Brake manufacturing method, winding machine manufacturing method, and brake manufacturing device

Abstract

A brake manufacturing method according to the present disclosure is for manufacturing a brake that includes a brake drum and a lining having a substantially arc-shaped surface and that functions in accordance with the substantially arch-shaped surface of the lining coming into contact with the brake drum, the brake manufacturing method comprising a step for machining the substantially arc-shaped surface in accordance with a relative motion being made between the lining and a dummy drum that contacts the lining, the area of the portion of the dummy drum that contacts the lining being smaller than the area of the substantially arch-shaped surface.

Description

Brake manufacturing method, hoist manufacturing method, and brake manufacturing device

[0001] The present disclosure relates to a method for manufacturing a brake, a method for manufacturing a hoist, and an apparatus for manufacturing a brake.

[0002] The braking device of an elevator hoisting machine is equipped with a brake drum that rotates using the driving force of a motor, and braking is achieved by pressing a braking piece called a lining against the brake drum.In order to improve the braking torque of the elevator and ensure stability after it begins operation, a fitting process is carried out before the hoisting machine is shipped, in which the lining is pressed against the rotating brake drum to fit it.

[0003] It is known that when the lining is rubbed against the drum, a transfer layer forms, which increases the braking torque. Furthermore, when a transfer layer forms due to the lining and drum rubbing, the surface of the lining becomes discolored. The rub-in process is carried out until the discolored surface reaches a standard percentage or higher to ensure the stability of the braking torque after the start of operation.

[0004] Patent Document 1 discloses a grinding device for elevator brake linings. The device includes a cutting material that is placed between the elevator brake wheel and brake lining with its cutting surface facing the brake lining, an upper handle provided on one side of the cutting material so that the cutting material is positioned above the brake wheel when the cutting surface faces the brake lining, and a lower handle provided on the other side of the cutting material so that the cutting material is positioned below the brake wheel when the cutting surface faces the brake lining.

[0005] Japanese Patent Publication No. 2019-112195

[0006] Although slight lapping is sufficient to improve braking torque, the process takes a long time to create a lapping surface that meets or exceeds the standard ratio. Even if the lining is processed to fit the drum shape before lapping, the contact between the drum and lining deteriorates due to deformation of the drum or lining caused by frictional heat during lapping, or deformation of the drum and lining when the lining is pressed against the drum, and it takes time to create a lapping surface that meets or exceeds the standard ratio. This has caused the entire lapping process to take a long time.

[0007] The present disclosure has been made to solve the above-mentioned problems, and an object of the present disclosure is to provide a brake manufacturing method, a hoist manufacturing method, and a brake manufacturing device that can shorten the time required for the fitting process.

[0008] A brake manufacturing method according to the present disclosure is a method for manufacturing a brake that has a brake drum and a lining having a substantially circular arc surface and functions when the lining contacts the brake drum at the substantially circular arc surface, and includes a step of processing the substantially circular arc surface by relative movement between the lining and a dummy drum that contacts the lining over a contact area smaller than the area of ​​the substantially circular arc surface.A hoist manufacturing method according to the present disclosure includes a step of attaching a brake manufactured using the above brake manufacturing method to a hoist.A brake manufacturing apparatus according to the present disclosure is an apparatus for manufacturing a brake that has a brake drum and a lining having a substantially circular arc surface and functions when the lining contacts the brake drum at the substantially circular arc surface, and includes a step of processing the substantially circular arc surface by relative movement between the lining and a dummy drum that contacts the lining over a contact area smaller than the area of ​​the substantially circular arc surface.

[0009] According to the present disclosure, it is possible to provide a brake manufacturing method, a hoist manufacturing method, and a brake manufacturing device that can shorten the time required for the fitting process.

