Escalator additional brake pawl in-place detection system based on photoelectric detection

Abstract

The utility model provides an escalator additional brake pawl in place detection system based on photoelectric detection relates to escalator technical field, including main control panel, main control panel and escalator operation state detection module communication connection, escalator operation state detection module and additional brake electromagnet controller connection, additional brake electromagnet controller's output and pawl controller connection, additional brake electromagnet controller and photoelectric detection module connection, photoelectric detection module and photoelectric switch connection, photoelectric switch and photoelectric signal judging module connection, photoelectric signal judging module and main control panel connection. The utility model has prevented the mechanical wear and tear problem caused by contact, collision, has realized long -life, maintenance -free or less maintenance operation, has guaranteed accurate and stable, has promoted detection precision and anti -interference ability.

Description

Technical Field

[0001] This utility model relates to the field of escalator technology, and more specifically, to an escalator auxiliary brake pawl positioning detection system based on photoelectric detection. Background Technology

[0002] Additional brakes are crucial safety devices for escalators and moving walkways, used to trigger braking in abnormal situations such as overspeeding, reverse rotation, or drive chain breakage to prevent uncontrolled operation. To ensure the reliability of the additional brake, its pawl must be monitored in real time to ensure it is properly engaged, preventing brake failure or malfunction. Currently, the industry commonly uses mechanical limit switches for detection, where the mechanical movement of the pawl triggers the limit switch contacts, thus outputting a signal.

[0003] Existing mechanical limit switches are easily affected by interference during testing, resulting in reduced accuracy and low stability. Utility Model Content

[0004] The present invention aims to solve the problems of mechanical limit switches being easily interfered with during detection, resulting in reduced accuracy and low stability.

[0005] To solve the above problems, this utility model provides an escalator auxiliary brake pawl positioning detection system based on photoelectric detection, including a main control board, an escalator running status detection module, an auxiliary brake electromagnet controller, a pawl controller, a photoelectric detection module, a photoelectric switch, and a photoelectric signal judgment module;

[0006] The main control board and the escalator operation status detection module are connected in communication, and the escalator operation status detection module is connected in communication with the input terminal of the auxiliary brake electromagnet controller.

[0007] The output of the auxiliary brake electromagnet controller is connected to the pawl controller via communication.

[0008] The auxiliary brake electromagnet controller and photoelectric detection module are connected in communication.

[0009] The photoelectric detection module and the photoelectric switch are connected in communication.

[0010] The photoelectric switch and the photoelectric signal judgment module are connected in communication.

[0011] The photoelectric signal judgment module and the main control board are connected for communication.

[0012] This utility model provides an escalator auxiliary brake pawl positioning detection system based on photoelectric detection, which has the following advantages compared to the prior art:

[0013] This invention achieves ultra-high reliability and long lifespan through non-contact detection. Utilizing photoelectric principles, the detection element (photoelectric switch) has no physical contact with the pawl of the object being detected, fundamentally eliminating mechanical wear caused by contact or collision. This results in long lifespan and maintenance-free or minimal-maintenance operation. It completely solves problems such as poor contact, adhesion, or failure of mechanical contacts caused by oxidation, oil contamination, or arc erosion, ensuring the reliability of signal output from a physical perspective. This guarantees accuracy and stability, improving detection precision and anti-interference capabilities.

[0014] Furthermore, the escalator operation status detection module includes a stop detection unit and an operation detection unit.

[0015] Furthermore, the main control board output terminal is communicatively connected to the detection status display.

[0016] Furthermore, the output of the main control board is also connected to the alarm.

[0017] Furthermore, the main control board is a microprocessor or a PLC.

[0018] Preferably, the main control board has a dual-CPU redundant structure.

[0019] Furthermore, the photoelectric signal judgment module is an independent sensor.

[0020] Furthermore, the photoelectric switch is a through-beam or mirror-reflective photoelectric switch.

[0021] Furthermore, the photoelectric switch is vertically mounted above the additional brake pawl via a mounting bracket.

[0022] Furthermore, the mounting distance between the photoelectric switch and the additional brake pawl is between 2mm and 2.5mm. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the escalator auxiliary brake pawl positioning detection system based on photoelectric detection, according to an embodiment of the present invention.

