Brake device

Abstract

This application discloses a brake device, comprising: a pressure plate; a dynamic friction plate, stacked on top of the pressure plate; a spring cavity, disposed on the side of the pressure plate away from the dynamic friction plate; a main spring, one end of which abuts against the spring cavity and the other end of which abuts against the pressure plate, and configured to push the pressure plate toward the dynamic friction plate to brake the dynamic friction plate; a cylinder head, disposed on the side of the spring cavity away from the main spring, the cylinder head and the spring cavity forming a gas cavity, the cylinder head being connected to the pressure plate and movable relative to the spring cavity, so as to drive the pressure plate to separate from the dynamic friction plate under the action of the gas pressure in the gas cavity; and a hydraulic cylinder, including a cylinder body mounted outside the cylinder head and a piston rod movably mounted in the cylinder body, the piston rod extending into the gas cavity to drive the pressure plate to separate from the dynamic friction plate by pushing the spring cavity.

Description

Technical Field

[0001] This invention relates to the field of hydraulic braking technology, specifically to a fast-response safety brake device for power-off spring braking and pressurized release in electric excavators used in engineering machinery, petroleum machinery, and mining machinery. Background Technology

[0002] The opening and closing status of traditional pneumatic brake devices is determined by monitoring whether the air pressure has reached the required level using a pressure switch. If the air path becomes blocked due to icing, it will cause the system to misjudge the situation, which may lead to damage to the brake device during operation.

[0003] Existing hydraulic brake devices are all single-disc structures, and generally suffer from slow braking response (even if some hydraulic brake devices have fast response performance, their safety, reliability and the ability to accurately maintain each component need to be effectively improved), numerous monitoring elements and large radial space occupied by the brake disc.

[0004] The existing hydraulic brake device opens the brake device by the piston compressing the spring through the rod chamber of the hydraulic cylinder. There is only one set of piston rod seals between the rod chamber and the brake disc (pressure disc or intermediate disc). Once oil leakage occurs, it can easily cause the brake disc to fail.

[0005] Existing technology cannot monitor in real time the minor oil leaks caused by abnormal wear of the hydraulic cylinder piston seal in the hydraulic brake device. The leaks can only be detected after they are visible. Once the oil leaks onto the brake disc, it will significantly reduce the braking torque and pose a safety risk.

[0006] Current technology cannot use a single sensor to simultaneously monitor the brake device's opening gap, opening and closing status, response time of each braking action, and wear of the entire brake disc after each operation in real time.

[0007] There are other solutions on the market for similar problems, such as monitoring whether the brake device is worn beyond the limit by using limit switches. This solution has the following problems: 1) Limit switches are generally installed on the outside of the brake device, and their retainers are prone to collision deformation or even damage to the sensor.

[0008] 2) Adjusting the installation of limit switches requires a complicated process, which takes a long time to maintain and repair. Furthermore, if an installation error occurs, false alarms are likely to occur during subsequent use, resulting in a high failure rate of the brake device.

[0009] 3) The limit switch can only issue an early warning when the entire brake device wears beyond the limit. It cannot monitor abnormal situations where the brake device is less than the minimum gap, nor can it monitor the amount of wear during each operation of the equipment in real time; nor can it monitor the braking response time of the brake device in real time.

[0010] 4) The most common, effective, and reliable method for real-time monitoring of brake wear and braking response time is to use a magnetostrictive displacement sensor. However, the magnetostrictive displacement sensor has a monitoring blind zone of at least 25-30mm at both ends of the probe, and the signal monitored within the blind zone is inaccurate and unstable. Furthermore, the internal space of a multi-disc brake device is small, so even if a displacement sensor is installed, it cannot reliably and effectively perform its function. Summary of the Invention

[0011] The present invention aims to provide a brake device to improve the problem in the related art where pneumatic brake devices can cause system misjudgment and damage to the brake device during operation if the air passage is blocked by ice.

[0012] According to one aspect of the present invention, a brake device is provided, the brake device comprising: Pressure plate; The dynamic friction disc is stacked with the pressure disc; The spring cavity is located on the side of the pressure plate away from the dynamic friction plate; The main spring has one end abutting against the spring cavity and the other end abutting against the pressure plate, and is configured to push the pressure plate against the moving friction plate to brake the moving friction plate; The cylinder head is located on the side of the spring cavity away from the main spring. The cylinder head and the spring cavity form a gas cavity. The cylinder head is connected to the pressure plate and can move relative to the spring cavity so that under the action of the gas pressure in the gas cavity, it can drive the pressure plate to separate from the dynamic friction plate. A hydraulic cylinder includes a cylinder body mounted outside a cylinder head and a piston rod movably mounted inside the cylinder body. The piston rod extends into a gas chamber to push a pressure plate away from a dynamic friction plate by pressing a spring chamber.

[0013] In some embodiments, the hydraulic cylinder includes a rodless chamber into which hydraulic oil is introduced to push the piston rod toward a spring chamber, the main spring being configured to push the piston rod away from the spring chamber, the hydraulic cylinder also including a rod chamber that receives the piston rod, and the brake device further including a monitoring device for monitoring the amount of hydraulic oil leaking from the rodless chamber to the rod chamber.

[0014] In some embodiments, the monitoring device includes: The housing is connected to the rod chamber and is configured to contain hydraulic oil leaking from the rodless chamber into the rod chamber; The detection component is configured to detect the level of hydraulic oil in the container, and the detection component includes a first oil level sensor and / or a first oil level mirror for observing the oil level in the container.