[0010] 8 is a diagram showing a comparison of the surfaces to be ground when the ground surface is large and when it is small. FIG. 9 is a side view and a top view from two directions showing a brake lining grounding device for carrying out a brake manufacturing method according to Embodiment 1. FIG. 10 is a side view and a top view from two directions showing a brake lining grounding device for carrying out a brake manufacturing method according to Embodiment 2. FIG. 11 is a diagram showing a modified example of Embodiment 2. FIG. 12 is a side view from two directions showing a brake lining grounding device for carrying out a brake manufacturing method according to Embodiment 3. FIG. 13 is a side view from two directions showing a brake lining grounding device for carrying out a brake manufacturing method according to Embodiment 4. FIG. 14 is a side view from two directions showing a brake lining grounding device for carrying out a brake manufacturing method according to Embodiment 5. FIG. 15 is a diagram showing a comparison of the surfaces to be grounded when the grounding surface is large and when it is small. FIG. 16 is a cross-sectional view showing a modified example of FIG. 10.

[0011] Hereinafter, embodiments will be described with reference to the drawings. Common or corresponding elements in each drawing are designated by the same reference numerals, and descriptions thereof will be simplified or omitted. Note that the configurations shown in the following embodiments are examples of the technical ideas of the present disclosure, and may be combined with other known technologies, or multiple technical ideas described in the present disclosure may be combined. Furthermore, it is also possible to omit or modify part of the configuration without departing from the gist of the present disclosure.

[0012] FIG. 1 is a diagram comparing the mating surfaces when the mating surface is large and when it is small. FIG. 1 compares the ratio of the mating surface between the rough surface (target surface) indicated by the dashed line and the ideal plane, shown by the long side (surface A) and the short side (surface B), in the x direction, when the ideal plane moves in the x direction on a rough surface. Each ideal plane is pressed with a constant load from the y direction, and the rough surface and the ideal plane always maintain contact at one point. The contact point between the target surface and the ideal plane is the maximum value of the roughness of the target surface within the range of the ideal plane. In FIG. 1, the surface indicated by the thick line is the mating point. Therefore, as a method for improving the surface contact in mating, dividing the surface of the drum or lining into smaller pieces can improve the ability to follow the undulations of the mating material.

[0013] Embodiment 1. Figure 2 is a side view and a top view from two directions showing a brake lining lapping apparatus 200 that implements a brake manufacturing method according to Embodiment 1. The brake lining lapping apparatus 200 of this embodiment is also called a brake manufacturing apparatus. For ease of explanation, Figure 2 and figures described below illustrate a three-dimensional Cartesian coordinate system including a Z axis, with the vertically upward direction being the positive direction and the vertically downward direction being the negative direction.

[0014] As shown in Figure 2, the brake lining lapping device 200 of this embodiment has a weight 201, a load arm 202, a wear element 203, a dummy drum 204, a lining 205, and a shoe 206. The load arm 202 has an elongated shape extending along the x-axis direction. The wear element 203 is provided at one end of the load arm 202. The weight 201 is provided at the upper end of the wear element 203. The dummy drum 204 is provided at the lower end of the wear element 203. A rotation shaft 207 is provided at the other end of the load arm 202. The load arm 202 is rotatable around the rotation shaft 207.

[0015] The lining 205 has an approximately arcuate surface 208 with an arc-shaped cross section that is machined to fit the shape of the brake drum. The lining 205 is provided on the shoe 206 with the approximately arcuate surface 208 facing upward. The dummy drum 204 comes into contact with the approximately arcuate surface 208. The lining 205 may be that of a brake device attached to an elevator hoist.

[0016] In this embodiment, in order to reduce the contact surface with the drum during fitting, a dummy drum 204 is used that comes into contact with the lining 205 over a contact area smaller than the area of ​​the approximately arcuate surface 208. The range of the area of ​​the dummy drum 204 is set so that the area of ​​the dummy drum 204 projected onto the lining 205 is smaller than the area of ​​the lining 205. In addition, it is desirable to set the size of the contact area of ​​the dummy drum 204 so that the contact portion is smaller than the distance between the peaks at which the height of the lining 205 is greatest in Figure 1.

[0017] The material of the dummy drum 204 is the same as that of the brake drum, but can be changed depending on the lapping conditions. The dummy drum 204 is attached to a lapping device 200 having an abrasion element 203 and a load arm 202, and a weight 201 is attached to the top of the abrasion element 203. While the dummy drum 204 is pressed against the lining 205, the lining 205 having a substantially arcuate surface 208 or the dummy drum 204 is moved back and forth in the x-axis direction, and the lining 205 having the substantially arcuate surface 208 and the dummy drum 204 are moved relative to each other, thereby performing lapping. The pressing force during lapping can be changed by changing the weight of the weight 201.

