Mechanical brake disc bearing device and monitoring platform

Abstract

The utility model relates to the technical field of hydroelectric equipment state monitoring, and discloses a mechanical brake disc bearing device and a monitoring platform, the mechanical brake disc bearing device comprises a mobile unit, the mobile unit comprises a fixed platform and a driving assembly installed on the fixed platform; the bearing unit comprises a box body, two handles symmetrically and fixedly mounted on the two sides of the box body, and two supporting rods symmetrically and fixedly mounted on one side of the top of the box body; wherein the moving unit is mounted above the box body. The beneficial effects of the utility model are that the bearing unit can provide installation support for the mobile unit, and the mobile unit can realize full-stroke digital monitoring of the air brake travel switch, thereby ensuring the safety of equipment operation, and reducing the risk of faults.

Description

Technical Field

[0001] This utility model relates to the field of hydropower equipment condition monitoring technology, and in particular to a mechanical brake disc bearing device and monitoring platform. Background Technology

[0002] In my country, hydroelectric generators generally employ two braking methods: electric braking and mechanical braking. Electric braking can reduce wear on unit bearings, brakes, and brake rings, as well as dust pollution in the turbine pit. However, due to the high system cost and stringent environmental requirements of electric braking, most hydroelectric plants use purely mechanical braking for their turbine generators. More advanced hydroelectric plants, on the other hand, combine electric and mechanical braking.

[0003] The turbine generator brake (commonly known as the air damper) is an important component of the unit's mechanical braking system. The mechanical braking system consists of the brake, the oil-air circuit, and manual and automatic control devices. Its main functions are: (1) to prevent the unit from running at low speed for a long time during shutdown and to brake quickly; (2) to use jacks to lift the rotor during unit installation or maintenance; (3) to prevent the unit from rotating when it is not in operation; and (4) to facilitate the re-establishment of the oil film in the unit. The mechanical brake air damper is a very important piece of equipment in a hydropower plant. The equipment must work stably and reliably to ensure the safe operation of the hydropower plant's units. If the mechanical brake air damper monitoring system malfunctions, it will affect the unit's start-up process, leading to start-up failure. In more serious cases, it will cause the unit to shut down, resulting in huge economic losses to the power plant.

[0004] Traditional domestic methods for calibrating mechanical brake damper limit switches employ static methods and only calibrate the mechanical brake damper limit switch element. This method can only calibrate individual components and lacks the digital calibration function for the entire stroke of the damper as it rises and falls. If a unit accident occurs due to the sensor not being dynamically simulated and calibrated, the consequences would be unimaginable. Existing technologies have the following problems: they are not convenient for stable installation of the brake disc, causing deviations during monitoring, and they cannot monitor the movement of the brake disc throughout its entire stroke. Utility Model Content

[0005] In this section, as well as in the abstract and title of this application, some simplifications or omissions may be made to avoid obscuring the purpose of this section, the abstract, and the title of this application. Such simplifications or omissions shall not be used to limit the scope of this utility model.

[0006] The purpose of this invention is to provide a mechanical brake disc support device that can solve the problem of inconvenient and stable installation of the brake disc, which causes displacement during monitoring.

[0007] To solve the above-mentioned technical problems, this utility model provides the following technical solution: a mechanical brake disc bearing device, which includes a moving unit, the moving unit including a fixed platform and a drive assembly installed on the fixed platform; a bearing unit, the bearing unit including a housing, two handles symmetrically fixedly installed on both sides of the housing, and two support rods symmetrically fixedly installed on one side of the top of the housing; wherein, the moving unit is installed above the housing.

[0008] As a preferred embodiment of the mechanical brake disc bearing device of this utility model, the fixed platform is fixedly installed on one side of the housing, the bottom of the fixed platform is fixed to the top of the support rod, a first through hole is opened in the center of the fixed platform, and six proximity switches are provided on the top of the fixed platform and inside the housing, with the proximity switches on the top of the fixed platform corresponding to the proximity switches inside the housing.

[0009] As a preferred embodiment of the mechanical brake disc support device of this utility model, the drive assembly includes a mounting bracket fixedly installed on the top of the fixed platform, a three-phase motor installed in the housing, and a lead screw disposed above the three-phase motor.