[0024] Figure 2 This is a schematic diagram of the detection logic of the escalator auxiliary brake pawl positioning detection system based on photoelectric detection, according to an embodiment of this utility model.

[0025] Figure 3 This is a schematic diagram of the main control board in an embodiment of the present utility model. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings showing multiple embodiments according to this application. It should be understood that the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments described in this application without creative effort will fall within the scope of protection of this application.

[0027] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used in the description of this application is for the purpose of describing specific embodiments only and is not intended to limit this application; the terms "comprising," "including," "having," "containing," etc., in the description, claims, and accompanying drawings of this application are open-ended terms. Therefore, "comprising," "including," or "having" refers to, for example, a method or apparatus having one or more steps or elements, but is not limited to having only these one or more elements. The terms "first," "second," etc., in the description, claims, or accompanying drawings of this application are used to distinguish different objects, not to describe a specific order or hierarchy. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0028] In the description of this utility model, it should be understood that the terms "upper", "lower", "left", "right", "front", "rear", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model 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. Therefore, they should not be construed as limitations on this utility model.

[0029] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "attachment" 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; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0030] It should be emphasized that when the term "comprising / including" is used in this specification, it is used to explicitly indicate the presence of the stated feature, integer, step, or component, but does not exclude the presence or addition of one or more other features, integers, steps, parts, or groups of features, integers, steps, or parts.

[0031] In this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, in this application, the character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0032] In recent years, photoelectric sensing technology has been widely used in industrial inspection due to its advantages such as non-contact operation, high precision, and long lifespan. This paper proposes a novel non-contact inspection scheme that uses a photoelectric sensor with an additional brake pawl, enabling it to handle various complex working conditions more stably and reliably.

[0033] See Figures 1-3 The photoelectric detection-based escalator auxiliary brake pawl positioning detection system of this utility model includes a main control board, an escalator running status detection module, an auxiliary brake electromagnet controller, a pawl controller, a photoelectric detection module, a photoelectric switch, and a photoelectric signal judgment module.

[0034] The main control board and the escalator operation status detection module are connected in communication, and the escalator operation status detection module is connected in communication with the input terminal of the auxiliary brake electromagnet controller.

[0035] The output of the auxiliary brake electromagnet controller is connected to the pawl controller via communication.

[0036] The auxiliary brake electromagnet controller and photoelectric detection module are connected in communication.

[0037] The photoelectric detection module and the photoelectric switch are connected in communication.

[0038] The photoelectric switch and the photoelectric signal judgment module are connected in communication.

[0039] The photoelectric signal judgment module and the main control board are connected for communication.

[0040] The main control board, as the core processing unit of the system, is used to receive and process various detection signals and output control commands and status information.

[0041] The escalator operation status detection module is used to monitor the real-time operation status of escalators or moving walkways. It monitors escalator operating parameters such as motor speed and direction of travel. Its internal stop and run detection units accurately determine whether the escalator is stopped, running normally, overspeeding, or reversing. The module's output serves as the primary basis for determining whether the auxiliary brake should activate.

[0042] The auxiliary brake electromagnet controller is used to control the energization and de-energization of the auxiliary brake electromagnet according to the escalator's operating status.

[0043] The pawl controller is used to drive the pawl of the auxiliary brake to extend or retract. The auxiliary brake electromagnet controller receives instructions from the escalator operation status detection module. When the brake needs to be engaged and the pawl needs to retract, the electromagnet is energized; when the brake needs to be engaged and the pawl needs to extend, the electromagnet is de-energized.

[0044] The pawl controller directly drives the electromagnet mechanism of the auxiliary brake to control the movement of the pawl.

[0045] The photoelectric detection module can detect whether the pawl has been released. The photoelectric detection module is used to start the photoelectric detection process when the electromagnet is activated. The photoelectric detection module is responsible for starting the detection process of the photoelectric switch when the state of the electromagnet changes, especially when the power is off.

[0046] A photoelectric switch is vertically mounted at a specific position above the movement trajectory of the auxiliary brake pawl. It is used for non-contact detection of the pawl's position and outputs a corresponding photoelectric signal.

[0047] The photoelectric signal judgment module is communicatively connected to the photoelectric switch and is used to receive and process the signal output by the photoelectric switch to determine whether the pawl is in position.