[0018] Figure 2(b) shows a cross section taken along line A-A' in Figure 2. As shown in Figure 2(b), in order to reduce the contact area between the lining 205 having a substantially arcuate surface 208 and the dummy drum 204 in the y-axis direction, the contact surface of the dummy drum 204 is divided into multiple parts, and the entire surface of the lining 205 having a substantially arcuate surface 208 can be rubbed against each other by reciprocating the lining 205 having a substantially arcuate surface 208 or the dummy drum 204. The dummy drum 204 divided in the y-axis direction can be arranged in a straight line without any gaps, as shown in the lower diagram of Figure 2(a), or the dummy drums 204 can be arranged alternately, as shown in the upper diagram of Figure 2(a), so that the entire surfaces can be rubbed against each other.

[0019] As described above, the brake manufacturing method of this embodiment includes a step of machining the approximately arcuate surface 208 by relative movement of the lining 205 and the dummy drum 204, which contacts the lining 205 over a contact area smaller than the area of ​​the approximately arcuate surface 208. In this embodiment, the surface contact between the dummy drum 204 and the approximately arcuate surface 208 of the lining 205 is improved, allowing the dummy drum 204 and the lining 205 to come into contact efficiently, and a mating surface with a standard ratio or greater can be created in a short period of time. This reduces the time required for the mating step.

[0020] Furthermore, in this embodiment, the dummy drum 204 contacts the approximately arcuate surface 208 with contact surfaces divided into multiple parts, thereby further improving the surface contact and further shortening the time required for the fitting process.

[0021] The relative movement between the dummy drum 204 and the lining 205 may be a reciprocating movement of the lining 205 along the substantially arcuate surface 208. This simplifies the lapping operation.

[0022] The relative motion between the dummy drum 204 and the lining 205 may be a reciprocating motion of the dummy drum 204 along the approximately arcuate surface 208. This simplifies the fitting operation. Furthermore, in the case of a brake device attached to an elevator hoist, the manufacturing method for the hoist includes a step of attaching a brake manufactured using the above-described brake manufacturing method to the hoist. As shown in FIG. 2( d ), the hoist includes a fixed frame 209, a drum 210, a sheave 211, and a brake unit 212. The brake unit 212 has a lining 205 and a shoe 206.

[0023] Second Embodiment Next, a second embodiment will be described with reference to Figures 3 and 4, with the focus being on differences from the first embodiment described above, and common explanations will be simplified or omitted.

[0024] 3A and 3B are side views and a top view from two directions showing a brake lining lapping device 300 for carrying out a brake manufacturing method according to the second embodiment.

[0025] As shown in Figure 3, the brake lining lapping device 300 of this embodiment has a weight 301, a load arm 302, a wear element 303, a dummy drum 304, a lining 305, and a shoe 306. The load arm 302 has an elongated shape extending along the x-axis direction. The wear element 303 is provided at one end of the load arm 302. The weight 301 is provided at the upper end of the wear element 303. The dummy drum 304 is provided at the lower end of the wear element 303. A rotation shaft 307 is provided at the other end of the load arm 302. The load arm 302 is rotatable around the rotation shaft 307.

[0026] The lining 305 has a substantially arcuate surface 308 machined to fit the shape of the brake drum. The lining 305 is provided on the shoe 306 with the substantially arcuate surface 308 facing upward. Figure 4 shows a modified example of the second embodiment. The substantially arcuate surface of the lining 305 is not limited to the concave substantially arcuate surface 308, but can also be a convex substantially arcuate surface 308 as shown in Figure 4. The dummy drum 304 comes into contact with the substantially arcuate surface 308.

