Brake lining management device for rolling plants

Abstract

To provide a low-cost brake lining management device capable of managing the replacement timing of brake linings arranged in a rolling plant. [Solution] The brake lining management device includes a calculation unit that calculates the cumulative number of activations, which is the cumulative value of the number of brake activations in response to a brake activation command; a judgment unit that determines that it is time to replace the brake linings if the calculated cumulative number of activations is equal to or greater than a reference number; and a notification unit that prohibits operation of the brakes and electric motors and notifies the user that it is time to replace the brake linings if it is determined that replacement is required.

Description

[Technical Field]

[0001] The present disclosure relates to a brake lining management device for a rolling plant, and more particularly to a brake lining management device that manages replacement timings of brake linings attached externally to electric motors arranged in the rolling plant. [Background technology]

[0002] Rolling equipment installed in rolling plants, such as conveyor tables, rolling rolls, and hoists, are equipped with multiple electric motors. Among these multiple electric motors, there are electric motors with external brakes. The linings of external brakes (hereinafter also referred to as "brake linings") wear out with use, so their replacement intervals must be managed appropriately.

[0003] For example, Patent Document 1 discloses a brake lining wear detection device that includes an optical cable embedded in the brake lining, a light projector that projects light onto the input end of the optical cable, and a light receiver that receives light at the output end of the optical cable, and is configured to detect brake lining wear based on the light received by the light receiver. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2009-257550 Summary of the Invention [Problem to be solved by the invention]

[0005] However, embedding an optical cable in a replaceable brake lining as described in Patent Document 1 is not preferable because it increases the cost of parts. Furthermore, the need for a light projector and a light receiver increases the number of parts, leading to higher costs. In particular, since a rolling plant is equipped with many electric motors, the number of brake linings is naturally large, making the cost increase even more significant.

[0006] Therefore, an object of the present disclosure is to provide a low-cost brake lining management device that can manage the replacement timing of brake linings arranged in a rolling plant. [Means for solving the problem]

[0007] A first aspect of the present disclosure is a brake lining management device for a rolling plant. The brake lining management device manages the replacement timing of brake linings of brakes externally attached to electric motors arranged in the rolling plant. The brakes operate in response to brake activation commands based on the rolling plan of the rolling plant. The brake lining management device includes a calculation unit that calculates an accumulated number of activations, which is the accumulated value of the number of times the brakes have been activated in response to the brake activation commands, a determination unit that determines that it is time to replace the brake linings if the calculated accumulated number of activations is equal to or greater than a reference number, and a notification unit that prohibits operation of the brakes and electric motors and notifies the user that it is time to replace the brake linings if it is determined that replacement is required.

[0008] However, the brakes may be activated in response to an emergency stop command. In this case, the brakes are activated more strongly than when activated in response to a brake activation command during normal operation, resulting in a higher load on the brake linings. The second aspect has the same features as the first aspect, but also includes the following: The calculation unit is configured to add the number of emergency activations, which is the number of times the brakes are activated in response to an emergency stop command, to the cumulative number of activations.

[0009] The third aspect has the following characteristics in addition to the second aspect: the calculation unit is configured to multiply the number of emergency operations by a weighting coefficient for weighting the number of emergency operations relative to the number of brake operations, and add the number of emergency operations multiplied by the weighting coefficient to the cumulative number of operations. [Effects of the Invention]

[0010] According to the first aspect of the present disclosure, it is determined that the brake linings have not yet reached the time to be replaced, and the brakes and electric motors can be operated, until the cumulative number of operations reaches a reference number. When the cumulative number of operations reaches or exceeds the reference number, it is determined that the brake linings have reached the time to be replaced, operation of the brakes and electric motors is prohibited, and a notification is issued that the brake linings should be replaced. This makes it possible to manage the replacement times of brake linings installed in a rolling plant. Moreover, since the number of parts does not increase, the system is low cost.

