Brake Inspection Device Torque Segmentation
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Solution Overview
Problem
Existing brake inspection methods fail to accurately detect brake abnormalities, such as insufficient brake holding torque, brake release issues, and motor abnormalities, due to variations in load torque caused by gravity and mechanical friction, and are prone to erroneous determinations.
Innovation Solution
A brake inspection device with a load torque measurement unit that measures load torques during normal and reverse rotation in a released state and in a locked state, and a determination unit that calculates and compares these torques using specific formulas to determine the brake's state, thereby distinguishing between gravity load torque, mechanical friction torque, and brake holding torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a load torque measurement method comparing measured torque with a preset normal torque is used, then the inspection process is simple, but the detection accuracy is low due to gravity and friction variations
Solution Approach 1:
The load torque is segmented into three distinct components: gravity load torque (measured during reverse rotation in released state), mechanical friction torque (calculated as difference between normal and reverse rotation torques in released state), and brake holding torque (difference between locked state torque and gravity load torque). This segmentation allows each component to be measured and analyzed separately, eliminating the interference that causes detection errors in conventional methods.
Solution Approach 2:
The inspection method changes the operational parameters of the motor to isolate different torque components. By measuring torque under four specific conditions (normal rotation in released state, reverse rotation in released state, normal rotation in locked state, and reverse rotation in locked state), the method extracts gravitational and frictional effects as separate variables, enabling accurate determination of brake holding torque independent of these interfering factors.
2Loss of time
If the brake inspection is performed by comparing load torque with a preset value, then the inspection time is short, but erroneous determinations occur due to insufficient discrimination of torque components
Solution Approach 1:
The method performs preliminary measurements of gravity load torque and mechanical friction torque during the released state before evaluating brake holding torque. These preliminary actions establish baseline values that are stored and used for comparison during the actual brake inspection, enabling rapid and reliable determination without requiring complex real-time analysis.
Solution Approach 2:
The inspection system uses feedback by comparing the calculated brake holding torque against a predetermined threshold value. The determination unit receives the measured torques, processes them through the segmentation algorithm, and provides feedback on whether the brake is functioning normally or abnormally, enabling automated inspection decisions.
Data Source
AI summary
Provided is a brake inspection device including: load torque measurement units configured to respectively measure: load torques as a motor is normally rotated and reversely rotated in a released state where an operation of a brake for holding a rotor with respect to a stator of the motor is released; and a load torque as the motor is rotationally driven in either one of a normal direction or a reverse direction in a locked state where the brake is operated; and a determination unit configured to determine a state of the brake based on the load torques measured by the load torque measurement units.