[0027] In this embodiment, a thin cylindrical drum is used as the dummy drum 304. The area of ​​the dummy drum 304 is set so that the area of ​​the dummy drum 304 projected onto the lining 305 is smaller than the area of ​​the lining 305. The size of the contact area of ​​the dummy drum 304 is desirably set so that the contact portion is smaller than the distance between the peaks of the lining 305 at the maximum height in FIG. 1 .

[0028] The material of the dummy drum 304 is the same as that of the brake drum, but can be changed depending on the lapping conditions. The dummy drum 304 is attached to a lapping device 300 having an abrasion element 303 and a load arm 302, and a weight 301 is attached to the top of the abrasion element 303. While the dummy drum 304 is pressed against the lining 305, the lining 305 having a substantially arcuate surface 308 or the dummy drum 304 is moved back and forth in the x-axis direction, and the lining 305 having a substantially arcuate surface 308 and the dummy drum 304 are moved relative to each other, thereby performing lapping. The pressing force during lapping can be changed by changing the weight of the weight 301.

[0029] The dummy drum 304 can rotate along a substantially arcuate surface 308, and the lapping is performed by combining the relative movement of the lining 305 having the substantially arcuate surface 308 and the dummy drum 304. The rotation direction of the dummy drum 304 is such that the relative speed at the contact surface between the lining 305 having the substantially arcuate surface 308 and the dummy drum 304 is increased, i.e., accelerated. By increasing the relative speed, the time required for lapping can be further shortened.

[0030] 3(b) shows a cross section taken along line A-A' in FIG. 3(c). As shown in FIG. 3(b), in order to reduce the contact area between the lining 305 having the approximately arcuate surface 308 and the dummy drum 304 in the y-axis direction, the contact surface of the dummy drum 304 is divided into multiple parts, and the entire surface of the lining 305 having the approximately arcuate surface 308 can be rubbed together by reciprocating the lining 305 having the approximately arcuate surface 308 or the dummy drum 304. In order to rub the entire surface of the lining 305 having the approximately arcuate surface 308 against each other, the dummy drum 304 divided in the y-axis direction can be arranged in a straight line without any gaps, as shown in the lower diagram of FIG. 3(a). Alternatively, the dummy drum 304 can be rubbed against the lining 305 while moving it in the y-axis direction in addition to reciprocating in the x-direction, as shown in the upper diagram of FIG. 3(a).

[0031] As described above, the manufacturing method of the brake of this embodiment includes a step of machining the approximately arcuate surface 308 by relative movement between the lining 305 and the dummy drum 304, which is in contact with the lining 305 over a contact area smaller than the area of ​​the approximately arcuate surface 308. In this embodiment, the surface contact between the dummy drum 304 and the approximately arcuate surface 308 of the lining 305 is improved, thereby making it possible to shorten the time required for the fitting step.

[0032] Furthermore, in this embodiment, the dummy drum 304 contacts the approximately arcuate surface 308 with contact surfaces divided into multiple parts, thereby further improving the surface contact and further shortening the time required for the fitting process.

[0033] The relative movement between the dummy drum 304 and the lining 305 may be a reciprocating movement of the lining 305 along the substantially arcuate surface 308. This simplifies the lapping operation.

[0034] The relative movement between the dummy drum 304 and the lining 305 may be a reciprocating movement of the dummy drum 304 along the substantially arcuate surface 308. This simplifies the lapping operation.

[0035] The relative movement between the dummy drum 304 and the lining 305 may be a movement in which the dummy drum 304 rotates along the substantially arcuate surface 308. This simplifies the lapping operation.

[0036] Third Embodiment Next, a third embodiment will be described with reference to Fig. 5, with the focus being on differences from the first embodiment described above, and common explanations will be simplified or omitted.

[0037] FIG. 5 is a side view from two directions showing a brake lining lapping device 400 for implementing a brake manufacturing method according to a third embodiment. As shown in FIG. 5 , in this embodiment, a dummy drum 404 is attached to the brake lining lapping device 400, which has a wear element 403 and a load arm 402. The dummy drum 404 is pressed against a lining 405 having a substantially arcuate surface 408 by a coil spring 401 attached to the upper part of the wear element 403 or the load arm 402. The lining 405 having the substantially arcuate surface 408 or the dummy drum 404 is reciprocated, thereby moving the lining 405 and the dummy drum 404 relative to each other, thereby performing lapping. The load arm 402 is rotatable about a rotation axis 407. In this embodiment, the use of the coil spring 401 improves the surface contact due to the pressing and enables fine adjustment of the pressing force during lapping.