[0048] The photoelectric signal judgment module is communicatively connected to the main control board and uploads its judgment results to the main control board.

[0049] The main control board integrates the signals from the photoelectric signal judgment module to ultimately determine the position status of the auxiliary brake pawl, and performs display, alarm, or safety interlock control accordingly.

[0050] Furthermore, the escalator operation status detection module includes a stop detection unit and an operation detection unit;

[0051] Furthermore, the main control board output terminal is communicatively connected to the detection status display;

[0052] Furthermore, the output of the main control board is also communicatively connected to the alarm.

[0053] The status display and alarm are connected to the main control board output. The display shows real-time information such as "Pawl retracted normally," "Pawl extended normally," and "Detection system fault." The alarm emits a strong audible and visual alarm signal when it detects abnormal pawl movement, such as failure to reach the correct position within time or a system malfunction.

[0054] Furthermore, the main control board is a microprocessor or a PLC;

[0055] Preferredly, the main control board features a dual-CPU redundant structure. In this structure, the two CPUs operate independently, simultaneously processing input signals and performing logical judgments. They compare results via internal communication, and if any inconsistency is detected, a preset safety strategy is immediately implemented, such as outputting a fault signal or entering a safe state, significantly improving system reliability.

[0056] Furthermore, the photoelectric signal judgment module is an independent sensor; such as another micro switch or proximity switch used to confirm the start of the action, to assist in confirming that the pawl has been released and started moving.

[0057] Furthermore, the photoelectric switch is a small, robust through-beam or mirror-reflective photoelectric switch with a protection rating of at least IP67, and has good resistance to oil and vibration.

[0058] Furthermore, the photoelectric switch is vertically mounted above the auxiliary brake pawl via a mounting bracket, with its photoelectric sensing surface's transmitting and receiving windows precisely aligned with the pawl's movement plane. The critical mounting distance H is strictly controlled between 2mm and 2.5mm. This distance is optimized to ensure sufficient proximity to obtain a strong reflected signal or reliable beam blocking effect, while also providing a safe clearance for pawl movement to avoid any possible collisions. A metal baffle is fixed to the top of the pawl, and this baffle moves synchronously with the pawl.

[0059] The photoelectric signal judgment module receives the switching signal output by the photoelectric switch, such as the NPN normally open type: when blocked, it outputs a high level of 24V, and when unobstructed, it outputs a low level of 0V. This module integrates a digital filtering algorithm with a judgment time window of approximately 50ms. Only when the signal state remains consistently high or low for more than this time window is it considered a valid state change, thus effectively filtering out instantaneous signal jitter caused by mechanical vibration.

[0060] During installation, the position of the photoelectric switch can be finely adjusted in three dimensions using the adjusting screws on the mounting bracket, ensuring that when the pawl is fully retracted under the action of the electromagnet, the metal baffle on top can completely and stably block the light path of the photoelectric switch.

[0061] In this specific embodiment, a photoelectric switch is vertically mounted 2-2.5mm above the pawl of the auxiliary brake, with its photoelectric sensing surface aligned with the pawl's moving plane. When the electromagnet is not energized, the pawl is in the extended position, the photoelectric switch's light path remains unobstructed, and it outputs a low-level signal to the control system. When the electromagnet is energized, the pawl extends to the working position under the action of the return spring, and the photoelectric switch's light is completely blocked by its top metal baffle, outputting a high-level signal. The control system determines the pawl's position by detecting changes in the port signal and sets a 50ms digital filtering time window to eliminate mechanical vibration interference. Fine-tuning of the installation position is achieved by adjusting the screw, ensuring that the pawl baffle completely blocks the light path when retracted.

[0062] The system workflow is as follows:

[0063] During normal operation: The escalator operation status detection module indicates operation. The main control board energizes the electromagnet, and the pawl retracts. At this time, the metal baffle at the top of the pawl should block the light path of the photoelectric switch, causing the photoelectric switch to output a high level. After filtering and confirmation, the photoelectric signal judgment module reports to the main control board that "pawl not extended to the correct position," indicating that it has retracted. The main control board confirms that this status is consistent with the operation command, and the system is normal.

