Permanent magnet power-off brake test equipment and test method

Abstract

The invention relates to a permanent magnet power-off brake test device and method, and the device comprises a reference platform, a motor, a torque sensor, a brake pad switching shaft, and a brake disc guide rail, and the reference platform is sequentially provided with the motor, the torque sensor, the brake pad switching shaft, and the brake disc guide rail from left to right. The motor is connected with the brake pad coupling shaft through the torque sensor. Wherein the brake pad adapter shaft is used for installing a rotor assembly of the permanent magnet power-off brake, and the brake disc guide rail is used for installing a stator assembly of the permanent magnet power-off brake. The motor, the torque sensor, the brake pad adapter shaft and the brake disc guide rail are sequentially arranged on the reference platform, the rotor assembly of the permanent magnet power-off brake is installed on the brake pad adapter shaft, and the stator assembly of the permanent magnet power-off brake is installed on the brake disc guide rail, so that the permanent magnet power-off brake testing equipment is constructed.

Description

Technical Field

[0001] This invention relates to the field of brake testing technology, and in particular to a test device and test method for a permanent magnet de-energized brake. Background Technology

[0002] Permanent magnet power-off brakes are widely used in servo drive systems, robot actuators, automated equipment, and safety protection systems. They rely on permanent magnet force to achieve braking in the event of a power outage, making them a crucial component for ensuring equipment positioning accuracy and operational safety. Key performance parameters of permanent magnet power-off brakes include dynamic braking torque, static braking torque, and response time. These parameters directly affect the braking reliability and system safety level of the equipment.

[0003] In existing technologies, the performance testing of permanent magnet de-energized brakes mainly employs the following methods: One method is the whole-machine assembly testing method, which involves installing the brake on the whole machine or a simulated load system for overall performance testing. This method has the following problems: the test results are affected by various factors such as the motor, transmission structure, and assembly tolerances, and cannot accurately reflect the actual performance of the brake as a single component; at the same time, the test conditions are limited, making it difficult to accurately obtain the peak torque and response time data during dynamic braking under controllable conditions.

[0004] Secondly, there are dedicated static torque testing devices that apply rotational force to the brake output shaft through levers, weights, or loading mechanisms until slippage occurs to determine the static brake torque. These devices typically only perform static tests and cannot simulate the dynamic braking process of the brake in a rotating state. Furthermore, the loading methods are mostly mechanical, resulting in problems such as high impact, low accuracy, and poor repeatability.

[0005] Thirdly, some simple dynamic testing devices use a common motor to drive the brake to rotate and then cut off the power to perform braking tests. However, these devices generally suffer from insufficient structural rigidity, large vibration interference, and high torque signal noise, making it difficult to accurately capture instantaneous dynamic brake torque; at the same time, they lack the ability to synchronously acquire the triggering time and torque change process, making it impossible to accurately calculate the response time.

[0006] In addition, existing testing equipment usually does not have a structure that can precisely adjust the air gap between the stator assembly and the mover assembly. The air gap adjustment relies on experience or simple mechanical adjustment methods, resulting in insufficient test repeatability and poor test data stability. Summary of the Invention

[0007] The purpose of this invention is to provide a testing device and method for a permanent magnet power failure brake, which can solve or at least alleviate one or more of the above-mentioned problems and other problems existing in the prior art.

[0008] To achieve the aforementioned objectives, a first aspect of the present invention provides a testing device for a permanent magnet de-energized brake, comprising: a reference platform, a motor, a torque sensor, a brake pad adapter shaft, and a brake disc guide rail. The reference platform is provided with the motor, torque sensor, brake pad adapter shaft and brake disc guide rail from left to right. The motor is connected to the brake pad adapter shaft via the torque sensor.

[0009] The brake pad adapter shaft is used to install the mover assembly of the permanent magnet power failure brake, and the brake disc guide rail is used to install the stator assembly of the permanent magnet power failure brake.

[0010] In the permanent magnet power failure brake test equipment described above, optionally, the output end of the motor is connected to the first end of the torque sensor via a first coupling, and the second end of the torque sensor is connected to the brake pad adapter shaft via a second coupling.

[0011] In the permanent magnet power failure brake testing equipment described above, the first coupling and the second coupling may optionally be rigid couplings.

[0012] In the permanent magnet power failure brake test equipment described above, optionally, a first fixed base is provided on the reference platform, the first fixed base being used to place the motor.

[0013] In the permanent magnet power failure brake test equipment described above, optionally, a second fixed base is provided on the reference platform, the second fixed base being used to place the torque sensor.

