An early warning system against faults in electric motor brake systems

Abstract

The invention pertains to an early warning system related to electric motor brakes used in maintaining desired positions and stopping rotational inertia of moving shafts (e.g., in applications like cranes). It aims to prevent potential malfunctions by detecting issues and addressing problems proactively.

Description

[0001] AN EARLY WARNING SYSTEM AGAINST FAULTS IN ELECTRIC MOTOR BRAKE SYSTEMS

[0002] TECHNICAL FIELD

[0003] The invention pertains to an early warning system related to electric motor brakes used in maintaining desired positions and stopping rotational inertia of moving shafts (e.g., in applications like cranes). It aims to prevent potential malfunctions by detecting issues and addressing problems proactively.

[0004] BACKGROUND

[0005] Electric motors are utilized for transporting loads in industrial material handling vehicles (e.g., cranes). In systems employing these motors, the safe transportation of the load and its precise positioning are paramount. To achieve this objective, electromechanical brake systems are employed, which ensure the electric motors come to a stop at the specified position. In these systems, the rotational motion of the shaft is stopped by a spring pressure. Typically, the system consists of a body, coils placed within the body to create a magnetic effect, pressure components associated with the brake body in a manner that aligns with the coils, springs that apply pressure to the brake to prevent the motor shaft from turning by pressing against it, and sensors that transmit information about the position of the pressure components (whether they are forward or behind) to a control panel. The mentioned systems do not incorporate structures for monitoring the stability of their components during operation. In such systems, it is only when a malfunction occurs and the system cannot disengage from the brake that a problem becomes apparent. Beyond this point, no solution can be provided other than replacing the components. By implementing an early warning system that alerts users to the improper functioning of the system, it will be possible to provide information before the equipment becomes completely non-operational. This will not only reduce repair costs but also enhance the overall safety of the system.

[0006] AIM OF THE INVENTION

[0007] The purpose of this invention is to continuously measure the gap between the brake pressure plate and the brake housing in crane motor brakes, which are used to maintain the desired position and stop the rotational inertia of moving shafts in cranes. In the event that this gap deviates from the ideal range, the invention aims to alert the user, providing them with the opportunity to intervene before the components become unusable. This approach ultimately prevents breakdowns and reduces operational costs.

[0008] LIST OF FIGURES

[0009] Figure 1. General View of the Brake System

[0010] Figure 2. A-A Sectional View of the Brake System

[0011] Figure 3. Assembled View of the Brake System

[0012] Figure 4. B Detailed View

[0013] Figure 5. Sensor Control Box

[0014] Equiavalents of the numbers given in the figures are:

[0015] 1. Brake Mounting Flange

[0016] 2. Brake Body

[0017] 3. Brake Coil

[0018] 4. Brake Pad

[0019] 5. Pad Pressure Flange

[0020] 6. Sensor

[0021] 7. Sensor Pin

[0022] 8. Coil Power Cable

[0023] 9. Sensor Data Cable

[0024] 10. Sensor Control Box

[0025] L. Clearance Gap

[0026] B. The section shown in Figure 4

[0027] DETAILED DESCRIPTION OF THE INVENTION

[0028] The invention pertains to a protection and early warning system against wear and malfunctions in electric motor brake systems. This system comprises a sensor (6) and a sensor control box (10). The invention is positioned to measure the clearance gap (L) on an existing brake system.

[0029] The operating principle of the brake systems where the invention is positioned is as follows: When electrical energy is supplied to the coil power cable (8), an electromagnetic attractive force is generated in the brake coil (3) located in the brake body (2), causing the pad pressure flange (5) to be pulled due to this force. The magnetic attractive force generated in the brake coil (3) pulls the pad pressure flange (5) because the part is made of iron or a steel derivative material. As a result, the pad pressure flange (5) disengages from the brake pad (4), and the force applied by the brake pad (4) to the motor ceases, bringing the braking process to an end. This is where the invention comes into play. When the coil magnetically pulls the pad pressure flange (5), a sensor pin (7) causes a change in the sensor's (6) logical position.

[0030] The sensor (6) is at least one of the types: optical, mechanical, magnetic, laser, hall, LVDT (Linear Variable Differential Transformers), or capacitive sensors. Its operation varies depending on the type. The sensor (6) is connected in a way that, once activated by the energy from the coil power cable (8), it starts continuous measurements. The details of the measurements will be explained in the following section.