[0011] According to the second aspect, the number of emergency operations based on the emergency stop command is added to the cumulative number of operations based on the rolling plan, so that the time to replace the brake linings can be determined more accurately. In this case, it is preferable to add the number of emergency operations multiplied by a weighting coefficient, as in the third aspect. This makes it possible to properly reflect the emergency stop command in the cumulative number of operations. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a diagram showing an example of a rolling plant to which a brake lining management device according to an embodiment is applied; [Figure 2] FIG. 2 is a diagram showing a brake externally attached to an electric motor. [Figure 3] 3 is a flowchart for explaining a brake lining management method performed by the brake lining management device. [Figure 4] FIG. 2 is a diagram illustrating an example of a hardware configuration of a brake lining management device. DETAILED DESCRIPTION OF THE INVENTION

[0013] Hereinafter, with reference to the drawings, a brake lining management device using a diameter tier according to an embodiment of the present disclosure will be described, taking as an example a case where it is applied to a rolling plant (steel plant). Common or corresponding elements in each drawing are given the same reference numerals, and descriptions thereof will be simplified or omitted.

[0014] FIG. 1 is a diagram showing an example of a rolling plant 2 to which a brake lining management device 1 according to an embodiment is applied. The rolling plant 2 will be described taking, for example, a plant having a hot rolling line as an example, but it may also be a plant having a cold rolling line. The rolling plant 2 is equipped with a heating furnace 3, a roughing mill 4, a finishing mill 5, a cooling device 6, a winder 7, and a conveying table (not shown) for conveying the rolled material Mr as main rolling equipment constituting the hot rolling line. Although not shown, the conveying table includes conveying rolls arranged side by side in the rolling direction and an electric motor for rotating the rolls.

[0015] The heating furnace 3 is configured to heat the rolled material (slab) Mr to a predetermined temperature (e.g., 1200°C) before rolling. The roughing mill 4 has one to three rolling stands R1 (one in the example shown in Figure 1) and rolls the rolled material Mr heated in the heating furnace 3 in multiple passes while switching the rolling direction. The roughing mill 4 is equipped with work rolls 41 and an electric motor 42 for roll rotation. The finishing mill 5 is a tandem rolling mill equipped with multiple rolling stands F1 to F7 (seven in the example shown in Figure 1) arranged side by side in the rolling direction of the rolled material Mr. Each rolling stand F1 to F7 is equipped with two upper and lower work rolls 51, two upper and lower backup rolls 52, and an electric motor 53 for roll rotation. The backup roll 52 is provided with a screw down device 54, which allows the roll gap to be adjusted. The cooling device 6 cools the rolled material Mr by injecting water into the rolled material Mr using a cooling bank. The cooled rolled material Mr is wound into a coil by a winder 7. The winder 7 is equipped with an electric motor 71. Various sensors are installed as measuring instruments at key points in the rolling plant 2. As the various sensors can be well-known ones, detailed description thereof will be omitted.

[0016] As described above, the rolling plant 2 is provided with a plurality of electric motors, including the electric motors 42, 53, and 71. FIG. 2 is a diagram showing brakes externally attached to the electric motors. As shown in FIG. 2, for example, a brake 8 is externally attached to the main body Mb of each of the electric motors 42, 53, and 71. The brake 8 includes a brake main body 81 and a brake lining 82. The brake 8 is configured to be able to move the brake lining 82 toward or away from the electric motor main body Mb based on a brake actuation command sent from a control computer 101, which will be described later. As the brake 8, for example, a known disc brake, drum brake, or electromagnetic brake can be used, and therefore a detailed description thereof will be omitted here. In order to manage the replacement timing of the brake lining 82 of the brake 8, a brake lining management device 1, which will be described later, is applied to the rolling plant 2.

[0017] The rolling plant 2 is operated by a control system using computers with a hierarchical structure. The computers include a control computer 101 and a host computer 102, which are connected to each other via a network. The control computer 101 is connected to the brake lining management device 1 via the network. The control computer 101 has a control controller such as a PLC (Programmable Logic Controller). The control computer 101 is connected to an HMI (Human Machine Interface) device 103 via the network. Data on the rolling equipment to be monitored is presented to the HMI device 103, allowing an operator to monitor or operate (control) the rolling equipment. When a rolling plan is input to the host computer 102, the host computer 102 sends the rolling plan to the control computer 101. The rolling plan also includes rolling information such as a target plate thickness, a target plate width, and a target temperature. The control computer 101 receives a rolling plan input from the host computer 102, calculates setting data including setting values ​​for each rolling equipment to be controlled, and transmits the calculated design data to the rolling plant 2, thereby controlling each rolling equipment constituting the rolling plant 2. The setting data includes a brake activation command for the brake 8. The brake activation command includes a brake release command and a brake lock command.