[0010] In a preferred embodiment of the mechanical brake disc bearing device of this utility model, the three-phase motor is fixed to the top of the housing by a fixing column, the lower end of the lead screw is fixed to the drive shaft of the three-phase motor by a coupling, the upper end of the lead screw passes through the fixing platform through the first through hole, and the lead screw and the first through hole are rotatably connected by a bearing.

[0011] In a preferred embodiment of the mechanical brake disc bearing device of this utility model, the outer ring of the lead screw is provided with a screw sleeve, and a brake disc is fixedly installed on the screw sleeve, and the screw sleeve cooperates with the lead screw.

[0012] As a preferred embodiment of the mechanical brake disc bearing device of this utility model, the top of the housing is provided with a mounting hole and a second through hole. The mounting hole is adapted to a three-phase motor, the second through hole corresponds to a proximity switch inside the housing, and two third through holes are provided on one side of the top of the housing.

[0013] The beneficial effects of this utility model are as follows: This utility model can provide installation support for the moving unit through the bearing unit, and the moving unit can realize the stable installation of the brake disc and drive the brake disc to move upward or downward.

[0014] The purpose of this invention is to provide a mechanical brake disc monitoring platform that can solve the problem of not being able to monitor the movement of the brake disc throughout its entire stroke.

[0015] To solve the above-mentioned technical problems, this utility model provides the following technical solution: a mechanical brake disc monitoring platform, which includes a PLC controller, an isolation transformer, a power supply and a photoelectric sensor installed at the bottom of the housing;

[0016] A touch screen, buttons, indicator lights, and a frequency converter are provided on one side of the enclosure;

[0017] The frequency converter is embedded inside the enclosure.

[0018] In a preferred embodiment of the mechanical brake disc monitoring platform described in this utility model, the controller is electrically connected to the encoder and proximity switch mounted on the mounting bracket, the bottom of the encoder is fixedly connected to the upper end of the lead screw, the power input terminal is electrically connected to the isolation transformer, and the output terminal of the isolation transformer is electrically connected to the input terminal of the PLC controller, the touch screen, the frequency converter, and the indicator light.

[0019] In a preferred embodiment of the mechanical brake disc monitoring platform described in this utility model, the output terminal of the frequency converter is electrically connected to the three-phase motor, and the photoelectric sensor is electrically connected to the PLC controller.

[0020] In a preferred embodiment of the mechanical brake disc monitoring platform described in this utility model, the buttons and indicator lights are all electrically connected to the PLC controller.

[0021] The beneficial effects of this utility model are as follows: By setting up a PLC controller, isolation transformer, photoelectric sensor, touch screen, buttons, indicator lights and frequency converter, this utility model can monitor the operating data of the displacement analog quantity of the mechanical brake, accurately determine the fault type and degree of the mechanical brake, and issue early warning information in a timely manner. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Among them:

[0023] Figure 1 This is a structural schematic diagram of the mechanical brake disc support device and system.

[0024] Figure 2 This is a schematic diagram of the mechanical brake disc support device and the moving unit in the system.

[0025] Figure 3 This is a structural schematic diagram of the mechanical brake disc bearing device and the bearing unit in the system. Detailed Implementation

[0026] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings.

[0027] Many specific details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0028] Secondly, the term "an embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that excludes other embodiments.

[0029] Example 1

[0030] Reference Figures 1-3 This is the first embodiment of the present invention. This embodiment provides a mechanical brake disc support device, which includes a moving unit 100, the moving unit 100 including a fixed platform 101 and a drive assembly 102 installed on the fixed platform 101; and a support unit 200, the support unit 200 including a housing 201, two handles 202 symmetrically fixedly installed on both sides of the housing 201, and two support rods 203 symmetrically fixedly installed on one side of the top of the housing 201; wherein, the moving unit 100 is installed above the housing 201.

[0031] The moving unit 100 can monitor the position and action of the mechanical brake, greatly improving the reliability of status monitoring and the credibility of data acquisition. The supporting unit 200 can effectively support the moving unit 100 and provide installation space for the other components of the device.

[0032] The fixed platform 101 is used to fix the proximity switch 101a and ensure the stability of the proximity switch 101a when it is being monitored. At the same time, the drive component 102 can move the brake disc 102f up and down. Through the cooperation with the PLC controller, isolation transformer, photoelectric sensor and other components, it ensures full-stroke digital detection of the mechanical brake.