[0015] In some embodiments, the container also includes an oil drain port communicating with the return oil tank. A first check valve is installed on the oil drain port. The inlet of the first check valve is communicating with the container, and the outlet of the first check valve is communicating with the return oil tank. The oil drain port is configured to deliver hydraulic oil not higher than a first oil level to the return oil tank.

[0016] In some embodiments, the detection component is configured to detect that the hydraulic oil in the reservoir has reached a second oil level, which is higher than the first oil level.

[0017] In some embodiments, the containment further includes a breathing port for communicating the atmosphere with the rod chamber.

[0018] In some embodiments, a second one-way valve is installed on the breathing port, the inlet of the second one-way valve being in communication with the atmosphere, and the outlet of the second one-way valve being in communication with the rod chamber.

[0019] In some embodiments, the brake device further includes a displacement sensor configured to detect the gap between the pressure plate and the cylinder head to determine the opening and closing state of the brake device, the braking response time, and the amount of wear on the pressure plate and / or the dynamic friction plate.

[0020] In some embodiments, the rodless chamber of the hydraulic cylinder is connected to the hydraulic pump via a first control valve and to the return oil tank via a second control valve.

[0021] In some embodiments, bolt holes are provided on the wall of the cylinder body of the hydraulic cylinder, the bolt holes extending from one end of the cylinder body to the other end in the axial direction, and the cylinder body is fixed to the cylinder head by bolts passing through the bolt holes.

[0022] In some embodiments, the cylinder head is provided with a mounting hole for accommodating a hydraulic cylinder, the hydraulic cylinder being detachably mounted on the mounting hole, and the brake device further includes a sealing cover for closing the mounting hole after the hydraulic cylinder has been removed.

[0023] In some embodiments, at least two dynamic friction discs are stacked together, and the brake device further includes an intermediate disc disposed between two adjacent dynamic friction discs. The intermediate disc is connected to the pressure disc so as to move synchronously with the cylinder head.

[0024] In some embodiments, the cylinder head is further provided with an air pipe interface, which is configured to introduce gas to cause the cylinder head to drive the pressure plate to separate from the dynamic friction plate.

[0025] By applying the technical solution of this application, even when the brake device is in a working condition where the air passage is prone to blockage due to icing, the hydraulic cylinder can also realize the state switching of the brake device. Therefore, it improves the problem that the pneumatic brake device will cause the system to misjudge and thus damage the brake device during operation once the air passage is blocked due to icing.

[0026] Other features and advantages of the invention will become clear from the following detailed description of exemplary embodiments of the invention with reference to the accompanying drawings. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the 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.

[0028] Figure 1 A schematic diagram of the structure of a brake device according to some embodiments of the present invention is shown.

[0029] Figure 2 It shows Figure 1 A schematic diagram of the cross-sectional structure at point AA.

[0030] Figure 3 It shows Figure 1 Schematic diagram of the cross-sectional structure at point BB.

[0031] Figure 4 It shows Figure 1 A magnified view of a section at point E in the middle.

[0032] Figure 5 A schematic diagram of the brake device according to an embodiment of the present invention is shown.

[0033] Figure 6 It shows Figure 5 A schematic diagram of the cross-sectional structure at point CC.

[0034] Figure 7 It shows Figure 5 A schematic diagram of the cross-sectional structure at point DD.

[0035] Figure 8 A schematic diagram of the brake device according to other embodiments of the present invention is shown.

[0036] Figure 9 A schematic diagram of the monitoring device of the brake device according to some embodiments of the present invention is shown.

[0037] Figure 10A schematic diagram of the monitoring device of the brake device according to other embodiments of the present invention is shown.

[0038] Figure 11 A schematic diagram of the monitoring device of the brake device according to other embodiments of the present invention is shown.

[0039] Figure 12 A three-dimensional structural schematic diagram of the hydraulic cylinder of the brake device according to some embodiments of the present invention is shown.

[0040] Figure 13 A schematic diagram of the hydraulic cylinder of the brake device according to some embodiments of the present invention is shown.

[0041] Figure 14 It shows Figure 5 A schematic diagram of the cross-sectional structure at point FF.

[0042] Figure 15 A comparison diagram of the hydraulic cylinders of the brake device according to some embodiments of the present invention and conventional hydraulic cylinders is shown.

[0043] Figure 16 A comparison diagram of the hydraulic cylinder of the brake device and the hydraulic cylinder of the transmission is shown in some embodiments of the present invention.

[0044] Figure 17 A schematic diagram of the hydraulic system of the brake device according to some embodiments of the present invention is shown.

[0045] Figure 18 A cross-sectional structural schematic diagram of the hydraulic cylinder of the brake device according to some embodiments of the present invention is shown.

[0046] In the diagram: 1. Displacement sensor; 2. Flange base; 3. Dynamic friction disc; 4. Separation spring; 5. Main spring; 6. Positioning sleeve; 7. Pressure disc; 8. Intermediate disc; 9. Spring cavity; 10. Cylinder head; 11. Pad; 12. Sensor mounting bracket; 13. Air pipe interface; 14. Hydraulic cylinder; 15. Fixing bolt; 16. Sensor seal; 17. Cover; 18. Fixing screw; 19. Fixing sleeve; 20. Spring cavity seal; 21. Measuring rod; 22. Fixing sleeve; 23. Magnetic shielding pad; 24. Magnetic ring; 25. Sealing cover; 26. Sealing ring; 27. Guide post; 28. Housing; 29. ​​Connecting oil pipe; 30. Second unit 31. Check valve; 32. Container; 33. Second oil level; 34. First oil level; 35. First oil level sensor; 36. First oil level mirror; 37. Breather port; 38. Four-way pipe; 39. Bend; 40. Three-way pipe; 41. Second oil level sensor; 42. Second oil level mirror; 43. Hydraulic pump; 44. First control valve; 45. Second control valve; 46. Return oil tank; 141. Cylinder body; 142. Piston rod; 143. Bolt hole; 144. Inlet / outlet; 145. Drain port; 146. Piston; 147. End cap; 148. Piston seal; 149. Piston rod seal; 1410. Buffer groove. Detailed Implementation

[0047] 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. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. 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.

