmission mechanism. This method effectively solves the problem of accurately locating faults caused by small-amplitude cumulative changes in pressure signals and inconsistent output torque when the motor is stalled at a small duty cycle.

[0027] Other features and advantages of the present invention will be described in detail in the following detailed description section. Attached Figure Description

[0028] The above and other objects, features and advantages of the present invention will become more apparent from the more detailed description of exemplary embodiments of the invention in conjunction with the accompanying drawings, wherein the same reference numerals generally represent the same components in the exemplary embodiments of the invention.

[0029] Figure 1 A front view schematic diagram of a brake actuator fault detection device according to an embodiment of the present invention is shown;

[0030] Figure 2 A schematic diagram of a brake actuator structure according to an embodiment of the present invention is shown;

[0031] Figure 3 A schematic diagram of the coupling structure of a brake actuator fault detection device according to an embodiment of the present invention is shown;

[0032] Figure 4 A schematic diagram of the torque sensor structure of a brake actuator fault detection device according to an embodiment of the present invention is shown;

[0033] Figure 5 A schematic diagram of the support structure of a brake actuator fault detection device according to an embodiment of the present invention is shown;

[0034] Explanation of reference numerals in the attached figures:

[0035] 1. Brake actuator; 2. Coupling; 3. Torque sensor; 4. Brake bracket; 5. Brake controller; 6. Industrial computer. Detailed Implementation

[0036] The following will refer to the appendix. Figures 1 to 5 The present invention will now be described in more detail, with preferred embodiments shown herein. It should be understood that the preferred embodiments are for illustrative purposes only and are not intended to limit the scope of protection of the invention.

[0037] like Figures 1 to 5 As shown, the present invention provides a brake actuator fault detection device, which includes a brake actuator 1, a coupling 2, a torque sensor 3, a bracket 4, a brake controller 5, and an industrial control computer 6.

[0038] The brake actuator 1 contains two independent actuators (actuator I and actuator II), each including a motor and a transmission mechanism. One end of the coupling 2 is coaxially connected to the output shaft of the motor under test (such as the motor of actuator I) in the brake actuator 1 via its motor connection hole and a key, enabling torque transmission. The input shaft of the torque sensor 3 is connected to it via the torque sensor connection hole and a key at the other end of the coupling 2. The output shaft of the torque sensor 3 is connected to the torque sensor connection hole on the bracket 4 via a key. The bracket 4 is fixed to the housing of the brake actuator 1 using fasteners through its bracket fixing slot. Thus, the torque sensor 3 is installed in series between the motor under test and the actuator housing, allowing for real-time and accurate monitoring of the motor's output torque.

[0039] The signal output terminal of the torque sensor 3 is electrically connected to the brake controller 5. The brake controller 5 receives the feedback signal from the torque sensor 3 and is also communicatively connected to the industrial computer 6. The industrial computer 6 runs dedicated testing software to send control commands (such as target torque commands or fixed duty cycle commands) to the brake controller 5, and to display and record in real time the torque value fed back by the torque sensor 3 and the motor control duty cycle output by the brake controller 5.

[0040] The above describes the embodiments of the brake actuator fault detection device in this application. The following describes the brake actuator fault detection method in this application through embodiments. The specific implementation process of the brake actuator fault detection method of this invention is as follows:

[0041] When fault detection is required on a specific actuator of brake actuator 1 (for example, actuator I), the hardware connection is first established: the output shaft of the motor of actuator I is connected to the input end of torque sensor 3 via coupling 2, and the output end of torque sensor 3 is fixed to the actuator housing via bracket 4. Subsequently, the control mode is selected and commands are sent through the test software of industrial control computer 6.

[0042] Example 1: Closed-loop control detection mode

[0043] The industrial computer 6 sends a constant target torque command to the brake controller 5. The brake controller 5 uses a PID control algorithm to dynamically adjust the control duty cycle output to the motor based on the deviation between the actual torque value fed back by the torque sensor 3 and the target torque value, in order to maintain the target torque.