[0033] The housing 201 provides a base for the installation of various components of the device. The handle 202 makes it easy for workers to move the housing 201. The support rod 203 can support one side of the fixed platform 101. The shape of the housing 201 ensures the stability of the fixed platform 101.

[0034] Example 2

[0035] Reference Figures 1-3 This is the second embodiment of the present invention, which differs from the first embodiment in that: it also includes a fixed platform 101 fixedly installed on one side of the housing 201, the bottom of the fixed platform 101 is fixed to the top of the support rod 203, a first through hole 101b is opened in the center of the fixed platform 101, and six proximity switches 101a are provided on the top of the fixed platform 101 and inside the housing 201, with the proximity switches 101a on the top of the fixed platform 101 and inside the housing 201 corresponding to each other.

[0036] The fixed platform 101 provides safe support for the proximity switch 101a and the drive assembly 102.

[0037] The proximity switch 101a is an electromagnetic interference resistant type, model number: Fi10A-TM30-OP6L-Q12. It has a 30mm probe diameter, a rated working distance of 10mm, a normally open PNP output signal, a 10~30VDC operating power supply, and an ambient temperature range of -25~70 degrees Celsius. The M12 connection allows for easy disassembly and replacement. The product features a metal housing, a threaded cylindrical shape, a PTFE coating, a three-wire DC output, resistance to acid and alkali corrosion, resistance to sparks and splashes, optimized anti-interference features, an IP67 protection rating, and a high-brightness LED indicator.

[0038] The proximity switch 101a can perform non-contact monitoring of the brake disc 102f to determine the position of the brake disc 102f, thereby determining the open or closed state between the brake disc 102f and the brake.

[0039] The setup of six proximity switches 101a enables simultaneous monitoring of multiple sets of data on the movement of the brake disc 102f, increasing the work efficiency of the staff.

[0040] Specifically, the drive assembly 102 includes a mounting bracket 102a fixedly installed on the top of the fixed platform 101, a three-phase motor 102c installed in the housing 201, and a lead screw 102d disposed above the three-phase motor 102c.

[0041] Furthermore, the three-phase motor 102c is fixed to the top of the housing 201 by 102g, the lower end of the lead screw 102d is fixed to the drive shaft of the three-phase motor fixing column 102c by a coupling, the upper end of the lead screw 102d passes through the fixing platform 101 through the first through hole 101b, and the lead screw 102d and the first through hole 101b are rotatably connected by a bearing.

[0042] Furthermore, a sleeve 102e is provided on the outer ring of the lead screw 102d, and a brake disc 102f is fixedly installed on the sleeve 102e. The sleeve 102e cooperates with the lead screw 102d.

[0043] The three-phase motor 102c can provide the corresponding power for the movement of the sleeve 102e. The three-phase motor 102c drives the lead screw 102d to rotate. Due to the cooperation between the lead screw 102d and the sleeve 102e, when the lead screw 102d rotates, it can drive the sleeve 102e to move upward, similar to a ball screw.

[0044] The three-phase motor 102c can be stably installed by the fixing column 102g, ensuring the stability of the three-phase motor 102c during operation.

[0045] The travel distance of the brake disc 102f is the distance between the lead screw 102d and the fixed platform 101 and the bottom coupling minus the distance of the lead sleeve 102e.

[0046] Specifically, the top of the housing 201 is provided with a mounting hole 201b and a second through hole 201a. The mounting hole 201b is adapted to the three-phase motor 102c, and the second through hole 201a corresponds to the proximity switch 101a inside the housing 201. Two third through holes 201c are provided on one side of the top of the housing 201.

[0047] The opening of the second through hole 201a facilitates the monitoring of the stroke of the brake disc 102f by the photoelectric sensor and encoder 102b installed in the housing 201. The mounting hole 201b is used to install the three-phase motor 102c. The opening of the third through hole 201c facilitates the passage of the connecting cables of the encoder 102b and proximity switch 101a, ensuring the operation of the device.