[0048] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0049] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0050] In the description of this application, it should be noted that, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," and "outer," etc., indicating orientation or positional relationships, are only for the convenience of describing this application 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, and therefore should not be construed as a limitation on this application. Furthermore, the terms "first," "second," and "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance. "Vertical" is not vertical in the strict sense, but within the allowable tolerance range. "Parallel" is not parallel in the strict sense, but within the allowable tolerance range.

[0051] The directional terms used in the following description refer to the directions shown in the figures and are not intended to limit the specific structure of this application. It should also be noted in the description of this application that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0052] Unless otherwise specified, the terms "comprising" and "including" as used in this application can be open-ended or closed-ended. For example, "comprising" and "including" can mean that other components not listed may also be included, or that only the listed components may be included.

[0053] Unless otherwise specified, the term "or" is inclusive in this application. For example, the phrase "A or B" means "A, B, or both A and B". More specifically, the condition "A or B" is satisfied by any of the following conditions: A is true (or exists) and B is false (or does not exist); A is false (or does not exist) and B is true (or exists); or both A and B are true (or exist).

[0054] See Figures 1 to 3 The brake device in this embodiment includes a pressure plate 7, a dynamic friction plate 3, a spring cavity 9, a main spring 5, a cylinder head 10, and a hydraulic cylinder 14.

[0055] The dynamic friction disc 3 and the pressure disc 7 are stacked on top of each other. The spring cavity 9 is located on the side of the pressure disc 7 away from the dynamic friction disc 3.

[0056] One end of the main spring 5 abuts against the spring cavity 9, and the other end abuts against the pressure plate 7. The main spring 5 is configured to push the pressure plate 7 toward the moving friction plate 3 to brake the moving friction plate 3.

[0057] The cylinder head 10 is located on the side of the spring cavity 9 away from the main spring 5. The cylinder head 10 and the spring cavity 9 form a gas cavity. The cylinder head 10 is connected to the pressure plate 7 and can move relative to the spring cavity 9 so that under the action of the gas pressure in the gas cavity, it can drive the pressure plate 7 to separate from the dynamic friction plate 3.

[0058] The hydraulic cylinder 14 includes a cylinder body mounted outside the cylinder head 10 and a piston rod movably mounted inside the cylinder body. The piston rod extends into the gas chamber to push the pressure plate 7 away from the dynamic friction plate 3 by pushing the spring chamber 9.

[0059] In this embodiment, when the brake device is in a working condition where it is prone to blockage due to icing of the air passage, the hydraulic cylinder can also realize the state switching of the brake device. Therefore, it improves the problem that if the air passage of the pneumatic brake device is blocked due to icing, the system will misjudge and thus damage the brake device during operation.

[0060] This embodiment of the brake device installs a specially structured cylinder head 10 and hydraulic cylinder 14 on the basis of a pneumatic brake device, enabling the conversion from a pneumatic brake device to a hydraulic brake device without changing the original main braking structure such as the pressure plate 7, main spring 5, and dynamic friction plate 3. Furthermore, while maintaining the advantage of a compact structure in a multi-plate pneumatic brake device, it solves the problems of valve core corrosion and jamming, as well as icing and blockage of the air pipe, that are common in pneumatic brake devices.

[0061] In some embodiments, at least two dynamic friction discs 3 are stacked together, and the brake device further includes an intermediate disc 8 disposed between two adjacent dynamic friction discs 3. The intermediate disc 8 is connected to the pressure disc 7 so as to move synchronously with the cylinder head 10.

[0062] The brake device also includes a flange base 2, which is spaced apart from the pressure plate 7. The dynamic friction plate 3 is located between the flange base 2 and the pressure plate 7. Under the elastic force of the main spring 5, the pressure plate 7 pushes the dynamic friction plate 3 toward the flange base 2.

[0063] A separation spring 4 is provided between the intermediate plate 8 and the flange base 2 to separate the two. A separation spring 4 is also provided between the intermediate plate 8 and the pressure plate 7 to separate the two.

[0064] See Figure 3 The flange base 2 and the spring cavity 9 are fixedly connected by the fixing screw 19, and the pressure plate 7 and the cylinder head 10 are fixedly connected by the fixing bolt 15.

[0065] A positioning sleeve 6 is also fitted onto the fixing bolt 15, and the positioning sleeve 6 is located between the pressure plate 7 and the cylinder head 10. The positioning sleeve 6 is movably connected to the spring cavity 9 so that the cylinder head 10 can drive the pressure plate 7 to move relative to the spring cavity 9, thereby allowing the pressure plate 7 to be pushed against the moving friction plate 3 under the action of the main spring 5.

[0066] See Figures 5 to 7 The cylinder head 10 is also provided with an air pipe interface 13, which is configured to introduce gas so that the cylinder head 10 drives the pressure plate 7 to separate from the dynamic friction plate 3.

[0067] The brake device in this embodiment has a pneumatic release mode and a hydraulic release mode. When the brake device is in the pneumatic release mode, the air pipe interface 13 is connected to the air source through the gas pipeline. The high-pressure gas supplied by the air source enters the gas cavity formed by the cylinder head 10 and the spring cavity 9 through the air pipe interface 13, and drives the cylinder head 10 to separate the pressure plate 7 from the dynamic friction plate 3, thereby releasing the brake.