[0014] In the permanent magnet power failure brake test equipment described above, optionally, an adjustment unit is provided on the brake disc guide rail, the adjustment unit being used to adjust the air gap distance between the stator assembly and the mover assembly.

[0015] In the permanent magnet power failure brake test equipment described above, optionally, a laser tracker is provided on the reference platform, the laser tracker being used to obtain the air gap distance between the stator assembly and the mover assembly.

[0016] According to a second aspect of the present invention, a method for testing the dynamic brake torque based on a permanent magnet de-energized brake testing device is also provided, comprising the following steps: S1: Install the moving part assembly of the permanent magnet power failure brake on the brake pad adapter shaft, install the stator assembly of the permanent magnet power failure brake on the brake disc guide rail, and adjust the air gap distance between the stator assembly and the moving part assembly through the adjustment unit; S2: Start the motor and drive the brake pad adapter shaft to rotate at a preset speed so that the mover assembly reaches a stable operating state; S3: When the moving part is running stably, the permanent magnet de-energizer is triggered to cut off the power, so that the stator part and the moving part can generate a braking effect. At the same time, the torque data during the braking process is collected by the torque sensor. S4: Extract the instantaneous maximum torque value during the braking process from the collected torque data, and determine the instantaneous maximum torque value as the dynamic brake torque.

[0017] The dynamic brake torque test method described above may optionally include the following steps: S5: Record the time when the permanent magnet de-energizer is de-energized as T0; S6: Based on the collected torque data, determine the time corresponding to when the torque rises to 90% of the instantaneous maximum torque value as T1; S7: Calculate the time difference Δt between T1 and T0, Δt = T1 - T0, and determine the time difference as the electromechanical integrated response time of the permanent magnet de-energized brake.

[0018] According to a third aspect of the present invention, a static brake torque testing method based on a permanent magnet de-energized brake testing device is also provided, comprising the following steps: S1: Install the moving part assembly of the permanent magnet power failure brake on the brake pad adapter shaft, install the stator assembly of the permanent magnet power failure brake on the brake disc guide rail, and adjust the air gap distance between the stator assembly and the moving part assembly through the adjustment unit; S2: When the permanent magnet de-energized brake is in the braking state, control the motor to output the initial driving torque, and apply torque through the brake pads to the axial moving part assembly; S3: Gradually increase the output torque of the motor, and monitor the output torque in real time through the torque sensor; S4: When the test shows that the moving part starts to rotate, record the torque value at that moment and determine the torque value as the static brake torque.

[0019] Compared with the prior art, the beneficial effects of the present invention are: This invention utilizes a brake pad adapter shaft for mounting the brake mover assembly and a brake disc guide rail for mounting the brake stator assembly. This allows the mover and stator assemblies to be independently installed and coordinated on the testing equipment, enabling performance testing of permanent magnet de-energized brakes without relying on the entire system, thus improving the relevance and accuracy of the testing. The brake pad adapter shaft is driven to rotate by a motor, and torque sensors collect torque change data in real time during braking. The instantaneous maximum torque is extracted as the dynamic braking torque, accurately reflecting the braking performance of the permanent magnet de-energized brake under rotational conditions. By recording the braking trigger moment and the torque rise process, the moment when the torque reaches a certain percentage of its peak value is determined, and the time difference between the two is calculated, thus obtaining the electromechanical response time of the permanent magnet de-energized brake. By controlling the motor to gradually increase the output torque and monitoring torque changes in real time, the stress torque value is recorded as the static braking torque when the mover assembly begins to rotate. This avoids the problems of large impact and low measurement accuracy associated with traditional mechanical loading methods, improving the stability and repeatability of the test results. Attached Figure Description

[0020] Figure 1 This is a perspective view of the permanent magnet power-off brake testing equipment of the present invention; Figure 2 for Figure 1 Enlarged view of point A in the middle; Figure 3 This is a front view of the permanent magnet power-off brake testing equipment of the present invention.

[0021] In the diagram: 1. Reference platform; 11. Optical platform; 12. Support column; 2. Motor; 3. Torque sensor; 4. Brake pad adapter shaft; 5. First coupling; 6. Second coupling; 7. Brake disc guide rail; 8. First fixed base; 81. Horizontal plate; 82. Vertical plate; 83. Reinforcing plate; 9. Second fixed base; 91. Vertical support structure; 92. Top mounting seat; 10. Rectangular base plate; 13. Slider structure; 14. Mounting plate; 15. Locking mechanism. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] It should be noted that in the description of this invention, the terms "upper," "lower," "front," "rear," "left," "right," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. The terms "first," "second," and similar words used in the description of this invention do not indicate any order, quantity, or importance, but are only used to distinguish different components, and therefore should not be construed as limiting this invention.