[0038] Fourth Embodiment Next, a fourth embodiment will be described with reference to Fig. 6, with the focus being on differences from the first embodiment described above, and common explanations will be simplified or omitted.

[0039] FIG. 6 is a side view from two directions showing a brake lining lapping device 500 for implementing a brake manufacturing method according to a fourth embodiment. As shown in FIG. 6 , in this embodiment, a dummy drum 504 is attached to the brake lining lapping device 500, which has an abrasion element 503 and a load arm 502. A leaf spring 501 attached to the upper portion of the abrasion element 503 or the load arm 502 presses the dummy drum 504 against a lining 505 having a substantially arcuate surface 508. The lining 505 having the substantially arcuate surface 508 or the dummy drum 504 is reciprocated, causing relative movement between the lining 505 and the dummy drum 504, thereby performing lapping. The load arm 502 is rotatable about a rotation axis 507. This embodiment improves the surface contact due to the pressing force, and the use of the leaf spring 501 allows for a reduction in space compared to a coil spring, enabling the device to be made more compact.

[0040] Fifth Embodiment Next, a fourth embodiment will be described with reference to Figures 7 and 8, but the description will focus on the differences from the first embodiment described above, and common descriptions will be simplified or omitted.

[0041] 7 is a side view from two directions showing a brake lining lapping device 600 for carrying out a brake manufacturing method according to a fifth embodiment. In this embodiment, a dummy drum 602 having a plurality of projections and recesses in the circumferential direction is used to reduce the drum surface area during lapping, in relation to a lining 603 having a substantially arcuate surface 608 machined to fit the brake drum shape. A coil spring 601 is provided below a shoe 604. The dummy drum 602 is rotated by a motor 605.

[0042] Figure 8 shows a dummy drum surface 704 that is attached to each surface of the convex portion 702 of the dummy drum 602 to improve the conformability to the surface of the lining 603, which has an approximately arcuate surface 608 in the y-axis direction of the dummy drum 602.

[0043] To reduce the contact area between the lining 603 having a substantially arcuate surface 608 and the dummy drum surface 704 in the y-axis direction, the dummy drum surface 704 is divided into multiple pieces in the y-axis direction. The divided dummy drum surfaces 704 are passed horizontally by a rotation shaft 705 and fixed to a cover 706. The holes in the dummy drum surface 704 are larger than the rotation shaft 705, allowing slight movement in the z-axis direction when the dummy drum surface 704 is fixed to the cover 706. Furthermore, leaf springs 701 are inserted between each dummy drum surface 704 and the cover 706 in the z-axis direction. The lining 603 having a substantially arcuate surface is pressed against the dummy drum surface 704 using the coil springs 601 and leaf springs 701, and the dummy drum surface 704 in Figure 8 is attached to each surface of the convex portion 702 of the dummy drum 602 in Figure 7 and rotated to perform the lapping.

[0044] In this embodiment, the dummy drum 602 has a plurality of protrusions in the circumferential direction, and the dummy drum surface 704, which is the contact surface of the protrusions, comes into contact with the approximately arcuate surface of the lining 603. This improves the surface contact and shortens the time required for the fitting process.

[0045] In this embodiment, the dummy drum surface 704, which is the contact surface of the convex portion of the dummy drum 602, is divided into multiple surfaces, and each dummy drum surface 704 is configured to follow the approximately arcuate surface 608 of the lining 603 by means of the leaf spring 701, which is an elastic member. This improves the surface contact and shortens the time required for the fitting process.

[0046] Fig. 9 is a cross-sectional view showing a modification of Fig. 8. In the above example, the dummy drum surface 704 uses a leaf spring 701 as an elastic member. However, as shown in Fig. 9, by attaching each dummy drum surface 704 to an elastic material 801 such as rubber or silicone, the dummy drum surface 704 can conform to the approximately circular arc surface 608 of the lining 603 in multiple directions. In other words, the dummy drum surface 704, which is the contact surface of the convex portion of the dummy drum 602, is configured to conform to the approximately circular arc surface 608 or in the direction of the central axis of the approximately circular arc surface 608 by the elastic material 801. This improves surface contact and shortens the time required for the fitting process.

