Elevator brake cylinder sensor

Abstract

The utility model discloses a hoist brake cylinder body sensor relates to equipment state monitoring technical field, including brake cylinder body and the sensor assembly of setting on its outside, the sensor assembly includes fixed plate, sensor installation shell, monitoring sensor and sensor protection shell, is equipped with sensor interface on the casing of sensor installation shell, and the through hole is opened in the interface and is provided with the replaceable connecting piece, to flexible installation different types of non -contact monitoring sensor, such as temperature, range finding, vibration sensor etc., and the sensor protection shell cover shield is provided with protection outside, the utility model discloses through the modularization design, realized the integration of brake cylinder body temperature, eccentric, axial displacement, vibration etc.

Description

Technical Field

[0001] This utility model relates to the field of equipment condition monitoring technology, specifically to a hoist gate cylinder sensor. Background Technology

[0002] As a key piece of equipment in industries such as mining, metallurgy, and construction, the reliability of the braking system of hoists is directly related to the safety and stability of the entire production system; the brake cylinder (brake disc) is the core component of the braking system, and its operating status (such as temperature, eccentricity, vibration, deformation, etc.) is an important basis for judging the health of the braking system.

[0003] Currently, the methods for monitoring the condition of the hoist gate cylinder are relatively simple and outdated; the following methods are commonly used:

[0004] 1. Relying on maintenance personnel to use handheld thermometers, vibration meters and other equipment for offline and sampling inspections; this method is not only inefficient, but also cannot achieve continuous and real-time monitoring, making it easy to miss sudden faults and creating huge safety blind spots;

[0005] 2. In some situations, individual sensors (such as single temperature or vibration sensors) may be installed; however, these sensors are often installed independently, with a scattered layout and a lack of unified protection and integrated design. This leads to inconvenient installation, messy wiring harnesses, and the sensors themselves are easily damaged under harsh working conditions (such as high dust, high humidity, and mechanical impact), resulting in short service life. It is also difficult to conduct comprehensive analysis and linkage diagnosis of monitoring data.

[0006] 3. Existing monitoring devices typically have fixed functions, making it difficult to flexibly adjust the type and number of sensors according to different working conditions or monitoring priorities. When production processes change or monitoring parameters need to be added, the entire monitoring system often needs to be redesigned and modified, resulting in high costs, long cycles, and a lack of flexibility and scalability.

[0007] Therefore, there is a need for a comprehensive monitoring device that can integrate, modularize, provide real-time online monitoring of the hoist gate cylinder, and be flexibly configurable, in order to overcome the aforementioned deficiencies of the existing technology. Utility Model Content

[0008] (a) Technical problems to be solved

[0009] To address the shortcomings of existing technologies, this utility model provides a hoist gate cylinder sensor, which solves the aforementioned problems.

[0010] (II) Technical Solution

[0011] To achieve the above objectives, this utility model provides the following technical solution: a hoist brake cylinder sensor, comprising a brake cylinder and a sensor assembly sleeved on the outside of the brake cylinder. The sensor assembly includes a fixing plate, a sensor mounting shell, a monitoring sensor, and a sensor protective shell. The sensor mounting shell has a housing, and the housing is provided with a sensor interface for mounting the monitoring sensor. The sensor protective shell covers the outside of the sensor mounting shell and the monitoring sensor for protection. The monitoring sensor is used to monitor the operating status and geometric attitude of the brake cylinder in real time.

[0012] By adopting the above technical solution, an integrated non-contact monitoring system was constructed. This structure integrates multiple monitoring functions into a compact component, which is fitted on the outside of the brake cylinder. This enables real-time, in-situ monitoring of the operating status and geometric attitude of the core braking components of the hoist, providing a hardware foundation for fault early warning and predictive maintenance, and significantly improving the safety and reliability of the equipment.

[0013] Preferably, the monitoring sensor is one or more combinations selected from the following non-contact sensors according to the monitoring requirements:

[0014] A temperature sensor is used for non-contact monitoring of the operating temperature of the brake cylinder.

[0015] The first and second ranging sensors, which are disposed on both sides of the front end face of the housing, are used to perform non-contact ranging on both sides of the front end face of the brake cylinder to detect its axial offset.

[0016] The third ranging sensor, which is set on the arc-shaped surface of the housing, is arranged in the radial direction of the brake cylinder and is used to perform non-contact ranging on the circumferential side of the brake cylinder to monitor its eccentricity.

[0017] A vibration sensor is used to monitor the vibration amplitude and frequency of the brake cylinder in a non-contact manner in order to determine its dynamic equilibrium state.

[0018] A proximity switch is used to non-contactly sense whether the brake cylinder has reached a preset limit position;

[0019] An image sensor is used for non-contact visual monitoring of the surface of the brake cylinder.

