Brake Control System Fault Detection via Segmented Current Sensing
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Solution Overview
Problem
In systems where multiple brake devices are controlled by a single motor drive, existing technologies face challenges in identifying which brake device is faulty when a common power source and current sensor are used, as the current value from the shared power source is detected by a single sensor, making it difficult to specify the abnormal brake device.
Innovation Solution
A brake control system and method that utilize a position detecting section to transmit rotational positions to a brake control device, which includes a detecting section to monitor brake current or voltage and an insulating circuit to isolate the detection signal, allowing the system to specify faulty brake devices based on multiple detection signals from each brake device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If one brake-oriented power source and one current sensor are commonly utilized for multiple brake devices, then costs are reduced, but the ability to specify which brake device is faulty is lost
Solution Approach 1:
The patent segments the detection function by providing each brake device with its own detecting section (current sensor) while sharing the power source. This segmentation allows individual brake device monitoring, enabling fault specification without requiring separate power sources for each brake device.
Solution Approach 2:
The brake control device is designed with multi-functionality, serving both as a power distribution hub for multiple brake devices and as a central processing unit that receives and analyzes detection signals from all brake devices. This universal design enables cost reduction through component sharing while maintaining fault detection capability.
2Loss of information
If separate power sources and current sensors are provided for each brake device, then fault specification becomes possible, but costs increase
Solution Approach 1:
The patent merges the power source function at the brake control device level, where a single brake-oriented power source supplies current to multiple brake devices. This merging reduces the total number of power sources needed while the distributed detecting sections maintain individual fault detection capability.
3Quantity of substance
If one current sensor detects current from one brake-oriented power source, then costs are reduced, but the precision of fault detection is insufficient
Solution Approach 1:
The detection function is segmented and distributed to each brake device through individual detecting sections. Each detecting section measures current specific to its associated brake device, providing precise fault detection capability without requiring a separate central current sensor for the entire system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the specification of faulty brake devices while minimizing costs by using a shared power source and common components, preventing excess current flow and extending the life of friction plate components.
Implementation Method 1
an electromagnetic brake that has a brake coil and releases braking of the rotating shaft of the motor by electrification of the brake coil
Implementation Method 2
an insulating circuit section provided between the detecting section and the communication circuit section in order to electrically insulate the detecting section and the communication circuit section
Data Source
AI summary
A brake control system includes: a plurality of motors each provided with a brake device and a position detecting section; and a brake control device that controls a plurality of the brake devices using one brake-oriented power source. The position detecting section includes a position detecting circuit section and a communication circuit section. The brake device includes: a current detecting section that detects a brake current flowing through a brake coil of an electromagnetic brake; and an insulating circuit section that electrically insulates the current detecting section and the communication circuit section. The communication circuit section transmits to the brake control device the brake current acquired via the insulating circuit section. The brake control device includes a fault specifying section that specifies the faulty brake device based on a plurality of detection signals detected by a plurality of the current detecting sections.