[0044] Fault diagnosis: In this mode, if the system maintains the target torque unchanged, but the motor control duty cycle output by the brake controller 5 continues to increase or is significantly higher than the normal value, it indicates that the output torque capability of the motor under small duty cycle conditions has decreased. In order to maintain the predetermined torque, the drive has to be increased, which can be judged as a motor fault.

[0045] Example 2: Open-loop control detection mode

[0046] The industrial control computer 6 sends a fixed motor duty cycle control command to the brake controller 5. The brake controller 5 maintains this duty cycle constant, driving the motor of actuator I to run.

[0047] Fault diagnosis: In this mode, record and observe the torque value fed back by torque sensor 3.

[0048] If the torque value decreases over time or is significantly lower than the expected value, it is determined to be a motor malfunction.

[0049] If the torque value can remain stable and meet expectations, it indicates that the motor output is normal. The fault may exist in the subsequent transmission system (such as ball screw, reduction mechanism, etc.), which can be determined as a fault in the actuator transmission system.

[0050] By connecting the detection device to the motors of actuator I and actuator II in sequence using the above method, independent and accurate fault detection and location of the two actuators inside brake actuator 1 can be completed, effectively solving the fault diagnosis problem of inconsistent output torque under small-amplitude cumulative changes in pressure signal and low duty cycle stall conditions of motor.

[0051] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A brake actuator failure detection apparatus and method, characterised by, include: A torque sensor (3); a coupling (2) for connecting the motor output shaft of the brake actuator (1) to the input shaft of the torque sensor (3); a bracket (4) for connecting the output shaft of the torque sensor (3) to the housing of the brake actuator (1); a brake controller (5) for signal connection with the torque sensor (3); and an industrial computer (6) for communication connection with the brake controller (5); wherein the brake controller (5) is configured to receive the signal from the torque sensor (3) and perform closed-loop control based on PID control algorithm and open-loop control with fixed output duty cycle respectively; the industrial computer (6) is configured to send control commands to the brake controller (5) and display and record the torque value and motor control duty cycle.

2. The brake actuator fault detection device according to claim 1, characterized in that, One end of the coupling (2) is provided with a motor connection hole for connecting to the output shaft of the motor and having two flat key mounting slots, and the other end is provided with a sensor connection hole for connecting to the input shaft of the torque sensor (3) and having four flat key mounting slots.

3. The brake actuator fault detection device according to claim 1, characterized in that, The bracket (4) is provided with a connection hole for connecting to the output shaft of the torque sensor (3) and having four flat key mounting slots, and a bracket fixing slot for connecting to the housing of the brake actuator (1).

4. A method for detecting brake actuator failure using the device described in any one of claims 1-3, characterized in that, Includes the following steps: The torque sensor (3) is connected in series between the brake actuator motor and the housing to be tested via a coupling (2) and a bracket (4); the industrial control computer (6) sends control commands to the brake controller (5) and records the torque value fed back by the torque sensor (3) and the motor control duty cycle output by the brake controller (5); based on the relationship between the torque value and the motor control duty cycle, the fault is determined to be located in the motor or the transmission system.

5. The brake actuator fault detection method according to claim 4, characterized in that, The fault determination based on the relationship between torque value and motor control duty cycle specifically includes a closed-loop control determination mode: The brake controller (5) is controlled to enter a closed-loop control mode to maintain the target torque constant; If the motor control duty cycle continues to increase, it is determined to be a motor malfunction.

6. The brake actuator fault detection method according to claim 4, characterized in that, The fault determination based on the relationship between torque value and motor control duty cycle specifically includes an open-loop control determination mode: The brake controller (5) is controlled to enter the open-loop control mode to maintain a fixed duty cycle output; If the torque value continues to decrease, it is determined to be a motor malfunction; If the torque value remains stable, it is determined to be a fault in the actuator transmission system.

7. The brake actuator fault detection method according to claim 4, characterized in that, The brake actuator (1) contains two independent actuators. The method involves adjusting the installation position of the bracket (4) to perform independent fault detection and location on each actuator in sequence.

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