[0068] In some embodiments, the cylinder head 10 is provided with a mounting hole for accommodating a hydraulic cylinder 14, the hydraulic cylinder 14 being detachably mounted on the mounting hole. The brake device also includes a sealing cover 25 that closes the mounting hole after the hydraulic cylinder 14 has been removed. The brake device also includes a sealing ring 26 that is sleeved outside the mounting hole and located between the sealing cover 25 and the cylinder head 10 to improve the sealing performance of the gas chamber.

[0069] Figure 8 A schematic diagram of the brake device according to other embodiments is shown. The hydraulic cylinder 14 includes a housing 28 and a guide post 27 disposed within and connected to the housing 28. The pressure plate 7, the intermediate plate 8, and the dynamic friction plate 3 are stacked in a direction parallel to the guide post 27, and the pressure plate 7 and the intermediate plate 8 can move along the guide post 27 under the action of the cylinder head 10.

[0070] In this embodiment, the hydraulic cylinder 14 is a single-acting hydraulic cylinder that introduces hydraulic oil only into the rodless chamber. To address the problem in related technologies where leakage of hydraulic oil from the rodless chamber leads to decreased braking performance and poses a risk, the hydraulic cylinder 14 includes a rodless chamber that introduces hydraulic oil to push the piston rod towards the spring chamber 9. The main spring 5 is configured to push the piston rod away from the spring chamber 9. The hydraulic cylinder 14 also includes a rod chamber that accommodates the piston rod. The brake device further includes a monitoring device for monitoring the amount of hydraulic oil leaking from the rodless chamber to the rod chamber.

[0071] In some embodiments, see Figure 9The monitoring device includes a container 31 and a detection component. The container 31 communicates with the rod chamber and is configured to contain hydraulic oil leaking from the rodless chamber to the rod chamber. The detection component is configured to detect the hydraulic oil level within the container 31 and includes a first oil level sensor 35 and / or a first oil level mirror 36 for observing the oil level within the container 31.

[0072] The container 31 is connected to the rod chamber of the hydraulic cylinder 14 via the connecting oil pipe 29. The hydraulic oil leaking from the rodless chamber flows to the container 31 through the connecting oil pipe. The leakage of hydraulic oil in the hydraulic cylinder can be determined by detecting the oil level in the container 31 by the detection component.

[0073] The container 31 also includes an oil drain port connected to the return oil tank 46. A first check valve 34 is installed on the oil drain port. The inlet of the first check valve 34 is connected to the container 31, and the outlet of the first check valve 34 is connected to the return oil tank 46. The oil drain port is configured to deliver hydraulic oil not exceeding the first oil level 33 to the return oil tank 46. See [reference needed] Figure 17 .

[0074] In some embodiments, the detection component is configured to detect that the hydraulic oil in the containment 31 has reached a second oil level 32, which is higher than the first oil level 33.

[0075] In some embodiments, the housing 31 further includes a vent 37 for communicating the atmosphere with the rod chamber.

[0076] In some embodiments, a second one-way valve 30 is installed on the breathing port 37. The inlet of the second one-way valve 30 is in communication with the atmosphere, and the outlet of the second one-way valve 30 is in communication with the rod chamber.

[0077] As described above, the monitoring device includes an oil drain port 145 of the rod chamber of the hydraulic cylinder 14, a connecting oil pipe 29, a housing 31, a first oil level mirror 36, a first oil level sensor 35, a first check valve 34, a second check valve 30, a breather 37, and an air filter element disposed at the breather.

[0078] like Figure 9 As shown, the drain ports 145 of the three hydraulic cylinders 14 on the brake device face downwards (this requirement does not apply to brake devices with a vertically arranged central axis), and the drain port 145 of the rod chamber (as shown) Figure 9 The connecting oil pipe 29 from the piston seal status monitoring port converges into the housing 31, which contains the first oil level sensor 35, the first check valve 34, the second check valve 30, and the first oil level mirror 36.

[0079] The oil drain ports 145 of the rod chambers of all hydraulic cylinders 14 on the brake device are connected in parallel through connecting oil pipes 29 and converge into the housing 31. The upper edge of the housing 31 is lower than the oil drain port 145 of the rod chamber of the lowest hydraulic cylinder 14, ensuring that when the piston seal of the hydraulic cylinder 14 leaks internally, the leaked hydraulic oil flows into the cavity of the housing 31 under the action of gravity.

[0080] Within the normal wear range of the piston seal of the hydraulic cylinder 14 (for example, for a hydraulic cylinder 14 with an inner diameter of 40-90mm, the normal internal leakage is approximately 0.03-0.15ml / min), the internally leaked oil slowly accumulates in the container 31. Each time the brake device releases the brake (i.e., the piston rod of the hydraulic cylinder 14 is pushed out), the piston compresses the air in the rod chamber, causing the pressure in the container 31 to rise. The first one-way valve 34 is opened, draining the hydraulic oil above the first oil level 33 into the return oil tank 46. Therefore, under normal internal leakage, the oil level in the container 31 fluctuates stably around the first oil level 33 and will not trigger a warning.

[0081] When the piston seal of the hydraulic cylinder 14 experiences abnormally severe wear due to frequent and rapid movements, the internal leakage increases sharply. The oil level in the housing 31 rises significantly within a short period, reaching the second oil level 32 (i.e., the installation position of the first oil level sensor 35). At this time, the first oil level sensor 35 sends a signal, and the system generates an early warning, prompting maintenance personnel that the piston seal has worn to the point of needing replacement. This allows for intervention before the braking torque is significantly reduced, ensuring braking safety.

