Brake Holding Torque Calibration via Incremental Motor Control
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Solution Overview
Problem
Existing methods for determining the holding torque of a brake in material handling systems are limited, as they either require manual verification with potential for operator error or provide only a pass/fail test without indicating the actual torque value, necessitating a system for automatic and accurate determination.
Innovation Solution
A method and system using a motor controller to incrementally increase torque commands to an electric motor while monitoring feedback signals, allowing for the detection and display of the holding torque value, enabling precise calibration of the brake.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual verification with torque wrench is used, then the holding torque can be tested, but the method is limited by operator force capacity and requires partial disassembly
Solution Approach 1:
The patent replaces the manual mechanical torque wrench method with an automated electrical control system. The motor controller electronically commands the motor to apply incremental torque while the brake holds the load, eliminating the need for manual force application and partial disassembly. The system automatically measures holding torque through electrical signal monitoring rather than mechanical force application.
2Reliability
If a pass/fail test is performed, then the brake holding capability is verified, but the actual holding torque value is not provided for calibration
Solution Approach 1:
The patent implements a feedback mechanism where the motor controller continuously monitors the actual torque applied to the load and compares it with the commanded torque. The system incrementally increases torque commands and monitors feedback signals to detect when motion occurs, thereby determining the actual holding torque value. This feedback loop provides both verification and quantitative measurement for calibration purposes.
Data Source
AI summary
A system and method for determining the holding torque of a brake in a material handling system is disclosed. The material handling system may include a bridge, a trolley, and a hoist, each driven along a different axis by a motor. A brake is operatively coupled to the motor to prevent unwanted motion of the motor. A motor controller is coupled to each motor which controls operation of the motor and its corresponding brake. The motor controller generates a torque command to the motor while keeping the brake set. The initial torque command is less than the holding torque of the brake. The torque command is incremented until motion is detected on the motor. The torque value when motion is detected is stored in the motor controller and displayed to an operator.