[0031] The sensor (6) further comprises a sensor pin (7). As described earlier, when electrical energy is supplied to the coil power cable (8), generating an electromagnetic attractive force in the brake coil (3) located in the brake body (2) and causing the pad pressure flange (5) to be pulled, the sensor pin (7) positioned on the pad pressure flange (5), as shown in Figure 2, moves along with the flange (5). During this movement, the sensor pin (7) approaches the sensor (6), which, depending on the type of sensor, triggers interaction with the sensor.

[0032] In order for the pad pressure flange (5) to be pulled by the electromagnetic force generated by the brake coil (4), the clearance gap (L) must be within the range of 0-2 mm. When the clearance gap (L) exceeds this distance, the brake coil (3) cannot provide the necessary force to pull the pad pressure flange (5). In this situation, the brake pad (4) remains engaged with the brake mounting plate (1), causing damage and malfunctions in the motor connected to the brake and in the brake pad (4). At this point, the invention's sensor (6) measures the clearance gap (L) distance, and before any malfunction or damage occurs, when the distance is within the desired range (0-2mm), an early warning system is activated by sending a notification or information to the main terminal connected to the mechanism associated with the brake system. This alert is transmitted through a communication protocol such as CAN-bus or another communication protocol, facilitated by the microprocessor contained in the sensor control box (10). It also provides fault and warning outputs.

[0033] As previously mentioned, the sensor (6) starts continuous measurements after becoming active upon receiving energy from the coil power cable (8). The measurement referred to here involves the sensor pin (7) activating or deactivating the sensor (6). At the moment of each activation with the energy from coil power cable (8), the sensor (6) is indeed activated by the sensor pin (7). The sensor control box (10) monitors this activity through the sensor data cable (9). The sensor data cable (9) facilitates communication between the sensor and the sensor control box (10).

[0034] The sensor control box (10) initially detects the activation of the sensor (6), which becomes active with the energy from the coil power cable (8), through the sensor data cable (9). This process involves completing the circuit with the energy supplied to the sensor (6). Upon detecting that the sensor (6) is active, it is expected that the sensor (6) will be triggered by the sensor pin (7) until the energy from the coil power cable (8) comes to an end. During this time interval, if the sensor pin (7) does not trigger the sensor (6), the sensor control box (10) understands that the L distance has exceeded its normal value, and the sensor pin (7) is no longer approaching the sensor (6) sufficiently to activate it. All of these detection processes are carried out through the microprocessor contained within the sensor control box (10).

[0035] The operating principles of the sensor (6) vary depending on the sensor types, and these principles will be explained in this section.

[0036] When the sensor (6) is an optical sensor, its operation is as follows: The sensor pin (7) changes the sensor's state by interrupting the light between the transmitter LED and the receiver of the optical sensor (6). In other words, in this configuration, the optical sensor (6) emits continuous light, and the receiver continuously monitors it. With the energy coming from the coil power cable (8), the sensor pin (7) approaching the sensor (6) obstructs the path of the receiver that continuously detects the light emission, thereby disrupting the continuous light detection. This change is then detected by the sensor control box (10), causing it to logically switch from 1 to 0 or from 0 to 1. Therefore, it is understood by the microprocessor that the L distance is still within the desired range. This is because otherwise, the sensor pin (7) would not have approached close enough to interrupt the light emission. When the sensor (6) is a mechanical sensor, its operation is as follows: When the sensor pin (7) approaches the sensor (6) as defined earlier, it pushes a mechanical lever contained within the mechanical sensor (6), thereby changing the sensor's state. This change is monitored by the sensor control box (10) as long as the energy continues to come from the coil power cable (8). During this period, if the sensor pin (7) is within the desired distance range for L, it physically contacts the sensor (6), causing it to logically switch from 1 to 0 or from 0 to 1 . As a result, it is understood by the microprocessor that the L distance is still within the desired range. This is because otherwise, the sensor pin (7) would not have been able to make physical contact.

[0037] When the sensor (6) is a magnetic sensor, its operation is as follows: When the sensor pin (7) approaches the sensor (6) as defined earlier, it changes its state when it enters the detection range of the magnetic sensor (6). In other words, the sensor pin (7) is made from a metal that allows the movement of the magnetic sensor

[0038] (6) or from a magnet with opposite poles, and by approaching the sensor (6), it logically switches from 1 to 0 or from 0 to 1. As a result, it is understood by the microprocessor that the L distance is still within the desired range. Because otherwise, the sensor pin (7) would not have been able to approach closely enough to generate a magnetic effect.