[0082] When the brake device is de-energized (oil is discharged from the rodless chamber) and braking occurs, the main spring 5 pushes the piston rod back into the cylinder body of the hydraulic cylinder 14, increasing the volume of the rod chamber and creating a negative pressure inside the housing 31. The second check valve 30 (whose inlet is connected to the atmosphere and its outlet is connected to the housing 31) is opened, drawing in air filtered by the air filter element to replenish the volume of the chamber.

[0083] When the brake is released, oil enters the rodless chamber to push the piston rod out. The piston compresses the air (and any oil that may be present) in the housing 31, and the pressure in the rod chamber increases. The first check valve 34 is opened, and oil above the first oil level 33 is discharged to the return oil tank 46.

[0084] The above process ensures that the rod chamber of the hydraulic cylinder 14 is always in unidirectional communication with the atmosphere, effectively reducing air resistance during piston reciprocating motion, thereby improving the rapid response performance of the brake device.

[0085] The brake device in this embodiment monitors the early internal leakage of the hydraulic cylinder 14 in real time, enabling early prediction and timely replacement of the piston seal before it completely fails. This method, while avoiding a reduction in braking torque and ensuring braking safety, also effectively reduces air resistance during piston movement, thereby enhancing the rapid braking performance of the brake device. The specific method is as follows: The upper edge of the container 31 is lower than the drain port 145 of the lowest hydraulic cylinder 14. This ensures that if internal leakage occurs in the piston seal of the hydraulic cylinder 14, all the hydraulic oil generated will accumulate in the cavity of the container 31. Under normal circumstances, the hydraulic cylinder 14 of the brake device has a certain internal leakage rate (e.g., for a brake device with an inner diameter of 40-90mm, the normal internal leakage rate of the hydraulic cylinder 14 is approximately 0.03-0.15ml / min). Therefore, as the system operates, a certain amount of hydraulic oil will gradually accumulate in the container 31.

[0086] The container 31 is connected to the return oil pipe of the return oil tank via a spring-loaded first check valve 34. When the container 31 has a slight pressure, the oil flows to the return oil tank in the direction of the arrow; when the connection is reversed, the oil is blocked, and the oil in the return oil tank pipe cannot return to the container 31. The check valve can withstand a certain back pressure under the action of the spring in the direction of the arrow. Therefore, a certain amount of hydraulic oil leaking from the brake device can accumulate in the cavity of the container 31.

[0087] The upper section of the housing 31 is equipped with an air filter and a second one-way valve 30 located at the exhalation port, such as... Figure 9 As shown, the second one-way valve 30 is closed towards the breather 37, but open towards the housing 31 in the direction of the arrow. Each time the brake is de-energized, the main spring 5 compresses the brake hydraulic cylinder 14, causing it to retract into the cylinder body. At this time, the volume of the rod chamber increases, and the housing 31 connected to the piston rod hydraulic cylinder 14 is under negative pressure. Under this negative pressure, the second one-way valve 30 opens and draws in a certain amount of air.

[0088] When it is necessary to release the brake device (release the brake), the piston rod of the hydraulic cylinder 14 is pushed out under the action of oil pressure. At this time, the air that was previously drawn in is compressed, causing the pressure in the cavity of the container 31 to increase instantaneously. Under this pressure, the first check valve 34 is opened, and the hydraulic oil above the first oil level 33 is pushed into the hydraulic oil pipe of the guide oil tank.

[0089] When the oil level approaches the first oil level 33 near the port of the first check valve 34, the piston rod of the hydraulic cylinder 14 extends once to open the brake device, and the rod chamber is compressed once. The first check valve 34 opens to release a portion of the hydraulic oil back to the oil tank 46. Therefore, under normal conditions where the seals are not worn, the oil level fluctuates around the first oil level 33. Under normal internal leakage conditions, the oil level in the container 31 will not rise to the vicinity of the second oil level 32 of the first oil level sensor 35 (no false alarm will occur under normal circumstances).

[0090] When the piston rod seal of the hydraulic cylinder 14 experiences severe internal leakage due to excessive wear, the oil level in the container 31 will rise to the vicinity of the first oil level sensor 35 (second oil level 32) in a short period of time, which means that the piston seal has abnormal internal leakage due to wear. At this time, the system will issue an early warning under the action of the first oil level sensor 35.

[0091] Figure 10 Schematic diagrams of the monitoring device according to other embodiments of this application are shown. For example... Figure 10 As shown, the piston sealing status monitoring device of hydraulic cylinder 14 can also be implemented using a combination of connectors such as four-way pipe 38, three-way pipe and elbow pipe 39.

[0092] A first oil level mirror 36 can be installed near the first oil level sensor 35 so that even if the sensor fails, maintenance personnel can still determine whether the piston seal of the hydraulic cylinder 14 is leaking oil by observing the first oil level mirror 36.

[0093] Because the piston sealing status monitoring component of hydraulic cylinder 14 allows the rod chamber of hydraulic cylinder 14 to be unidirectionally connected to atmospheric pressure through breather 37, it effectively reduces the resistance caused by the change in air pressure during piston reciprocating operation, which is more conducive to the realization of the rapid response performance of the entire brake device.

[0094] Figure 11 A schematic diagram of the monitoring device according to some other embodiments of this application is shown. Referring to 11, the monitoring device of this embodiment includes a first oil level sensor 35 and a first oil level mirror 36 that detects the same oil level as the first oil level sensor 35. The monitoring device of this embodiment also includes a second oil level sensor 41 that detects an oil level higher than that detected by the first oil level sensor 35 and a second oil level mirror 42 that detects the same oil level as the second oil level sensor 42.

