In-System Test for Electromechanical Brake Redundancy
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Solution Overview
Problem
In systems with a single brake controller, manual intervention is required for brake redundancy testing, which is time-consuming and prone to delays, as service personnel must physically disconnect and reconnect brake coils to test each brake independently.
Innovation Solution
An electrically coupled test unit between the motion controller and redundant brakes, utilizing a microcontroller to selectively activate and test brakes automatically, eliminating the need for physical disconnection and reconnection of brake coils by converting coded pulse signals into control inputs for brake switches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual disconnection and reconnection of brake coils is performed to test each brake independently, then brake redundancy can be verified, but maintenance time and operational complexity increase significantly
Solution Approach 1:
The patent introduces a test unit with a microcontroller as an intermediary between the motion controller and the brake coils. This test unit automatically manages the electrical connection to each brake coil through controlled switching, eliminating the need for manual physical disconnection and reconnection. The microcontroller receives coded pulse signals and selectively activates brake coils through the switching circuitry, enabling automated testing while maintaining brake redundancy verification.
2Device complexity
If a single brake controller is used instead of two independent controllers, then device complexity is reduced, but the ability to automatically test brake redundancy is lost
Solution Approach 1:
The patent segments the testing function from the motion control function by introducing a dedicated test unit with a microcontroller. This separate testing subsystem can automatically manage brake coil activation through coded pulse signals and switching circuitry, even though there is only one brake controller. The segmentation allows automated testing capability to be added without requiring two independent brake controllers, thus maintaining simplicity while enabling automation.
3Ease of operation
If physical access to brake connections is required for testing, then direct brake testing is possible, but system cover removal and manual intervention are time-consuming
Solution Approach 1:
The patent replaces the mechanical process of physically disconnecting and reconnecting brake coils with an electrical control system. The test unit uses coded pulse signals and electronic switching to selectively activate brake coils through existing electrical connections, eliminating the need for manual mechanical intervention. This substitution maintains the ability to test individual brakes while eliminating the time-consuming steps of removing system covers and manually connecting/disconnecting physical components.
Data Source
AI summary
A test unit is electrically coupled between a motion controller and each of first and second redundant brakes. The test unit is responsive to the motion controller for automatically selecting one of the brakes to be tested. A microcontroller receives a signal from the motion controller that identifies one of the redundant brakes for activation, or deactivation, by an associated microcontroller output. The microcontroller outputs may be coupled respectively to activation terminals of respective brake switches connected in parallel to a brake activation voltage.