[0024] Furthermore, it should be understood that, for ease of description, the dimensions of the various components shown in the accompanying drawings are not drawn to actual scale; for example, the thickness or width of some layers may be exaggerated relative to other layers.

[0025] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined or described in one figure, it will not need to be discussed or described in detail in the description of the subsequent figures.

[0026] See Figure 1-3 According to one aspect of the present invention, a permanent magnet power failure brake testing device is provided, comprising: a reference platform 1, a motor 2, a torque sensor 3, a brake pad adapter shaft 4, and a brake disc guide rail 7.

[0027] The reference platform 1 is equipped with a motor 2, a torque sensor 3, a brake pad adapter shaft 4, and a brake disc guide rail 7, arranged from left to right.

[0028] In this embodiment, the reference platform 1 is an optical platform 11. In other possible embodiments, a granite platform or a precision welded base with the same high flatness, high rigidity, and high damping characteristics can also be used. Specifically, the reference platform 1 is a rectangular optical platform 11 with four support columns 12 and a rectangular support plate on the upper part. A motor 2 is installed on the leftmost side. The motor 2 is a servo motor with a precise speed and torque control mode. The servo motor is connected to one end of the torque sensor 3 through a first coupling 5. A second coupling 6 is installed on the other end of the torque sensor 3. A brake pad adapter shaft 4 is provided on the outer end of the second coupling 6. The mover assembly of the permanent magnet de-energized brake is installed on the brake pad adapter shaft 4. The mover assembly is a brake pad. The stator assembly of the permanent magnet de-energized brake is installed on the brake disc guide rail 7 located on the rightmost side. The stator assembly is a magnetic yoke / coil assembly. By starting the servo motor, the servo motor drives the input shaft of the torque sensor 3 to rotate through the first coupling 5. The output shaft of the torque sensor 3 drives the brake pad adapter shaft 4 through the second coupling 6, which in turn drives the moving part of the permanent magnet power failure brake mounted on the brake pad adapter shaft 4 to rotate, thereby creating the operating scenario of the permanent magnet power failure brake for subsequent performance testing.

[0029] Therefore, this application sets up a brake pad adapter shaft 4 for mounting the brake mover assembly and a brake stator assembly for mounting the brake disc guide rail 7, so that the mover assembly and the stator assembly can be installed and cooperated independently on the test equipment. This allows the performance test of the permanent magnet de-energized brake to be performed without relying on the whole system, thus improving the relevance and accuracy of the test.

[0030] Specifically, in this embodiment, mounting holes are provided on the reference platform 1. A rectangular base plate 10 is installed at the middle position of the upper surface of the reference platform 1. The rectangular base plate 10 is fixed to the reference platform 1 by bolts engaging with the mounting holes. The servo motor is mounted on the rectangular base plate 10 via a first fixed base 8, the torque sensor 3 is mounted on the rectangular base plate 10 via a second fixed base 9, and the brake disc guide rail 7 is also mounted on the rectangular base plate 10. The first fixed base 8 and the second fixed base 9 ensure that the output shaft of the servo motor and the measuring shaft inside the torque sensor 3 are coaxially aligned to guarantee the stability of torque transmission. The first fixed base 8 includes a vertical plate 82 and a horizontal plate 81. The horizontal plate 81 is mounted on the reference platform 1, and the vertical plate 82 is mounted on the horizontal plate 81. The vertical plate 82 and the horizontal plate 81 are fixedly connected in an L-shape. The servo motor is mounted on the vertical plate 82, and a reinforcing plate 83 is provided between the vertical plate 82 and the horizontal plate 81. The top of the second fixed base 9 is attached to the bottom of the torque sensor 3. The housing of the torque sensor 3 can be fixed to the top of the second fixed base 9 by means of bolts or other methods, and the specific fixing method is not limited. Specifically, the second fixed base 9 includes an I-shaped vertical support structure 91 and a top mounting seat 92. The vertical support structure 91 is used to increase the installation height of the torque sensor 3, so that the measuring axis of the torque sensor 3 can be coaxially arranged with the output shaft of the servo motor. The top mounting seat 92 is used to install and fix the housing of the torque sensor 3. The torque sensor 3 has high frequency response characteristics and is used to measure torque and speed signals synchronously in real time. In other possible embodiments, a combination of a separate high-response torque sensor and a high-resolution encoder can be used to achieve the same function.