[0064] During braking or testing: When an abnormality occurs requiring braking or testing, the main control board de-energizes the electromagnet. The pawl should extend rapidly under spring force. When it extends to the set working position, the metal baffle moves away from the light path, the photoelectric switch light path is unobstructed, and the output becomes low. After filtering and confirmation, the photoelectric signal judgment module reports "Pawl extended to the correct position" to the main control board. At the same time, the photoelectric signal judgment module also confirms that the pawl has been activated. The main control board combines the information from both to determine that the auxiliary brake has been activated correctly. If the "Pawl extended to the correct position" signal is not received within the specified time after the electromagnet is de-energized, the main control board immediately determines it as a fault, triggers the alarm, and may link the escalator main control system to perform emergency shutdown and other safety measures.

[0065] This invention proposes a non-contact detection scheme based on photoelectric switches, compared to existing mechanical detection methods for escalator auxiliary brakes. This scheme optimizes the selection, installation position, and signal processing of photoelectric sensors to achieve stable and reliable monitoring of the pawl's opening and closing state of the auxiliary brake. Specifically, this invention uses a high-performance photoelectric switch that is oil-resistant and vibration-resistant, installed directly above the pawl's movement trajectory. When the pawl reaches a set opening angle, the photoelectric switch detects changes in the reflected signal and outputs a corresponding signal to the control system, thereby accurately determining the brake's working state. The control system employs a dual-CPU structure with redundant detection technology, reducing interference and improving accuracy and stability. Compared to traditional mechanical limit switches, this invention avoids the wear problems caused by physical contact, significantly improving detection accuracy and service life, while reducing maintenance frequency and costs. Furthermore, this scheme has a compact structure, adapting to the limited installation space of escalators, and possesses good resistance to environmental interference, ensuring long-term stable operation under complex conditions such as vibration and oil contamination, providing a more reliable guarantee for the safe operation of escalators.

[0066] This invention achieves ultra-high reliability and long lifespan through non-contact detection.

[0067] Eliminating mechanical wear: This is the core advantage. Traditional mechanical switches rely on physical contact and force, inevitably leading to wear, fatigue, and aging of the contacts, points, and internal springs. This invention uses photoelectric principles; the photoelectric switch of the detection element has no physical contact with the pawl of the object being detected, fundamentally eliminating the problem of mechanical wear caused by contact and collision.

[0068] Significantly extended service life: Since there are no mechanical wear points, the lifespan of a photoelectric switch depends primarily on the lifespan of its electronic components, which is typically much longer than the operating lifespan of a mechanical switch. This means the detection device itself is more durable, achieving long-life, maintenance-free or low-maintenance operation.

[0069] Avoid contact failure: It completely solves the problems of poor contact, adhesion or failure of mechanical contacts caused by oxidation, oil contamination, arc erosion, etc., and ensures the reliability of signal output from the physical principle.

[0070] This invention ensures accuracy and stability, and improves detection precision and anti-interference capabilities.

[0071] High-precision positioning detection: The photoelectric switch has a fast response speed and high detection accuracy. By precisely controlling the installation distance to 2-2.5mm and aligning it with the pawl's movement plane, the system can sensitively and accurately capture minute positional changes of the pawl, ensuring extremely accurate judgment of the "positioned" state.

[0072] Advanced signal processing and anti-interference: The photoelectric signal judgment module's built-in digital filtering technology, such as a 50ms time window, effectively filters out signal jitter and transient interference caused by unavoidable mechanical vibrations during escalator operation. This ensures that only stable and continuous position signals are recognized as valid, greatly improving the stability and reliability of the detection results.

[0073] Enhanced environmental adaptability: The specially selected photoelectric switches, which are resistant to oil and vibration and have a high protection rating such as IP67, combined with non-contact detection methods, enable the system to easily cope with harsh working conditions such as oil, dust, moisture and continuous vibration commonly found in escalator shafts, reducing the impact of environmental factors on detection accuracy.

[0074] This utility model provides system-level security assurance: redundant design and intelligent diagnostics.

[0075] Dual-CPU redundancy architecture enhances system reliability: The main control board adopts a dual-CPU redundancy structure to process and cross-verify critical detection signals in parallel. This design significantly reduces the risk of the entire safety detection function failing due to a single processor failure, meeting the high reliability requirements of safety systems and realizing the principle of fault-oriented safety.