[0095] See Figure 4 and Figure 5 The brake device also includes a displacement sensor 1, which is configured to detect the distance between the pressure plate 7 and the cylinder head 10 to determine the opening and closing state of the brake device, the braking response time, and the amount of wear of the pressure plate 7 and / or the dynamic friction plate 3.

[0096] By using a single displacement sensor 1 and precise timing control, the multiplexing and coordination of sensor data are realized. At the same time, functions such as gap monitoring between pressure plate 7 and dynamic friction plate 3, brake device opening and closing status monitoring, brake response time monitoring, and wear monitoring are realized. At the same time, the complex adjustment process that must be performed on the limit switch during each maintenance is completely eliminated. As a result, the unexpected technical effect of "reducing the number of sensors, simplifying the system and maintenance process, and improving reliability" is achieved.

[0097] Work logic: Braking response time monitoring: The time when the solenoid valve (the control valve for controlling the oil inlet or outlet of the rodless chamber of hydraulic cylinder 14) is de-energized (oil is discharged from the rodless chamber of hydraulic cylinder 14 to achieve braking) is recorded as time t1; the time when the displacement of pressure plate 7 reaches 0.6 to 0.99 times d (the displacement stroke preset ratio can be set according to the working conditions) is recorded as time t2. If |t2-t1| is greater than the preset threshold, the response time is judged to be too long and an alarm is triggered. Wherein, d is the gap between pressure plate 7 and dynamic friction plate 3 in the non-braking mode of the brake device (when the brake is released) or the displacement of pressure plate during the complete braking process.

[0098] Single-cycle wear monitoring: When the solenoid valve is energized (oil enters the rodless chamber of hydraulic cylinder 14 to release the brake), displacement sensor 1 returns to zero; when the solenoid valve is de-energized for 2-10 seconds (depending on the time it takes for the load speed to return to zero), oil is discharged from the rodless chamber to achieve braking. The absolute value of the difference between the displacement of pressure plate 7 during braking and the displacement during non-wear is the wear amount. If the wear amount exceeds the threshold, it is judged as abnormal wear.

[0099] Equivalent substitution: threshold adjustment, timing fine-tuning, and implementation using PLC / microcontroller / industrial control computer are all considered equivalent methods.

[0100] The detection process using a displacement sensor in this embodiment is as follows: 1. See Figure 4 The brake device includes monitoring components such as the probe 21 of the displacement sensor 1, a magnetic ring 24, and a magnetic isolation pad 23. The specific installation method is as follows: a hole slightly larger than the diameter of the magnetic ring is made at a suitable position in the cylinder head 10; a hole allowing the displacement sensor 1 to move back and forth is made at a corresponding position in the pad 11; a fixing sleeve of a certain thickness is placed between the magnetic isolation pad and the pad 11, and the displacement sensor 1 is fixed to the cylinder head 10 using a sensor fixing component 12 (a U-shaped flange). This structure allows the magnetic ring to avoid the monitoring blind zone at the beginning and end of the probe, allows for the installation of the displacement monitoring component in a confined space, and ensures that it is not easily damaged by collisions during monitoring operation. A sensor seal 16 is provided between the sensor fixing component 12 and the cylinder head 10, see [link to documentation]. Figure 3 .

[0101] Equivalent coverage: Connection methods include bolt connection, welding, one-piece molding, snap-fit, and clamping.

[0102] 2. Methods for monitoring the real-time opening gap and opening / closing status of the brake device: When the solenoid valve controlling hydraulic cylinder 14 is energized (oil enters the rodless chamber, releasing the brake), the PLC and other electronic control devices automatically reset the output of displacement sensor 1 to zero, thus completely eliminating the complex adjustment process required for the limit switch during each maintenance. After the electronic control device detects that the pressure of hydraulic cylinder 14 has reached the working pressure, it delays for 3 to 10 seconds (this delay is the empirical time for hydraulic cylinder 14 to build up pressure and fully open the brake), and then records the output value d1 of displacement sensor 1. This value is the opening gap of the brake device, that is, the displacement caused by the cylinder head body driving the pressure plate 7 to overcome the elastic force of the main spring 5.

[0103] If d1=0, the system outputs an indication of the brake device's closed status; If d1 exceeds the specified threshold range, the system will issue a warning that the gap of the brake device is too large or too small; If d1 is within the specified threshold range, the system displays that the brake is in the open state.

[0104] Working logic: When the solenoid valve is energized (oil enters the rodless chamber), the brake is opened. Displacement sensor 1 is simultaneously zeroed. The pressure of hydraulic cylinder 14 reaches the standard and is delayed for 3 to 10 seconds. The displacement d1 is collected as the opening gap. Based on d1, the following judgments are made: d1=0 means the brake is closed; d1 exceeds the threshold and an abnormal gap warning is issued; d1 is within the threshold and the brake is normally opened.

[0105] 3) Methods for monitoring the braking response time of the holding brake device: Using displacement sensor 1 in conjunction with PLC and other electronic control devices, timing t1 begins when the solenoid valve is de-energized (oil is discharged from the rodless chamber of hydraulic cylinder 14, and braking begins). When the displacement of pressure plate 7 reaches 0.6 to 0.99 times d (the preset displacement stroke ratio can be set according to the working conditions), time t2 is recorded. If the time difference |t2-t1| is greater than the preset threshold (e.g., 0.5 to 2 seconds, the specific braking response time threshold can be set according to the working conditions), a warning is issued that the brake device is slow to respond, prompting the need to find the specific cause (e.g., whether the control solenoid valve core is stuck).