[0031] Furthermore, in this embodiment, both the first coupling 5 and the second coupling 6 are rigid couplings. Rigid couplings ensure high transmission stability between the servo motor and the torque sensor 3, and between the torque sensor 3 and the brake pad adapter shaft 4. A standardized interface is provided on the end of the brake pad adapter shaft 4 furthest from the torque sensor 3. This standardized interface is used for quick installation of the mover assembly of different models of permanent magnet de-energized brakes.

[0032] In addition, in this embodiment, an adjustment unit is provided on the brake disc guide rail 7. The adjustment unit is a slider structure 13, which can slide along the brake disc guide rail 7. The stator assembly is mounted on the slider structure 13, thereby driving the stator assembly mounted thereon to adjust its position along the axial direction of the brake pad adapter shaft 4, so as to change the relative position between the stator assembly and the mover assembly, thereby adjusting the air gap distance between them. In addition, the slider structure 13 is provided with a locking mechanism 15, which is used to lock and fix the slider structure 13 after the air gap adjustment is completed. Specifically, the brake disc guide rail 7 is a block structure with a guide groove on it along the axial direction of the brake pad adapter shaft 4. The slider structure 13 cooperates with the guide groove and can slide along the guide groove. At the same time, a mounting plate 14 is provided on the top of the slider structure 13, which is used to install the stator assembly. The locking mechanism 15 is a locking screw type locking mechanism 15. The screw passes through the slider structure 13 and the brake disc guide rail 7 to form a clamping force, thereby locking the position of the slider structure 13.

[0033] The air gap distance between the stator assembly and the mover assembly, as mentioned above, is detected by a laser tracker mounted on the reference platform 1. Before testing the permanent magnet de-energized brake, the position of the stator assembly is adjusted by moving the slider structure 13, and the air gap distance between the stator assembly and the mover assembly is tested using the laser tracker, thereby accurately setting the air gap. In subsequent tests, the air gap distance can be measured again using the laser tracker, thus achieving air gap reproduction.

[0034] According to another aspect of the present invention, a test method based on a permanent magnet power failure brake test device is also provided, the test method including dynamic brake torque test and static brake torque test.

[0035] During the dynamic brake torque test, the servo motor is started, driving the brake pad adapter shaft 4 to rotate at a preset speed, thereby rotating the mover assembly and bringing it to a stable operating state, for example, 500 / 1000 / 1500 RPM. When the mover assembly is running stably, the permanent magnet de-energized brake is de-energized, causing braking between the stator and mover assemblies. Torque change data during braking is collected by torque sensor 3. The instantaneous maximum torque value occurring during braking is extracted from the collected torque data and determined as the dynamic brake torque of the permanent magnet de-energized brake.

[0036] Furthermore, the electromechanical response time of the permanent magnet power failure brake can also be tested. When the permanent magnet power failure brake is triggered to disconnect power, the power-off time is recorded as T0. Based on the collected torque data, the time corresponding to the torque rising to 90% of the instantaneous maximum torque value is determined as T1. By calculating the time difference Δt between T1 and T0 (Δt = T1 - T0), the electromechanical response time of the permanent magnet power failure brake can be obtained.

[0037] During the static brake torque test, with the permanent magnet de-energized brake in the braking state, the servo motor is controlled to output an initial driving torque, which is applied to the mover assembly through the brake pad adapter shaft 4. The driving torque output by the servo motor is gradually increased, while the output torque and the rotational speed of the mover assembly are monitored in real time by the torque sensor 3. When the mover assembly begins to rotate (the acquired rotational speed signal jumps from 0 to a small but measurable non-zero value), the torque value at that moment is recorded, and this torque value is determined as the static brake torque of the permanent magnet de-energized brake.

[0038] Therefore, this application uses a servo motor to drive the brake pad adapter shaft 4 to rotate, and a torque sensor 3 to collect torque change data in real time during the braking process. The instantaneous maximum torque is extracted as the dynamic brake torque, which accurately reflects the braking performance of the permanent magnet de-energized brake in rotational states. By recording the braking trigger moment and the torque rise process, the moment when the torque reaches a certain percentage of its peak value is determined, and the time difference between the two is calculated, thus obtaining the electromechanical response time of the permanent magnet de-energized brake. By controlling the servo motor to gradually increase the output torque and monitoring torque changes in real time, the stress torque value is recorded as the static brake torque when the mover assembly begins to rotate. This avoids the problems of large impact and low measurement accuracy of traditional mechanical loading methods, improving the stability and repeatability of the test results.

