Brake Power Monitoring via Encoder Acceleration for Press Drives
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Solution Overview
Problem
Modern presses face challenges in reliable braking power monitoring due to increased performance, where existing standards are not sufficient to detect brake deterioration, especially at high speeds, and are not adaptable to electronic camshafts or fast processing systems, leading to inadequate safety locking and potential risks to operating personnel.
Innovation Solution
An apparatus and method for monitoring actual braking power by using a controller to determine acceleration from encoder signals and locking the drive when the braking power falls below a threshold, independent of overrun angle, allowing for flexible and versatile safety-related locking across various operating modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If overrun monitoring is used according to standards, then safety locking is provided, but brake deterioration cannot be detected at high speeds
Solution Approach 1:
The patent changes the monitoring parameter from overrun angle to braking power (acceleration). By measuring the deceleration of the drive shaft during braking using encoder signals, the system can detect brake deterioration at any speed, not just at low speeds where overrun is measurable. This parameter change enables reliable brake monitoring in high-speed operations.
Solution Approach 2:
The patent replaces the mechanical overrun monitoring mechanism with an electronic monitoring system that calculates acceleration from encoder signals. This substitution allows for continuous, high-speed monitoring of braking power without the limitations of mechanical measurement systems, enabling detection of brake deterioration even at very high operating speeds.
2Productivity
If electronic camshafts are used to increase productivity, then number of strokes per minute increases, but overrun monitoring becomes impossible
Solution Approach 1:
The patent replaces mechanical overrun monitoring with an electronic acceleration monitoring system that works with electronic camshafts. By calculating braking power from encoder-measured acceleration, the system adapts to electronic camshaft operation and maintains monitoring capability even at the high stroke rates enabled by electronic cam technology.
Solution Approach 2:
The patent changes the monitoring approach from position-based overrun measurement to acceleration-based braking power measurement. This parameter change makes the monitoring system compatible with electronic camshafts that operate at high speeds, as acceleration can be continuously calculated from encoder signals regardless of the camshaft type or operating speed.
3Manufacturing precision
If dynamic adjustment of brake switch-off angle is implemented, then press stops exactly at OTP, but brake wear cannot be detected
Solution Approach 1:
The patent replaces overrun-based wear detection with acceleration-based braking power monitoring. By measuring the actual deceleration during braking events, the system can detect brake wear independently of the dynamic switch-off angle adjustments, maintaining both precise stop positioning and wear detection capabilities.
Solution Approach 2:
The patent introduces acceleration measurement as an intermediary parameter that decouples wear detection from stop position control. The encoder signals provide acceleration data that reflects brake condition, while the controller independently manages dynamic switch-off angle adjustments for precise positioning, allowing both functions to operate without interference.
4Reliability
If standard safety controllers are used, then safety features are provided, but processing speed is too slow for high-speed presses
Solution Approach 1:
The patent replaces traditional safety controller monitoring with a standard controller that calculates braking power from encoder signals. This substitution enables high-speed processing while maintaining safety, as the standard controller can rapidly process encoder data to detect brake deterioration without the speed limitations of dedicated safety controllers.
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
Ensures reliable and uninfluenced monitoring of braking power, enabling effective safety locking even in high-speed systems, independent of air pressure and specific stop locations, and allows for precise detection of brake wear, enhancing overall safety and maintenance efficiency.
Implementation Method 1
receiving of an encoder signal from an encoder (50) coupled to a drive shaft (24)
Implementation Method 2
a brake (14) coupled to the drive shaft (24) acts on the drive shaft (24) of the drive (22) with the greatest possible braking force
Data Source
AI summary
An apparatus performs braking power monitoring and safety-related locking of a drive of a technical system. The technical system has two machine parts that are movable relative to one another and that are moved towards one another by the drive at a defined actuation interval. A first controller has an input for receiving an encoder signal from an encoder coupled to a drive shaft of the drive. The first controller has an output for outputting an error signal. The first controller determines a value for an acceleration from the encoder signal when a brake coupled to the drive shaft acts with its greatest possible braking force on the drive shaft of the drive and locks the drive in a safety-related manner when the determined value exceeds a limit value stored in the first controller.