[0106] 4) Methods for monitoring the wear and abnormal wear of the entire brake disc after each operation: When the brake device is running, the solenoid valve controlling the hydraulic cylinder 14 is energized (oil enters the rodless chamber, releasing the brake), and simultaneously, the PLC and other electrical control devices reset the output of displacement sensor 1 to zero. When the brake device needs to brake, the solenoid valve is de-energized (oil is discharged from the rodless chamber). Several seconds later (depending on the time from the de-energization of the brake device to the braking stop, generally 2 to 10 seconds), the absolute value of the difference between the output value d1 of displacement sensor 1 and the displacement of the pressure plate under non-wear conditions is the wear amount of the brake device after this operation. If the wear amount is greater than a certain set value after normal shutdown braking, there may be abnormal wear, and the specific cause needs to be checked (for example, the dynamic friction plate 3 and the pressure plate 7 or intermediate plate 8 are in a semi-clutch state, or the motor does not stop rotating after the parking brake is applied, thus causing abnormal wear of the brake device).

[0107] See Figures 12 to 14 The cylinder body 141 of the hydraulic cylinder 14 is provided with bolt holes 143 on its wall. The bolt holes 143 extend from one end of the cylinder body 141 in the axial direction to the other end. The cylinder body 141 is fixed to the cylinder head 10 by bolts passing through the bolt holes 143.

[0108] The hydraulic cylinder 14 also includes a piston 146 disposed in the cylinder body, a piston rod 142 connected to the piston 146, an end cap 147 that closes the rod chamber, an oil inlet and outlet port 144 that communicates with the rodless chamber, and an oil outlet port 145 that communicates with the rod chamber.

[0109] In this embodiment, the bolt hole 143 of the fixed hydraulic cylinder extends from one end of the cylinder body to the other end.

[0110] See Figure 17 The control valve for controlling the oil inlet or outlet of the rodless chamber of the hydraulic cylinder 14 includes a first control valve 44 and a second control valve. The rodless chamber of the hydraulic cylinder 14 is connected to the hydraulic pump 43 through the first control valve 44 and to the return oil tank 46 through the second control valve 45.

[0111] Figure 15 and Figure 16 A comparison diagram is shown between the hydraulic cylinder 14 (lower part) of this embodiment and the conventional hydraulic cylinder 14 (upper part).

[0112] To achieve a rapid response in the brake device, a relatively small amount of hydraulic oil is needed to overcome the spring and open the brake device, thereby reducing return oil resistance and enabling rapid return oil flow. To achieve the above objective, this invention employs a hydraulic cylinder 14 with a through-bolt hole cylinder structure as shown in the figure below.

[0113] Compared to the traditional flange-fixed cylinder block structure ( Figure 15 and 16(The upper part), the hydraulic cylinder 14 of this embodiment can withstand greater pressure under the premise of the same installation space and the same piston inner diameter. The function of controlling the brake device can be realized with fewer hydraulic cylinders 14, which can reduce the return oil resistance of the main return oil circuit, realize rapid return oil, and thus improve the rapid response performance of the brake device.

[0114] With the same inner diameter (d), the through bolt hole type cylinder body 141 of this embodiment has a larger wall thickness (h1>h2), so the hydraulic cylinder 14 can withstand greater pressure, requires fewer hydraulic cylinders 14, and occupies less space (E1<E2).

[0115] When the brake device is de-energized, the amount of oil that needs to be discharged from the cylinder is much smaller, and the piston of the hydraulic cylinder 14 can retract in a shorter time, making it easier to achieve rapid braking.

[0116] Figure 15 and 16 It is a cylinder block with a through bolt hole type 143, under the condition of the same inner diameter (d same).

[0117] See Figure 18 In this embodiment, a spring cavity seal 20 is provided between the spring cavity 9 and the cylinder head, a piston rod seal 149 is provided between the piston rod 142 and the end cap, and a piston seal 148 is provided between the piston 146 and the cylinder body. These multiple seals effectively prevent lubricating oil from leaking between the pressure plate 7 and the dynamic friction plate 3, thus affecting the braking performance.

[0118] Furthermore, a buffer groove 1410 is provided at the bottom of the cylinder, which is connected to the rodless chamber to prevent the piston 146 from having a hard impact with the bottom of the cylinder.

[0119] As described above, the brake device includes a flange base 2, a dynamic friction disc 3, a release spring 4, a main spring 5, a positioning sleeve 6, a pressure disc 7, an intermediate disc 8, a spring cavity 9, a cylinder head 10, a pad 11, a displacement sensor 1, a cover 17, a hydraulic cylinder 14, a fixing bolt 15, a fixing screw 18, and a fixing sleeve 19.

[0120] The dynamic friction disc 3 can be one disc, two discs, or multiple discs. This invention takes the structure of two dynamic friction discs 3 as an example.

[0121] The connection relationships of the main components are as follows: The spring cavity 9 of the brake device is fixed to the flange base 2 by the fixing screw 18 and the fixing sleeve 19. The hydraulic cylinder 14 and the displacement sensor 1 are fixed to the cylinder head 10.

[0122] The cylinder head 10 is fixed together with the positioning sleeve 6 and the pressure plate 7 by fixing bolts 15.

[0123] One end of the main spring 5 is fixed to the spring cavity 9, and the other end acts on the pressure plate 7.

[0124] When the hydraulic cylinder 14 is not pressurized, the pressure plate 7 presses the dynamic friction plate 3 and the intermediate plate 8 onto the flange base 2 under the action of the main spring 5, and the brake device is in the braking state at this time.