[0039] When the sensor (6) is a capacitive sensor, its operation is as follows: When the sensor pin (7) approaches the sensor (6) as defined earlier and enters the sensor's detection range, it changes the sensor's state. The capacitive sensor (6) continuously creates an electric field, and the sensor pin (7), by approaching the sensor (6), disrupts this electric field. In other words, it logically ensures that it becomes 0 when it is 1 or 1 when it is 0. Thus, it is understood by the microprocessor that the distance L is still within the desired range. Because otherwise, the sensor pin

[0040] (7) would not have been able to get close enough to disrupt the electric field.

[0041] The sensor (6) is positioned at a distance that may cause a change on the sensor (6) as a result of the back and forth movement of the sensor pin (7) and the pad pressure flange (5). In short, as a result of the proper alignment of the pad pressure flange (5), the sensor pin (7) should be able to create a change in the instantaneous perception of the sensor (6). Otherwise, the microprocessor will not be able to detect the change and the system will not be able to fulfill its purpose. The logical information obtained from the sensor (6) is evaluated by the microprocessor software located in the sensor control box (10). In the software, an algorithm has been created with an electronic circuit that detects the information from the sensor (6) and the energization of the coil. The algorithm is as follows: a numerical value is measured in relation to the time elapsed between the energization of the coil and the change in the status of the sensor (6). This numerical value is proportional to the movement distance of the pad pressure flange (5). The obtained numerical value provides information about how much the brake pad (4) has worn. When the brake pad (4) wears, the numerical value obtained is greater than the numerical value obtained when it's not worn. The difference between these magnitudes is detected to enable the sensor control box (10) to emit a warning signal. For the issuance of the warning signal, there is a signal output available on the sensor control box (10). This signal output can be transmitted to the user using any communication protocol (such as CANbus, Modbus, etc.). The signal output described here can also serve as a relay output. With this relay output, the brake system can be disabled, and audible or visual warnings can be activated. To activate the warnings using the signal obtained from the signal output, the control box (10) utilizes transistor outputs or relay contacts.

[0042] Within the microprocessor, a software is comprised, which further includes an interface. Through this interface on the control box (10), users can connect to the software via a computer. Using this interface, users can modify the values present in the invention by comparing numerical values in the control box (10). These values allow users to determine what constitutes an abnormal distance for the working clearance (L) and when a warning alert will be issued or at what clearance distance the relay output will become active. Consequently, in various types of motors, when conditions exceed the intervals set by the user, an early warning can be provided to the user when the brake pad (4) begins to wear.

Claims

CLAIMS1. A system for measuring working clearance (L) on a brake system, with the purpose of serving as a wear protection and early warning system against malfunctions in electric motor brake systems, characterized by comprising:- A sensor (6) that can be activated and deactivated with a sensor pin (7),- The sensor pin (7) positioned to move with a pad pressure flange (5) when electrical energy is supplied to a coil power cable (8) of the electric motor brake system, creating an electromagnetic attraction force in a brake coil (3) within a brake body (2) and, with this force, pulling the pad pressure flange (5) to activate or deactivate the sensor (6) as it moves with the flange (5),- A sensor control box (10) further comprising a microprocessor that detects whether the sensor (6) is active or not through the sensor data cable (9) that conveys information about the energy coming from the coil power cable (8) and includes a communication protocol for sending information to the main terminal.

2. The sensor (6) according to Claim 1 , characterized by being at least one of the following sensor types: optical, mechanical, magnetic, laser, hall, LVDT (Linear Variable Differential Transformers), or capacitive sensors.

3. The sensor (6) according to Claim 1 , characterized by being connected in a manner that, upon becoming active with the energy from the coil power cable (8), it continuously starts making measurements.

4. The microprocessor according to Claim 1 , characterized by, upon detecting that the sensor (6) is active, following the sensor's (6) activation by the sensor pin (7) until the energy from the coil feed cable (8) terminates.

5. The sensor pin (7) according to Claim 1 , characterized by, in cases where the sensor (6) is a magnetic sensor, being made of a metal or opposite-polarity magnet that enables the movement of the sensor (6).

6. The sensor pin (7) according to Claim 1 , characterized by being positioned at a distance that can be affected by the forward and backward movement of the pad pressure flange (5) and can induce changes on the sensor (6).

7. The microprocessor according to Claim 1, characterized by comprising a software that measures a numerical value proportional to the movement distance of the pad pressure flange (5) corresponding to the time elapsed between the energization of the coil and the change in the state of the sensor (6), allowing a determination of whether the brake pad (4) has worn based on the magnitude of the obtained numerical value.

8. The sensor control box (10) according to Claim 1, characterized by comprising a signal output.

9. The microprocessor according to Claim 1, characterized by comprising the software and an interface that allows a user to connect via a computer and modify the values present in the system.

Images