[0020] By adopting the above technical solution, a highly flexible and configurable sensor solution is provided. Users can freely select and combine sensors according to the actual monitoring focus (such as sway, temperature, vibration, etc.), realizing the modularization of functions. This not only meets the diverse working conditions and avoids resource waste, but also enables a more comprehensive and accurate assessment of the health status of the brake cylinder through multi-parameter fusion analysis.

[0021] Preferably, the sensor interface has a through hole, through which all the monitoring sensors perform non-contact monitoring of the brake cylinder.

[0022] By adopting the above technical solution, the through-hole structure provides a clear and unobstructed monitoring path for all non-contact sensors, ensuring the accuracy and reliability of monitoring data; at the same time, it isolates the sensor body from the harsh working environment, effectively extending the sensor's service life while ensuring functionality.

[0023] Preferably, the sensor interface is provided with a replaceable connector, one side of which is threaded to the sensor interface. The connector is used to adapt to different models of monitoring sensors. Users can install and fix different monitoring sensors to the sensor interface by selecting a connector that matches the selected monitoring sensor.

[0024] By adopting the above technical solution, the standardization and modularization of the sensor interface are achieved. By changing different connections, the same sensor interface can be adapted to various models of sensors. When it is necessary to replace or upgrade the sensor, there is no need to modify the main structure, only the connector needs to be replaced, which reduces the cost and complexity of later maintenance.

[0025] Preferably, the sensor protective housing includes a first housing and a second housing; the first housing covers the circumferential side of the housing and is used to protect the monitoring sensor installed on the arc-shaped surface of the housing; the second housing covers the front end face of the housing and is used to protect the monitoring sensor installed on the front end face of the housing; the second housing has a wire hole, and a wire harness sealing assembly is provided at the wire hole to seal and tighten the sensor wire harness passing through the wire hole;

[0026] By adopting the above technical solution, the sensor mounting shell protects different mounting surfaces of the sensor mounting shell; the setting of the wire hole and its sealing components provides a good sealing and locking function while realizing the wire harness lead-out, effectively preventing oil, dust and moisture from entering the interior of the protective shell along the wire harness;

[0027] Preferably, the sensor protective shell is fixedly connected to the sensor mounting shell via a connecting edge 2 at its end and a connecting edge 1 at its end, and the sensor mounting shell is fixedly connected to the fixing plate via a connecting edge 1 at its end.

[0028] (III) Beneficial Effects

[0029] This utility model provides a sensor for the gate cylinder of a hoist, which has the following advantages:

[0030] 1. By designing the sensor mounting shell and sensor protective shell as a compact assembly fitted onto the outside of the brake cylinder, the monitoring functions of multiple sensors are highly integrated into one unit; synchronous, in-situ, and real-time monitoring of brake cylinder temperature, axial offset, radial eccentricity, vibration, limit position, and surface condition is achieved, fundamentally changing the fragmented and inefficient situation of traditional monitoring methods.

[0031] 2. The sensor interface adopts standard specifications and is equipped with replaceable connectors, allowing users to freely select and replace different types of non-contact sensors according to actual needs. This design enables a single hardware system to adapt to various monitoring scenarios, greatly improving the versatility of the equipment and significantly reducing the cost and complexity of later upgrades and modifications.

[0032] 3. The through-hole in the sensor interface provides an unobstructed monitoring path for all non-contact sensors, ensuring data accuracy. At the same time, the robust sensor protective shell effectively isolates the core sensing element from the harsh external environment. Together with the reliable wire harness sealing assembly at the wiring hole, it provides excellent dustproof, waterproof, and mechanical shock protection for the internal sensors, significantly extending the service life of the entire monitoring system. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0034] Figure 2 This is a top sectional view of the overall structure of this utility model;

[0035] Figure 3 This is an analytical diagram of the overall structure of this utility model;

[0036] Figure 4 This is a schematic diagram of the sensor mounting shell structure in this utility model;

[0037] Figure 5 This is a schematic diagram of the sensor protective shell structure in this utility model;

[0038] In the diagram: Brake cylinder body-1, sensor assembly-2, fixing plate-21, sensor mounting shell-22, housing-221, sensor interface-222, connector-2221, connecting edge one-223, monitoring sensor-23, sensor protective shell-24, cover one-241, cover two-242, wire hole-243, wire harness sealing assembly-244, connecting edge two-245. Detailed Implementation

[0039] The following is in conjunction with the appendix Figure 1 - Appendix Figure 5 This application will be described in further detail below.

