Industrial brake monitoring device

Abstract

The application relates to the technical field of brake monitoring devices, and discloses an industrial brake monitoring device which comprises a data processing unit used for receiving various data and performing data processing; the data processing unit is respectively connected with a lining wear sensing unit, a temperature sensing unit, a displacement sensing unit and a force sensing unit; the lining wear sensing unit, the temperature sensing unit, the displacement sensing unit and the force sensing unit are all mounted on the monitored brake; the lining wear sensing unit is used for collecting lining wear data of the brake; the temperature sensing unit is used for collecting lining eccentric wear data of the brake; the displacement sensing unit is used for collecting opening and closing brake stroke data of the brake; and the force sensing unit is used for collecting brake force data of the brake; the industrial brake monitoring device can effectively reduce the manpower maintenance cost while ensuring safety.

Description

Technical Field

[0001] This application relates to the technical field of brake monitoring devices, specifically an industrial brake monitoring device. Background Technology

[0002] Industrial brakes are generally used in lifting and handling equipment in large freight yards, ports and other places. They brake the handling equipment by clamping the wheel disc with clamps.

[0003] For industrial brakes without brake monitoring devices, on-site personnel need to regularly check the wear of the brake pads, uneven wear, and brake compensation. If the installation location of the industrial brake is inconvenient for personnel access, the equipment is difficult to inspect, or the weather is bad, on-site maintenance becomes difficult and prone to oversights. Furthermore, as the service life of industrial brakes increases, their performance will inevitably decline, and this condition cannot be visually assessed.

[0004] This results in industrial brakes not only having high maintenance costs, but also posing safety hazards. Utility Model Content

[0005] The purpose of this application is to provide an industrial brake monitoring device that effectively reduces human maintenance costs while ensuring safety.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] This utility model discloses an industrial brake monitoring device, which includes a data processing unit for receiving and processing various data. The data processing unit is connected to a liner wear sensing unit, a temperature sensing unit, a displacement sensing unit, and a force sensing unit. The liner wear sensing unit, temperature sensing unit, displacement sensing unit, and force sensing unit are all installed and connected to the brake being monitored.

[0008] The pad wear sensing unit is used to collect pad wear data of the brake.

[0009] The temperature sensing unit is used to collect data on the uneven wear of the brake pads.

[0010] The displacement sensing unit is used to collect the opening and closing stroke data of the brake.

[0011] The force sensing unit is used to collect braking force data from the brake.

[0012] Furthermore, the pad wear sensing unit includes a pad wear sensor, the output terminal of which is connected to one input terminal of an optocoupler N1, the other input terminal of which is connected to a Zener diode ZD1, the cathode of which is connected to the pad wear sensor, and the output terminal of the optocoupler N1 is connected to the data processing unit.

[0013] Furthermore, the temperature sensing unit includes temperature sensors, with two temperature sensors installed on each pad. The output of each temperature sensor is connected to a first proportional operational amplifier circuit, and the output of the first proportional operational amplifier circuit is connected to the data processing unit.

[0014] Furthermore, the displacement sensing unit includes a displacement sensor, the force sensing unit includes a force sensor, both the displacement sensor and the force sensor are connected to a sampling resistor R77, the sampling resistor R77 is connected to the input terminal of the second proportional operational amplifier circuit, and the output terminal of the second proportional operational amplifier circuit is connected to the data processing unit.

[0015] Furthermore, the data processing unit includes a controller for data processing, which is connected to the pad wear sensing unit, temperature sensing unit, displacement sensing unit and force sensing unit respectively, and the controller is connected to a communication module and a memory.

[0016] The communication module is used for data interaction with the host computer;

[0017] The memory is used to store the data received and processed by the controller.

[0018] Furthermore, the data processing unit is connected to a display for monitoring the data display.