[0018] The brake lining management device 1 includes a calculation unit 11, a determination unit 12, and a notification unit 13. The calculation unit 11 calculates an accumulated activation count, which is the accumulated value of the number of brake activations in response to a brake activation command. The calculated accumulated activation count Nc is sent to the determination unit 12. The accumulated activation count Nc is counted up, for example, using a counter (not shown) stored in memory 100c. The calculation unit 11 also adds the emergency activation count, which is the number of times the brake 8 is activated in response to an emergency stop command, to the accumulated activation count Nc. At this time, the calculation unit 11 multiplies the emergency activation count by a weighting coefficient α for weighting the emergency activation count, and adds the emergency activation count multiplied by the weighting coefficient α. The weighting coefficient α is set to a value greater than 1, taking into account the effect (wear) that activation of the brake 8 in response to an emergency stop command has on the brake lining 82.

[0019] The determination unit 12 compares the cumulative number of actuations Nc with a reference number of actuations Nst. The reference number of actuations Nst is a threshold value for determining whether the brake linings 82 have worn down and need to be replaced, and can be set in advance through experiments or simulations. If the cumulative number of actuations Nc does not reach the reference number of actuations Nst, the determination unit 12 determines that the brake linings 82 do not need to be replaced. In this case, the brake 8 and the corresponding electric motors 42, 53, and 71 can be operated. The brake 8 can be released in response to a brake release command. If the cumulative number of actuations Nc is equal to or greater than the reference number of actuations Nst, the determination unit 12 determines that the brake linings 82 have worn down and need to be replaced. In this case, the operation of the brake 8 and the corresponding electric motors 42, 53, and 71 is prohibited. For example, the determination unit 12 can prohibit the operation of the brake 8 and the corresponding electric motors 42, 53, and 71 by forcibly turning off the power to these brakes 8 and the corresponding electric motors 42, 53, and 71 via the control computer 101. A function for prohibiting such an operation may be provided as an operation prohibiting section independent of the determining section 12.

[0020] The notification unit 13 notifies the user that it is time to replace the brake linings 82 by displaying the information on the HMI device 103. This allows the operator monitoring the HMI device 103 to be notified that it is time to replace the brake linings 82.

[0021] 3 is a flowchart illustrating the brake lining management method performed by the brake lining management device 1. First, it is determined whether or not a brake actuation command is present (step S1). If a brake actuation command is present, the process proceeds to step S2. On the other hand, if a brake actuation command is not present, the process proceeds to step S7.

[0022] In step S2, it is determined whether the cumulative number of actuations Nc is smaller than the reference number of actuations Nst. If the cumulative number of actuations Nc is smaller than the reference number of actuations Nst, the brake 8 is actuated in response to a brake actuation command (step S3). Thereafter, the cumulative number of actuations Nc is counted up (step S4). In this step S4, the cumulative number of actuations Nc is counted up by 1. Thereafter, this routine is temporarily terminated.

[0023] If the cumulative number of operations Nc is equal to or greater than the reference number of operations Nst (No in step S2), it is determined that the brake lining 82 needs to be replaced, and the process proceeds to step S5. In step S5, the operation of the brake 8 and the corresponding electric motors 42, 53, and 71 is prohibited. Next, the replacement time is notified to the HMI device 103 (step S6). After that, this routine is temporarily terminated.

[0024] In step S7, it is determined whether or not an emergency stop command has been issued. If there is no emergency stop command, this routine is temporarily terminated. On the other hand, if there is an emergency stop command, the brake 8 is activated (step S8). Thereafter, the cumulative number of activations Nc is counted up (step S9). In this step S9, the cumulative number of activations Nc is counted up by "α×1", where α is a weighting coefficient set to a value greater than 1. Thereafter, this routine is temporarily terminated.

[0025] As described above, according to this embodiment, it is determined that the time to replace the brake lining 82 has not yet arrived until the integrated number of activations Nc reaches the reference number of activations Nst, and the brake 8 is activated in response to a brake activation command. When the integrated number of activations Nc becomes equal to or greater than the reference number of activations Nst, it is determined that the time to replace the brake lining 82 has arrived, operation of the brake 8 and the corresponding electric motors 42, 53, 71 is prohibited, and an announcement is made that it is time to replace the brake lining 82. Therefore, it is possible to manage the time to replace the brake lining 82 of the external brake 8 arranged in the rolling plant 1. Moreover, there is no need for a light-emitter or light-receiver as in the conventional example, and the number of parts does not increase, resulting in low costs.