[0125] When the brake device needs to be released, the hydraulic system pressurizes the single-acting hydraulic cylinder 14. The piston rod 142 of the hydraulic cylinder 14 extends and presses against the right end face of the spring cavity 9. The cylinder head 10 drives the pressure plate 7 to compress the main spring 5. At this time, the pressure plate 7 separates from the moving friction plate 3 by a certain gap. The other moving friction plates 3 and the intermediate plate 8 also separate from each other under the action of the separation spring 4. The moving friction plates 3 rotate freely, and the brake device is in the open release state.

[0126] When the brake is required, the solenoid valve of the hydraulic system is de-energized, the hydraulic cylinder 14 is depressurized, and the pressure plate 7 presses the dynamic friction plate 3 and the intermediate plate 8 onto the flange base 2 under the action of the main spring 5. At this time, the brake device is in the braking state.

[0127] When the user at the installation site needs to use pneumatic pressure to drive the brake device, the hydraulic cylinder 14 can be removed, and a sealed cover or plug can be installed at the position of the hydraulic cylinder 14. The plug can be removed from the pneumatic interface and a pneumatic pipeline can be installed. The brake device can also be controlled by pneumatic pressure. Thus, with simple modification, the pneumatic mode and hydraulic mode can be switched back and forth. The braking performance remains unchanged after switching, and the displacement sensor 1 still works in the pneumatic mode.

[0128] The above are merely exemplary embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A brake device, characterized in that, include: Pressure plate (7); The dynamic friction disc (3) is stacked with the pressure disc (7); The spring cavity (9) is disposed on the side of the pressure plate (7) away from the dynamic friction plate (3); The main spring (5) abuts against the spring cavity (9) at one end and against the pressure plate (7) at the other end, and is configured to push the pressure plate (7) toward the moving friction plate (3) to brake the moving friction plate (3); The cylinder head (10) is located on the side of the spring cavity (9) away from the main spring (5). The cylinder head (10) and the spring cavity (9) form a gas cavity. The cylinder head (10) is connected to the pressure plate (7) and can move relative to the spring cavity (9) so that under the action of the gas pressure in the gas cavity, the pressure plate (7) can be driven to separate from the dynamic friction plate (3). The hydraulic cylinder (14) includes a cylinder body mounted outside the cylinder head (10) and a piston rod movably mounted inside the cylinder body. The piston rod extends into the gas chamber to push the spring chamber (9) to separate the pressure plate (7) from the dynamic friction plate (3).

2. The brake device according to claim 1, characterized in that, The hydraulic cylinder (14) includes a rodless chamber into which hydraulic oil is introduced to push the piston rod toward the spring cavity (9), the main spring (5) is configured to push the piston rod away from the spring cavity (9), the hydraulic cylinder (14) also includes a rod chamber that accommodates the piston rod, and the brake device also includes a monitoring device for monitoring the amount of hydraulic oil leaking from the rodless chamber to the rod chamber.

3. The brake device according to claim 2, characterized in that, The monitoring device includes: The container (31) is in communication with the rod chamber and is configured to receive hydraulic oil leaking from the rodless chamber into the rod chamber; A detection component is configured to detect the level of hydraulic oil in the container (31), the detection component including a first oil level sensor (35) and / or a first oil level mirror (36) for observing the oil level in the container (31).

4. The brake device according to claim 3, characterized in that, The container (31) also includes an oil drain port that communicates with the return oil tank (46). A first check valve (34) is installed on the oil drain port. The inlet of the first check valve (34) is communicated with the container (31), and the outlet of the first check valve (34) is communicated with the return oil tank. The oil drain port is configured to deliver hydraulic oil not higher than the first oil level (33) to the return oil tank.

5. The brake device according to claim 4, characterized in that, The detection component is configured to detect that the hydraulic oil in the container (31) has reached a second oil level (32), which is higher than the first oil level (33).

6. The brake device according to claim 3, characterized in that, The container (31) also includes a breathing port (37) for communicating the atmosphere with the rod chamber.

7. The brake device according to claim 6, characterized in that, A second one-way valve (30) is installed on the breathing port (37). The inlet of the second one-way valve (30) is connected to the atmosphere, and the outlet of the second one-way valve (30) is connected to the rod chamber.

8. The brake device according to claim 1, characterized in that, It also includes a displacement sensor (1) configured to detect the distance between the pressure plate (7) and the cylinder head (10) to determine the opening and closing state of the brake device, the braking response time, and the wear of the pressure plate (7) and / or the dynamic friction plate (3).

9. The brake device according to claim 1, characterized in that, The rodless chamber of the hydraulic cylinder (14) is connected to the hydraulic pump (43) through the first control valve (44) and to the return oil tank (46) through the second control valve (45).

10. The brake device according to claim 1, characterized in that, The cylinder body (141) of the hydraulic cylinder (14) has a bolt hole (143) on its wall. The bolt hole (143) extends from one end of the cylinder body (141) to the other end in the axial direction. The cylinder body (141) is fixed to the cylinder head (10) by bolts passing through the bolt hole (143).

11. The brake device according to claim 1, characterized in that, The cylinder head (10) is provided with a mounting hole for accommodating the hydraulic cylinder (14), the hydraulic cylinder (14) is detachably mounted on the mounting hole, and the brake device further includes a sealing cover (25) for sealing the mounting hole after the hydraulic cylinder (14) is removed.

12. The brake device according to claim 1, characterized in that, The moving friction discs (3) are at least two stacked together. The brake device also includes an intermediate disc (8) disposed between two adjacent moving friction discs (3). The intermediate disc (8) is connected to the pressure disc (7) so as to move synchronously with the cylinder head (10) along with the pressure disc (7).

13. The brake device according to claim 1, characterized in that, The cylinder head (10) is also provided with an air pipe interface (13), which is configured to introduce gas so that the cylinder head (10) drives the pressure plate (7) to separate from the dynamic friction plate (3).

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