[0048] In use, first install the brake disc 102f onto the threaded sleeve 102e. Then, complete the installation and position of the device. Turn on the three-phase motor 102c. The rotation of the three-phase motor 102c drives the lead screw 102d to rotate. The rotation of the lead screw 102d causes the threaded sleeve 102e to move up or down. The encoder 102b, by monitoring the rotation of the lead screw 102d, can accurately monitor the movement distance of the brake 102f. Furthermore, the proximity switch 101a further performs non-contact monitoring of the movement of the brake disc 102f to ensure the brake's movement is controlled. The movement range of the brake disc 102f is limited to prevent it from moving beyond its range, which could cause friction between the brake disc 102f and the device, resulting in damage to the device or its components. Since proximity switches 101a are installed at both the top and bottom, when the brake disc 102f moves to the designated position, a signal can be transmitted to the PLC controller through the proximity switches 101a. The PLC controller can then start and stop the three-phase motor 102c. The presence of proximity switches 101a on both the top and bottom sides further ensures the stability of the brake disc 102f during movement.

[0049] Example 3

[0050] Reference Figures 1-3 This is the third embodiment of the present invention. Based on the previous two embodiments, this embodiment provides a mechanical brake disc monitoring platform, which includes a PLC controller, an isolation transformer, a power supply and a photoelectric sensor installed at the bottom of the housing 201; a touch screen, buttons, indicator lights and a frequency converter are provided on one side of the housing 201; the frequency converter is embedded in the housing 201.

[0051] Furthermore, the controller is electrically connected to the encoder 102b and the proximity switch 101a mounted on the mounting bracket 102a, respectively. The bottom of the encoder 102b is fixedly connected to the upper end of the lead screw 102d. The power input terminal is electrically connected to the isolation transformer. The output terminal of the isolation transformer is electrically connected to the input terminal of the PLC controller, the touch screen, the frequency converter, and the indicator light, respectively.

[0052] Furthermore, the output of the frequency converter is electrically connected to the three-phase motor 102c, and the photoelectric sensor is electrically connected to the PLC controller.

[0053] Furthermore, the buttons and indicator lights are all electrically connected to the PLC controller.

[0054] One end of the lead screw 102d is connected to the encoder 102b. The encoder 102b monitors the vertical displacement of the lead sleeve 102e by monitoring the rotation of the lead screw 102d, and provides precise position information, which is beneficial for precise control and safe operation of the mechanical brake. By analyzing the monitoring data of the encoder 102b, potential faults of the mechanical brake can be diagnosed, such as stroke exceeding the expected range or abnormal speed, and timely warning information can be issued.

[0055] This photoelectric sensor, an electromagnetic interference resistant product, model number OSM40-KL160CBLIUQ12.1, has a detection range of 60–160 mm, uses a red laser, supports NPN / PNP switch output for exit position signals, supports 4–20 mA analog output, has a detection resolution of 0.01 mm, and uses an M12 connection cable for easy replacement and maintenance. This product is a laser displacement sensor using a 655 nm laser light source, a metal housing, and features an LED display and button settings for switch output parameters.

[0056] The cooperation between the photoelectric sensor and the proximity switch 101a effectively avoids the malfunctions and failures to operate caused by the mechanical dead zone and actuation dead zone of the contact position switch, greatly improving the safety of equipment operation and reducing the risk of mechanical brake malfunction and equipment damage.

[0057] The photoelectric sensor, acting as a displacement sensor, can monitor the displacement stroke of the brake disc 102f in real time and determine its movement distance on the lead screw 102d. The photoelectric sensor can also monitor changes in the gap between the brake pads and the brake disc 102f, thus reflecting the wear condition of the brake pads in real time.

[0058] The isolation control transformer has an AC220V input / AC220V output and a capacity of 50VA. Because the system is designed with a frequency converter, the isolation transformer is placed at the front end of the frequency converter to prevent the EMC harmonic interference of the frequency converter from affecting the control power supply of the system.

[0059] The power input is AC220V, the output is DC24V, and the power capacity is 120W. It provides a reliable DC24V power supply with sufficient capacity for the PLC's IO signal loop, control loop, touch screen and sensors.

[0060] The inverter model is ATV320U02M2C, with a power of 0.18kW and a maximum current of 1.5A. It is a single-phase AC220V input and a three-phase AC220V output, used to control the forward and reverse rotation, start and stop, and speed regulation of a three-phase motor 102c.

[0061] The touchscreen is a TPC7032Ni, a 7-inch LCD touchscreen that communicates with the PLC to display status and real-time data, set system parameters, handle alarm events, and provide dynamic system simulation functions. It supports USB connection to a printer to print report data and test results. It also supports Wi-Fi connectivity, allowing for the development of advanced applications via the cloud.