[0026] Furthermore, when an emergency stop command is issued, the number of emergency operations based on the emergency stop command is added to the cumulative number of operations Nc based on the rolling plan, so that the determination unit 12 can more accurately determine the time to replace the brake linings 82. At this time, it is preferable to add the number of emergency operations multiplied by the weighting coefficient α, "α×1". This allows the number of emergency operations to be properly reflected in the cumulative number of operations Nc.

[0027] FIG. 4 is a diagram showing an example of the hardware configuration of the brake lining maintenance device 1. The above-described functions of the brake lining maintenance device 1 can be realized by a processing circuit 100 shown in FIG. 4. The processing circuit 100 may be dedicated hardware 100a. The processing circuit 100 may also include a processor 100b and a memory 100c. The processing circuit 100 may be partially formed as dedicated hardware 10a and further include a processor 10b and a memory 100c. In the example shown in FIG. 4, the processing circuit 100 is partially formed as dedicated hardware 100a, and also includes a processor 100b and a memory 100c. The processing circuit 100 may be at least one dedicated hardware 100a. In this case, the processing circuit 100 may be, for example, a single circuit, a composite circuit, a programmed processor, a parallel programmed processor, an ASIC, an FPGA, or a combination thereof. The processing circuit 100 may also include at least one processor 100b and at least one memory 100c. In this case, each function of the brake lining management device 1 is realized by software, firmware, or a combination of software and firmware. The software and firmware are written as programs and stored in the memory 10c. The processor 100b realizes each function of the brake lining management device 1 by reading and executing the programs stored in the memory 100c. The processor 100b is also called a CPU (Central Processing Unit), processing device, arithmetic device, microprocessor, microcomputer, or DSP. The memory 100c corresponds to a storage device such as a non-volatile or volatile semiconductor memory, such as RAM, ROM, flash memory, EM-ROM, or EEM-ROM. In this way, the processing circuit 100 can realize each function of the brake lining management device 1 by hardware, software, firmware, or a combination of these.

[0028] Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above embodiments and can be implemented in various modifications without departing from the spirit of the present disclosure. In the above embodiments, an example has been described in which the HMI device 103 is provided outside the brake lining management device 1, but the HMI device 103 may also be provided inside the brake lining management device 1.

[0029] In the above embodiment, the notification unit 13 notifies the operator of the replacement time by displaying the replacement time on the HMI device 103, but the notification may be made by voice, or by both a display and voice.

[0030] Furthermore, when the number, quantity, amount, range, etc. of each element is mentioned in the above-mentioned embodiments, the present invention is not limited to the mentioned numbers unless otherwise specified or clearly specified in principle. Furthermore, the structures, etc. described in the above-mentioned embodiments are not necessarily essential to the present invention unless otherwise specified or clearly specified in principle. [Explanation of symbols]

[0031] 1...Brake lining management device, 11...Calculation unit, 12...Determination unit, 13...Notification unit, 101...Control computer, 102...Host computer, 103...HMI device, 2...Rolling plant, 42, 53, 71...Electric motor, 8...Brake, 81...Brake body, 82...Brake lining, Nc...Cumulative number of operations, Nst...Reference number, Mb...Electric motor body, Mr...Rolled material

Claims

1. A brake lining management device for a rolling plant that manages replacement times of brake linings of brakes attached externally to electric motors arranged in the rolling plant, The brake operates in response to a brake operation command based on a rolling plan of the rolling plant, a calculation unit that calculates an integrated number of brake operations, which is an integrated value of the number of brake operations in response to the brake operation command; a determination unit that determines that it is time to replace the brake lining when the calculated cumulative number of operations is equal to or greater than a reference number; a notification unit that, when it is determined that the brake lining needs to be replaced, inhibits operation of the brake and the electric motor and notifies the user that the brake lining needs to be replaced; A brake lining management device for a rolling plant comprising:

2. 2. The brake lining management device for a rolling plant according to claim 1, The brake lining management device for a rolling plant is configured so that the calculation unit adds an emergency activation count, which is the number of times the brakes have been activated in response to an emergency stop command, to the cumulative activation count.

3. 3. The brake lining management device for a rolling plant according to claim 2, the calculation unit multiplies the number of emergency activations by a weighting coefficient for weighting the number of emergency activations relative to the number of brake activations, and adds the number of emergency activations multiplied by the weighting coefficient to the cumulative number of activations.

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