[0040] like Figures 1 to 5 As shown, a preferred embodiment of a hoist brake cylinder sensor provided by this utility model includes a brake cylinder 1 and a sensor assembly 2 sleeved on the outside of the brake cylinder 1. The sensor assembly 2 includes a fixing plate 21, a sensor mounting shell 22, a monitoring sensor 23, and a sensor protective shell 24. The sensor mounting shell 22 has a housing 221, and a sensor interface 222 for mounting the monitoring sensor is provided on the housing 221. The sensor protective shell 24 covers the outside of the sensor mounting shell 22 and the monitoring sensor 23 for protection. The monitoring sensor 23 is used to monitor the operating status and geometric attitude of the brake cylinder 1 in real time.

[0041] An integrated non-contact monitoring system was constructed, which integrates multiple monitoring functions into a compact component and is fitted on the outside of the brake cylinder. This enables real-time, in-situ monitoring of the operating status and geometric attitude of the core braking components of the hoist, providing a hardware foundation for fault early warning and predictive maintenance, and significantly improving the safety and reliability of the equipment.

[0042] The monitoring sensor is one or more combinations selected from the following non-contact sensors according to the monitoring requirements:

[0043] A temperature sensor is used for non-contact monitoring of the operating temperature of the brake cylinder 1;

[0044] The first and second distance sensors, which are disposed on both sides of the front end face of the housing 221, are used to perform non-contact distance measurement on both sides of the front end face of the brake cylinder 1 to detect its axial offset.

[0045] The third ranging sensor, which is set on the arc-shaped surface of the housing 221, has its detection direction set along the radial direction of the brake cylinder 1. It is used to perform non-contact ranging on the circumferential side of the brake cylinder 1 to monitor its eccentricity.

[0046] A vibration sensor is used to monitor the vibration amplitude and frequency of the brake cylinder 1 in a non-contact manner in order to determine its dynamic equilibrium state.

[0047] A proximity switch is used to non-contactly sense whether the brake cylinder 1 has reached a preset limit position;

[0048] An image sensor is used for non-contact visual monitoring of the surface of the brake cylinder 1;

[0049] All monitoring sensors (23) meet the requirement of non-contact monitoring of the brake cylinder (1) through the through hole in the sensor interface (222). The working principle is that the detection signal emitted by the sensor itself (such as infrared light, laser, ultrasonic wave, electromagnetic wave, etc.) or the target signal received (such as infrared radiation, reflected light, visible light image) can pass through the through hole without obstruction and interact with the surface of the brake cylinder (1), thereby realizing the perception of the target parameters. The whole process does not require physical contact with the brake cylinder (1).

[0050] Various methods of non-contact monitoring using sensors:

[0051] Temperature sensors measure the temperature of a brake cylinder by receiving infrared energy radiated outwards from its surface. Through-holes provide a path for the propagation of infrared radiation, as seen in the CTlaser series of infrared temperature sensors.

[0052] The distance sensor emits a detection signal (laser, ultrasonic wave, etc.) onto the surface of the brake cylinder and receives the signal reflected back from the surface. It accurately measures the distance by calculating the time difference or phase difference. Through-holes ensure the transmission and reception of the detection signal, as seen in the ZX2-L series laser displacement sensor.

[0053] The vibration sensor employs the laser Doppler vibration measurement principle, measuring vibration by detecting frequency changes in a laser beam reflected from the brake cylinder surface. Through-holes provide an optical channel for laser emission and reception, as seen in the VibroFlex series laser Doppler vibration meters.

[0054] A proximity switch generates an electromagnetic field through its internal oscillator. When a metal brake cylinder enters the range of this magnetic field, the internal circuit state changes and outputs a switching signal. The through hole does not affect the propagation of the electromagnetic field, such as the NAMUR series inductive proximity switch.

[0055] Image sensors capture visible light images of the brake cylinder surface through a lens. The through-hole acts as a protective "viewing window," ensuring a clear view while preventing the lens from being contaminated or damaged, as seen in Blackfly S series industrial cameras.

[0056] By providing a highly flexible and configurable sensor solution, users can freely select and combine sensors according to actual monitoring priorities (such as yaw, temperature, vibration, etc.), realizing modularization of functions. This not only meets diverse working conditions and avoids resource waste, but also enables a more comprehensive and accurate assessment of the health status of the brake cylinder through multi-parameter fusion analysis.

[0057] The sensor interface 222 has a through hole, through which all monitoring sensors 23 perform non-contact monitoring of the brake cylinder 1.

[0058] The through-hole structure provides a clear and unobstructed monitoring path for all non-contact sensors, ensuring the accuracy and reliability of monitoring data; at the same time, it isolates the sensor body from the harsh working environment, effectively extending the sensor's service life while ensuring functionality.

[0059] A replaceable connector 2221 is provided at the sensor interface 222. One side of the connector 2221 is connected to the sensor interface 222 by a thread. The connector 2221 is used to adapt to different models of monitoring sensors 23. By selecting the connector 2221 that matches the selected monitoring sensor 23, the user can install and fix different monitoring sensors 23 onto the sensor interface 222.