[0076] This utility model features real-time status monitoring and intelligent alarm: the system not only detects position but also intelligently judges whether the action logic is correct, such as whether it extends when it should and retracts when it should. Once an abnormal status or timeout occurs, an audible and visual alarm is immediately triggered, and fault information is displayed on the status monitor. This allows for rapid fault detection and location, facilitating quick response from maintenance personnel and greatly improving the safety management level and maintainability of the equipment.

[0077] Advantages of this utility model in terms of structure and operation and maintenance: Compact and easy to use, reducing costs. Compact structure and convenient installation: The photoelectric switch is small in size and flexible in installation, making it particularly suitable for installation conditions with limited internal space in escalators. The fine-tuning mechanism for the adjusting screw position on the mounting bracket facilitates precise on-site debugging, ensuring optimal testing results and reducing the difficulty of installation and debugging.

[0078] This invention significantly reduces the total life cycle cost: Reduced maintenance costs: Because the equipment itself is more durable and has a lower failure rate, the required daily inspections, replacement of spare parts and other maintenance work and costs are greatly reduced.

[0079] This invention reduces downtime losses: higher reliability means less downtime due to detection device failure, thus improving equipment operating efficiency.

[0080] This invention saves on replacement costs: its long lifespan significantly extends the replacement cycle of spare parts, indirectly reducing long-term operating costs.

[0081] This invention achieves high-precision, high-reliability, and long-life monitoring of the pawl position of the auxiliary brake through the aforementioned non-contact photoelectric detection scheme combining hardware and software, significantly improving the operational safety of escalators and moving walkways.

[0082] Although the present invention has been disclosed above, its scope of protection is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and all such changes and modifications will fall within the scope of protection of the present invention.

Claims

1. A photoelectric detection-based escalator auxiliary brake pawl positioning detection system, characterized in that, It includes a main control board, an escalator operation status detection module, an auxiliary brake electromagnet controller, a pawl controller, a photoelectric detection module, a photoelectric switch, and a photoelectric signal judgment module; The main control board and the escalator operation status detection module are connected in communication, and the escalator operation status detection module is connected in communication with the input terminal of the auxiliary brake electromagnet controller. The output of the auxiliary brake electromagnet controller is connected to the pawl controller via communication. The auxiliary brake electromagnet controller and photoelectric detection module are connected in communication. The photoelectric detection module and the photoelectric switch are connected in communication. The photoelectric switch and the photoelectric signal judgment module are connected in communication. The photoelectric signal judgment module and the main control board are connected for communication.

2. The escalator auxiliary brake pawl positioning detection system based on photoelectric detection according to claim 1, characterized in that, The escalator operation status detection module includes a stop detection unit and an operation detection unit.

3. The escalator auxiliary brake pawl positioning detection system based on photoelectric detection according to claim 2, characterized in that, The main control board output is connected to the detection status display.

4. The escalator auxiliary brake pawl positioning detection system based on photoelectric detection according to claim 3, characterized in that, The main control board output is also connected to the alarm.

5. The escalator auxiliary brake pawl positioning detection system based on photoelectric detection according to claim 4, characterized in that, The main control board is a microprocessor or a PLC.

6. The escalator auxiliary brake pawl positioning detection system based on photoelectric detection according to claim 4, characterized in that, The main control board has a dual-CPU redundant structure.

7. The escalator auxiliary brake pawl positioning detection system based on photoelectric detection according to claim 5 or 6, characterized in that, The photoelectric signal judgment module is an independent sensor.

8. The escalator auxiliary brake pawl positioning detection system based on photoelectric detection according to claim 7, characterized in that, The photoelectric switch is either a through-beam or a mirror-reflective photoelectric switch.

9. The escalator auxiliary brake pawl positioning detection system based on photoelectric detection according to claim 8, characterized in that, The photoelectric switch is vertically mounted above the auxiliary brake pawl via a mounting bracket.

10. The escalator auxiliary brake pawl positioning detection system based on photoelectric detection according to claim 9, characterized in that, The installation distance between the photoelectric switch and the auxiliary brake pawl is between 2 mm and 2.5 mm.

Images