[0047] Of the features of the above-described multiple embodiments, two or more features that can be combined may be combined and implemented.

[0048] 200 Brake lining lapping device, 201 Weight, 202 Load arm, 203 Wear element, 204 Dummy drum, 205 Lining, 206 Shoe, 207 Rotating shaft, 208 Approximately circular arc surface, 209 Fixed frame, 210 Drum, 211 Sheave, 212 Brake unit, 300 Brake lining lapping device, 301 Weight, 302 Load arm, 303 Wear element, 304 Dummy drum, 305 Lining, 306 Shoe, 307 Rotating shaft, 308 Approximately circular arc surface, 400 Brake lining lapping device, 401 Coil spring, 402 Load arm, 403 Wear element, 404 Dummy drum, 405 Lining, 407 Rotating shaft, 408 Approximately circular arc surface, 500 Brake lining lapping device, 501 Leaf spring, 502 Loading arm, 503 Wear element, 504 Dummy drum, 505 Lining, 507 Rotating shaft, 508 Approximately circular arc surface, 600 Brake lining lapping device, 601 Coil spring, 602 Dummy drum, 603 Lining, 604 Shoe, 605 Motor, 608 Approximately circular arc surface, 701 Leaf spring, 702 Convex portion, 704 Dummy drum surface, 705 Rotating shaft, 706 Cover, 801 Elastic material

Claims

1. A method for manufacturing a brake that has a brake drum and a lining with a substantially arcuate surface, the brake functioning when the lining comes into contact with the brake drum at the substantially arcuate surface, the method comprising the step of machining the substantially arcuate surface by moving the lining relative to a dummy drum that comes into contact with the lining over a contact area smaller than the area of ​​the substantially arcuate surface.

2. A method for manufacturing a brake as set forth in claim 1, wherein the dummy drum contacts the substantially arcuate surface at a contact surface divided into a plurality of parts.

3. A method of manufacturing a brake according to claim 1 or 2, wherein the dummy drum is pressed against the approximately arcuate surface by the restoring force of a coil spring.

4. A method of manufacturing a brake according to claim 1 or 2, wherein the dummy drum is pressed against the approximately arcuate surface by the restoring force of a leaf spring.

5. A method for manufacturing a brake according to any one of claims 1 to 4, wherein the relative movement is a reciprocating movement of the lining along the substantially arcuate surface.

6. A method for manufacturing a brake according to any one of claims 1 to 4, wherein the relative movement is a movement in which the dummy drum rotates along the substantially arcuate surface.

7. A method for manufacturing a brake according to any one of claims 1 to 4, wherein the relative motion is a reciprocating motion of the dummy drum along the substantially arcuate surface.

8. A method of manufacturing a brake as set forth in claim 6, wherein the dummy drum has a plurality of protrusions in the circumferential direction, and the contact surfaces of the protruding portions come into contact with the approximately arcuate surface.

9. A method for manufacturing a brake as set forth in claim 8, wherein the contact surface of the convex portion is divided into a plurality of surfaces, each of which is configured to follow the approximately arcuate surface by means of an elastic member.

10. A method for manufacturing a brake as set forth in claim 8, wherein the contact surface of the convex portion is configured to follow the approximately arcuate surface or the direction of the central axis of the approximately arcuate surface by means of an elastic member.

11. A method for manufacturing a hoist, comprising a step of attaching a brake manufactured using the method for manufacturing a brake according to any one of claims 1 to 10 to the hoist.

12. A brake manufacturing device that has a brake drum and a lining with a substantially arcuate surface, the lining contacting the brake drum at the substantially arcuate surface to function, and that carries out a step of machining the substantially arcuate surface by moving the lining relative to a dummy drum that contacts the lining over a contact area smaller than the area of ​​the substantially arcuate surface.

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