Brake Torque Monitoring Using Position Sensor Data
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Solution Overview
Problem
Existing systems for testing the operation of industrial screwdrivers' braking devices lack a reliable method to detect malfunctions in torque and angle measurements without adding additional components to the test stand, which affects the accuracy and reliability of the testing process.
Innovation Solution
An electronic system with a self-diagnosis mechanism that performs statistical, static, and dynamic controls to monitor braking torque and rotation angle, using threshold settings and correction coefficients to identify and address potential malfunctions, signaling issues to the operator and disabling faulty brakes to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external measurement transducers are used to monitor braking torque and rotation angle, then measurement capability is provided, but system complexity and cost increase
Solution Approach 1:
The brake's existing position sensor is made to serve dual purposes: controlling the brake position and detecting torque/angle measurements. The control unit analyzes position data over time to derive torque and angle information without requiring separate measurement transducers, thus eliminating additional components while maintaining measurement capability
Solution Approach 2:
The position sensor is transformed into a multi-functional device that simultaneously performs brake position control and torque/angle measurement functions. The control unit processes position data to extract multiple parameters (position, torque, angle, speed, revolutions) from a single sensor source, making the system more versatile without adding components
2Reliability
If statistical controls with alarm and control thresholds are implemented, then reliability of brake operation is improved, but complexity of monitoring system increases
Solution Approach 1:
The control unit continuously monitors operational parameters (torque, angle, speed, revolutions) and compares them against predetermined alarm and control thresholds. When parameters exceed these thresholds, the system provides feedback through alarm signals and can disable the brake, creating a closed-loop monitoring system that enhances reliability through automated decision-making
Solution Approach 2:
Alarm and control thresholds are predetermined and configured in advance based on brake specifications and operational requirements. This preliminary setup allows the system to automatically detect and respond to abnormal conditions without requiring real-time complex analysis, simplifying the monitoring process while maintaining high reliability
Data Source
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AI summary
System for checking the correct operation of braking devices on a test stand for industrial screwdrivers comprising a plurality of hydraulic brakes (F), to which the screwdriver is associated with, suitably controlled by a hydraulic circuit comprising a pump (P), a pressure regulating valve (VP). Each brake is provided with external measurement transducers (TR) connected to an electronic control board (SP). An electronic processor (U) that communicates with such board and controls such hydraulic circuit, such pump and such valve, comprises a suitable control programme stored therein.