[0019] Compared with the prior art, the beneficial effects of this application are:

[0020] 1. It solves the problem of performance degradation of industrial brakes after years of use, and the inability to visually assess their condition;

[0021] 2. Significantly reduces the time required for on-site personnel to inspect the wear, uneven wear, and brake compensation of industrial brake pads, saving manpower maintenance costs;

[0022] 3. It avoids equipment damage caused by human error during inspection, thus ensuring safety. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0024] Figure 1 This is a circuit structure block diagram of this utility model;

[0025] Figure 2 This is a circuit diagram of the pad wear sensing unit of this utility model;

[0026] Figure 3 This is a circuit diagram of the temperature sensing unit of this utility model;

[0027] Figure 4 This is a circuit diagram of the displacement sensing unit and force sensing unit of this utility model. Detailed Implementation

[0028] The following specific examples illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model. It should be noted that, unless otherwise specified, the following embodiments and features described therein can be combined with each other.

[0029] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Therefore, the drawings only show the layers related to the present invention and are not drawn according to the actual number, shape and size of the layers in the actual implementation. In the actual implementation, the form, number and proportion of each layer can be arbitrarily changed, and the layer layout may also be more complex.

[0030] Numerous details are explored in the following description to provide a more thorough explanation of embodiments of the present invention; however, it will be apparent to those skilled in the art that embodiments of the present invention may be practiced without these specific details.

[0031] Please see Figure 1An industrial brake monitoring device includes a data processing unit for receiving and processing various data. The data processing unit is connected to a liner wear sensing unit, a temperature sensing unit, a displacement sensing unit, and a force sensing unit. The liner wear sensing unit, temperature sensing unit, displacement sensing unit, and force sensing unit are all installed and connected to the brake being monitored.

[0032] The pad wear sensing unit is used to collect pad wear data of the brake.

[0033] Please see Figure 2 The pad wear sensing unit includes a pad wear sensor. The output terminal of the pad wear sensor is connected to one input terminal of an optocoupler N1. The other input terminal of the optocoupler N1 is connected to a Zener diode ZD1. The cathode of the Zener diode ZD1 is connected to the pad wear sensor. The output terminal of the optocoupler N1 is connected to the data processing unit.

[0034] Please see Figure 2 The pad wear sensing unit includes a first surge protection circuit connected to the pad wear sensor, a first voltage divider resistor circuit connected to the first surge protection circuit, and an optocoupler isolation circuit connected to the first voltage divider resistor circuit. The optocoupler isolation circuit is connected to the data processing unit and specifically includes resistors R41, R33, R40, R42, transient suppression diode TVS5, diode D5, Zener diode ZD1, capacitor C18, capacitor C28, and optocoupler N1.

[0035] The data processing unit monitors the voltage signal changes of the gasket wear sensing unit. When the gasket wear is normal, the Zener diode ZD1 is turned on, the optocoupler N1 is turned on, and the electrical signal continuously monitored by the data processing unit is at a high level. When the gasket wears to the design life, the Zener diode ZD1 is turned off, the optocoupler N1 is not turned on, and the electrical signal monitored by the data processing unit becomes low level.

[0036] The temperature sensing unit is used to collect data on brake pad wear; please refer to... Figure 3 The temperature sensing unit includes temperature sensors, with two temperature sensors installed on each pad. The output of each temperature sensor is connected to a first proportional operational amplifier circuit, and the output of the first proportional operational amplifier circuit is connected to the data processing unit.

[0037] The temperature sensing unit includes a second surge protection circuit connected to the temperature sensor, a Wheatstone bridge circuit connected to the second surge protection circuit, a second voltage divider resistor circuit connected to the Wheatstone bridge circuit, a first proportional operational amplifier circuit connected to the second voltage divider resistor circuit, and the first proportional operational amplifier circuit connected to the data processing unit. Specifically, it includes resistors R1, R2, R13, R9, R11, R5, R15, R7, transient suppression diode TVS1, diode D1, operational amplifier IC1C, capacitors C1, C3, C9, C7, and C5.