[0060] The sensor interface 222 has been standardized and modularized. By replacing different connectors 2221, the same sensor interface 222 can be adapted to various models of sensors. When the sensor needs to be replaced or upgraded, there is no need to change the main structure. Only the connector 2221 needs to be replaced, which reduces the cost and complexity of later maintenance.

[0061] The sensor protective housing 24 includes a first housing 241 and a second housing 242. The first housing 241 covers the circumferential side of the housing 221 and is used to protect the monitoring sensor 23 installed on the arc surface of the housing 221. The second housing 242 covers the front end face of the housing 221 and is used to protect the monitoring sensor 23 installed on the front end face of the housing 221. A wire hole 243 is provided on the second housing 242, and a wire harness sealing assembly 244 is provided at the wire hole 243 to seal and tighten the sensor wire harness passing through the wire hole 243.

[0062] The wire harness sealing assembly 244 may employ well-established solutions known in the art, such as, but not limited to, the following two:

[0063] 1. Standard waterproof cable connector is used: The waterproof cable connector is connected to the wire hole 243 by threads, and its internal sealing ring and clamping mechanism can reliably seal and fix one or more sensor wire harnesses.

[0064] 2. A combination of flexible tubing and connectors: In actual installation, multiple sensor wire harnesses 23 can be first fitted into a flexible tubing, such as heat shrink tubing, to form a neat bundle. Then, a waterproof cable connector that matches the outer diameter of the combined wire harness is selected and installed at the wire hole 243. By tightening the connector, the clamping mechanism and sealing ring inside will uniformly compress and seal the outer wall of the flexible tubing. This not only eliminates the gaps between multiple independent wire harnesses using the tubing, achieving efficient sealing, but also provides tensile mechanical protection through the connector. At the same time, it makes the wire harness layout neater and facilitates on-site management and maintenance.

[0065] Those skilled in the art will understand that any of the above-mentioned known technologies can effectively solve the sealing and fixing problem of multiple wire harnesses, ensuring the overall protection level of the sensor protective housing 24.

[0066] The sensor protective housing 24 protects the different mounting surfaces of the sensor mounting housing 22; the wire hole 243 and its sealing component 244 provide good sealing and locking functions while realizing the wire harness lead-out, effectively preventing oil, dust and moisture from entering the interior of the protective housing along the wire harness.

[0067] The sensor protective housing 24 is fixedly connected to the sensor mounting housing 22 via the connecting edge 245 at its end and the connecting edge 223 at its end. The sensor mounting housing 22 is fixedly connected to the fixing plate 21 via the connecting edge 223 at its end.

[0068] The implementation principle of this utility model is based on the idea of ​​modular integration and multi-parameter fusion diagnosis. It achieves real-time and comprehensive monitoring of the health status of the hoist gate cylinder 1 through the following workflow:

[0069] 1. First, the user selects one or more monitoring sensors 23 from the non-contact sensor library supported by this utility model according to specific monitoring needs, such as focusing on temperature, vibration or deformation; by installing the selected sensor onto the standardized sensor interface 222 with the help of the replaceable connector 2221, the functional configuration of the sensor assembly 2 is quickly completed; then, the entire sensor assembly 2 is installed at an appropriate position on the outside of the brake cylinder 1 through the fixing plate 21.

[0070] 2. After the system is powered on, each monitoring sensor 23 performs non-contact measurement on the brake cylinder 1 through the through hole in the sensor interface 222.

[0071] The temperature sensor collects surface temperature data in real time during the braking process;

[0072] The first and second ranging sensors monitor the axial offset of the front end face of the brake cylinder 1;

[0073] The third ranging sensor monitors the radial eccentricity of the brake cylinder 1;

[0074] Vibration sensors capture the vibration spectrum and amplitude during operation;

[0075] Proximity switches provide binary safety signals at extreme positions;

[0076] Image sensors capture visual state information of a surface;

[0077] All sensor wiring harnesses are led out through wiring harness sealing assembly 244 at wiring hole 243 and connected to an external control and analysis system.

[0078] 3. The external control and analysis system receives and processes multiple signals from sensor component 2; by fusing and analyzing multi-parameter data such as temperature, displacement, vibration, and vision, the system can construct a comprehensive health status model of the brake cylinder 1; this model can accurately determine whether the cylinder has fault modes such as overheating, swaying, eccentricity, abnormal vibration, or surface damage.

[0079] 4. When the analysis results exceed the preset safety threshold, the system will immediately issue a warning or alarm signal to prompt the operator to take action, thereby achieving predictive maintenance. This avoids the blindness of traditional periodic maintenance or the major safety accidents that may be caused by the failure to detect faults in time, fundamentally improving the safety and reliability of hoist operation.

[0080] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

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