[0062] The travel of the brake (i.e. the open and closed positions of the brake) is consistent with the travel of the brake disc 102f. When the brake is fully released, the brake disc 102f is in a fully open state; when the brake is pressed, the brake disc 102f is pressed. Therefore, monitoring the travel of the brake disc 102f can accurately determine whether the brake is within the predetermined travel range.

[0063] In summary, during use, the three-phase motor 102c drives the brake disc 102f to move up or down through the cooperation between the lead screw 102d and the lead sleeve 102e. Through the encoder 102b and photoelectric sensor, the displacement of the brake disc 102f can be monitored in real time as it moves, and the monitoring data is transmitted to the PLC controller. The corresponding data can be viewed on the touch screen. When an abnormal situation is detected, the indicator light will issue a fault reminder, and the device will issue an alarm, so that the staff can be informed in a timely manner.

[0064] It should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solution of this utility model without departing from the spirit and scope of the technical solution of this utility model, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. A mechanical brake disc bearing device, characterized in that: include, The mobile unit (100) includes a fixed platform (101) and a drive assembly (102) mounted on the fixed platform (101); The support unit (200) includes a box (201), two handles (202) symmetrically fixedly installed on both sides of the box (201), and two support rods (203) symmetrically fixedly installed on one side of the top of the box (201); The mobile unit (100) is mounted on top of the housing (201).

2. The mechanical brake disc bearing device as described in claim 1, characterized in that: The fixed platform (101) is fixedly installed on one side of the box (201). The bottom of the fixed platform (101) is fixed to the top of the support rod (203). A first through hole (101b) is opened in the center of the fixed platform (101). Six proximity switches (101a) are provided on the top of the fixed platform (101) and inside the box (201). The proximity switches (101a) on the top of the fixed platform (101) correspond to the proximity switches (101a) inside the box (201).

3. The mechanical brake disc bearing device as described in claim 2, characterized in that: The drive assembly (102) includes a mounting bracket (102a) fixedly installed on the top of the fixed platform (101), a three-phase motor (102c) installed in the housing (201), and a lead screw (102d) disposed above the three-phase motor (102c).

4. The mechanical brake disc bearing device as described in claim 3, characterized in that: The three-phase motor (102c) is fixed to the top of the housing (201) by a fixing column (102g). The lower end of the lead screw (102d) is fixed to the drive shaft of the three-phase motor (102c) by a coupling. The upper end of the lead screw (102d) passes through the fixing platform (101) through the first through hole (101b), and the lead screw (102d) and the first through hole (101b) are rotatably connected by a bearing.

5. The mechanical brake disc bearing device as described in claim 4, characterized in that: The lead screw (102d) is fitted with a lead sleeve (102e) on its outer ring. A brake disc (102f) is fixedly installed on the lead sleeve (102e). The lead sleeve (102e) cooperates with the lead screw (102d).

6. The mechanical brake disc bearing device as described in claim 5, characterized in that: The top of the housing (201) is provided with a mounting hole (201b) and a second through hole (201a). The mounting hole (201b) is adapted to the three-phase motor (102c). The second through hole (201a) corresponds to the proximity switch (101a) inside the housing (201). Two third through holes (201c) are provided on one side of the top of the housing (201).

7. A mechanical brake disc monitoring platform, characterized in that: Including the mechanical brake disc support device as described in any one of claims 1 to 6, and The bottom of the enclosure (201) is equipped with a PLC controller, an isolation transformer, a power supply, and a photoelectric sensor. The enclosure (201) is equipped with a touch screen, buttons, indicator lights and frequency converter on one side; The frequency converter is embedded inside the enclosure (201).

8. The mechanical brake disc monitoring platform as described in claim 7, characterized in that: The controller is electrically connected to the encoder (102b) and the proximity switch (101a) mounted on the mounting bracket (102a). The bottom of the encoder (102b) is fixedly connected to the upper end of the lead screw (102d). The input terminal of the power supply is electrically connected to the isolation transformer. The output terminal of the isolation transformer is electrically connected to the input terminal of the PLC controller, the touch screen, the frequency converter, and the indicator light.

9. A mechanical brake disc monitoring platform as described in claim 8, characterized in that: The output terminal of the frequency converter is electrically connected to the three-phase motor (102c), and the photoelectric sensor is electrically connected to the PLC controller.

10. A mechanical brake disc monitoring platform as described in claim 9, characterized in that: The buttons and indicator lights are all electrically connected to the PLC controller.

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