[0039] Based on the above embodiments of the present invention, a permanent magnet de-energized brake testing device is constructed by sequentially arranging a servo motor, a torque sensor 3, a brake pad adapter shaft 4, and a brake disc guide rail 7 on a reference platform 1, mounting the mover assembly of the permanent magnet de-energized brake on the brake pad adapter shaft 4, and mounting the stator assembly of the permanent magnet de-energized brake on the brake disc guide rail 7. This device enables dynamic braking torque testing, static braking torque testing, and electromechanical integrated response time testing of the permanent magnet de-energized brake, thereby allowing for performance testing of the permanent magnet de-energized brake.

[0040] 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 testing device for a permanent magnet de-energized brake, characterized in that, include: Reference platform (1), motor (2), torque sensor (3), brake pad adapter shaft (4), brake disc guide rail (7). The reference platform (1) is provided with the motor (2), torque sensor (3), brake pad adapter shaft (4), and brake disc guide rail (7) from left to right. The motor (2) is connected to the brake pad adapter shaft (4) via the torque sensor (3). The brake pad adapter shaft (4) is used to install the mover assembly of the permanent magnet power failure brake, and the brake disc guide rail (7) is used to install the stator assembly of the permanent magnet power failure brake.

2. The permanent magnet de-energized brake testing equipment as described in claim 1, characterized in that, The output end of the motor (2) is connected to the first end of the torque sensor (3) through the first coupling (5), and the second end of the torque sensor (3) is connected to the brake pad adapter shaft (4) through the second coupling (6).

3. The permanent magnet de-energized brake testing equipment as described in claim 2, characterized in that, The first coupling (5) and the second coupling (6) are rigid couplings.

4. The permanent magnet de-energized brake testing equipment as described in claim 1, characterized in that, The reference platform (1) is provided with a first fixed base (8), which is used to place the motor (2).

5. The permanent magnet de-energized brake testing equipment as described in claim 1, characterized in that, The reference platform (1) is provided with a second fixed base (9), which is used to place the torque sensor (3).

6. The permanent magnet de-energized brake testing equipment as described in claim 1, characterized in that, An adjustment unit is provided on the brake disc guide rail (7), which is used to adjust the air gap distance between the stator assembly and the mover assembly.

7. The permanent magnet de-energized brake testing equipment as described in claim 6, characterized in that, A laser tracker is provided on the reference platform (1), which is used to obtain the air gap distance between the stator assembly and the mover assembly.

8. A dynamic brake torque testing method based on a permanent magnet de-energized brake testing device, characterized in that, Using the permanent magnet power-off brake test equipment as described in any one of claims 1-7, the following steps are included: S1: Install the moving part of the permanent magnet de-energized brake onto the brake pad adapter shaft (4), install the stator part of the permanent magnet de-energized brake onto the brake disc guide rail (7), and adjust the air gap distance between the stator part and the moving part through the adjustment unit; S2: Start the motor (2) to drive the brake pad adapter shaft (4) to rotate at a preset speed, so that the moving part assembly reaches a stable operating state; S3: When the moving part is running stably, the permanent magnet de-energizer is triggered to cut off the power, so that the stator part and the moving part can generate a braking effect. At the same time, the torque data during the braking process is collected by the torque sensor (3). S4: Extract the instantaneous maximum torque value during the braking process from the collected torque data, and determine the instantaneous maximum torque value as the dynamic brake torque.

9. The dynamic brake torque testing method as described in claim 8, characterized in that, It also includes the following steps: S5: Record the time when the permanent magnet de-energizer is de-energized as T0; S6: Based on the collected torque data, determine the time corresponding to when the torque rises to 90% of the instantaneous maximum torque value as T1; S7: Calculate the time difference Δt between T1 and T0, Δt = T1 - T0, and determine the time difference as the electromechanical integrated response time of the permanent magnet de-energized brake.

10. A static brake torque testing method based on a permanent magnet de-energized brake testing device, characterized in that, Using the permanent magnet power-off brake test equipment as described in any one of claims 1-7, the following steps are included: S1: Install the moving part of the permanent magnet de-energized brake onto the brake pad adapter shaft (4), install the stator part of the permanent magnet de-energized brake onto the brake disc guide rail (7), and adjust the air gap distance between the stator part and the moving part through the adjustment unit; S2: When the permanent magnet de-energized brake is in the braking state, control the motor (2) to output the initial driving torque and apply torque to the mover assembly through the brake pad adapter shaft (4); S3: Gradually increase the output torque of the motor (2) and monitor the output torque in real time through the torque sensor (3); S4: When the test shows that the moving part starts to rotate, record the torque value at that moment and determine the torque value as the static brake torque.

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