[0038] The data processing unit monitors the resistance signal change of the temperature sensing unit in real time. Two temperature sensing units are installed on the two pads of the industrial brake. When the pads are worn unevenly, the temperature values ​​will be inconsistent. The temperature change monitored by the temperature sensor is proportional to the change in its own resistance value. When the pads are worn unevenly, the temperature sensor detects that the pad temperature has increased, and the resistance value of the temperature sensor itself has also increased. The voltage at the non-inverting input terminal of the first proportional operational amplifier circuit also increases, and the voltage at the output terminal of the first proportional operational amplifier circuit also increases. The voltage received by the data processing unit increases.

[0039] The displacement sensing unit is used to collect the opening and closing stroke data of the brake.

[0040] The force sensing unit is used to collect braking force data from the brake.

[0041] Please see Figure 4 The displacement sensing unit includes a displacement sensor, and the force sensing unit includes a force sensor. Both the displacement sensor and the force sensor are connected to a sampling resistor R77. The sampling resistor R77 is connected to the input terminal of the second proportional operational amplifier circuit, and the output terminal of the second proportional operational amplifier circuit is connected to the data processing unit.

[0042] The displacement sensing unit and force sensing unit monitor the braking compensation status, braking frequency, clamping force magnitude, and stroke magnitude of the industrial brake in the open and closed states. It includes a third surge protection circuit connected to both the displacement and force sensors, a third voltage divider resistor circuit connected to the third surge protection circuit, and a second proportional operational amplifier circuit connected to the sampling resistor circuit. Specifically, it includes a voltage divider resistor R75, a sampling resistor R77, a resistor R73, a varistor RV9, a diode D13, an operational amplifier IC5C, a capacitor C33, and a capacitor C31.

[0043] The data processing unit monitors the current signal changes of the force sensing unit and displacement sensing unit in real time. The force sensor monitors the braking force of the industrial brake, which is proportional to the output current. The displacement sensor monitors the opening and closing stroke of the industrial brake, which is also proportional to the output current. When the braking force or displacement increases, the voltage value collected by the sampling resistor R77 increases, the voltage at the non-inverting input of the second proportional operational amplifier circuit also increases, the voltage at the output of the second proportional operational amplifier circuit also increases, and the voltage received by the data processing unit increases. When the braking force or displacement decreases, the voltage value collected by the sampling resistor R77 decreases, the voltage at the non-inverting input of the second proportional operational amplifier circuit also decreases, the voltage at the output of the second proportional operational amplifier circuit also decreases, and the voltage collected by the data processing unit decreases. The displacement sensing unit monitors the braking compensation and the number of braking cycles. Braking compensation refers to the initial stroke value when the brake is closed, and the number of braking cycles is monitored by the displacement sensing unit by detecting the switching number of strokes when the brake is opened and the compensation stroke.

[0044] Please see Figure 1 The data processing unit includes a controller for data processing. The controller is connected to the pad wear sensing unit, temperature sensing unit, displacement sensing unit and force sensing unit respectively. The controller is also connected to a communication module and a memory.

[0045] The communication module is used for data interaction with the host computer;

[0046] The memory is used to store the data received and processed by the controller.

[0047] The system communicates with host computers such as PLCs via a communication module to upload various statuses and fault entries of the industrial brakes in real time.

[0048] Please see Figure 1 The data processing unit is connected to a display for monitoring the data display.

[0049] The display screen is a touch screen, which allows for quick modification of the brake model, making it very convenient to set the model on-site. The display shows the brake status and prompts in real time.

[0050] This invention solves the problem of performance degradation of industrial brakes after years of use, and the inability to visually assess their condition; it significantly reduces the time required for on-site personnel to inspect the wear of industrial brake pads, uneven wear, and brake compensation, saving manpower and maintenance costs; it avoids equipment damage caused by human oversights, ensuring safety.

[0051] In the above embodiments, although the present invention has been described in conjunction with specific embodiments thereof, many substitutions, modifications, and variations of these embodiments will be apparent to those skilled in the art from the foregoing description. The embodiments of the present invention are intended to cover all such substitutions, modifications, and variations falling within the broad scope of the appended claims.

[0052] The above embodiments are merely illustrative of the principles and effects of this utility model and are not intended to limit the scope of this utility model. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this utility model. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this utility model should still be covered by the claims of this utility model.

Images