Braking Unit Modulation for Rope Transport Safety
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Solution Overview
Problem
Existing braking units in rope transport installations face inefficiencies due to increased stopping time when one braking means fails, leading to potential safety hazards as the second braking means takes over, and simultaneous failures of both braking means exacerbate this issue, resulting in longer stopping distances beyond regulatory limits.
Innovation Solution
The implementation of a second modulation circuit in the control unit to simultaneously modulate command signals for both braking means, using a deceleration setpoint curve with a greater instantaneous value than the first, ensuring simultaneous and independent modulation to prevent pulsation and compensate for failures, thereby reducing braking time even in dual failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If sequential modulation of braking means is used, then device complexity is reduced, but stopping time increases beyond regulatory limits
Solution Approach 1:
The control system is segmented into two independent modulation circuits (first and second modulation circuits), each capable of independently modulating command signals to its respective braking means. This segmentation allows parallel operation without increasing overall system complexity, as each circuit operates autonomously according to the same deceleration setpoint curve.
Solution Approach 2:
The second modulation circuit is prepared and activated simultaneously with the first modulation circuit at the onset of braking, rather than sequentially. This preliminary action ensures that both braking means are ready to contribute immediately, preventing any delay in stopping time while maintaining manageable device complexity through standardized circuit design.
2Device complexity
If only one braking means is modulated, then device complexity is reduced, but reliability decreases upon failure
Solution Approach 1:
Each modulation circuit is designed with identical local quality and capability to modulate its respective braking means independently. This ensures that if one braking means fails, the other can immediately take over with full modulation capability, maintaining system reliability without requiring complex asymmetric control logic.
Solution Approach 2:
The system utilizes parameter changes in the deceleration setpoint curve to coordinate both braking means. By modifying the deceleration parameter dynamically during braking, the system ensures that both modulation circuits operate harmoniously, achieving reliable braking performance while keeping the overall device complexity manageable through parameter-based control.
3Loss of time
If simultaneous modulation of both braking means is implemented, then stopping time is reduced, but device complexity increases
Solution Approach 1:
Both modulation circuits are designed with universal functionality to perform the same modulation task on their respective braking means. This multi-functionality allows simultaneous operation without proportionally increasing complexity, as each circuit is a replicated, standardized unit rather than a uniquely complex component.
Solution Approach 2:
The second modulation circuit is essentially a copy of the first modulation circuit, both receiving the same deceleration setpoint curve and performing identical modulation functions. This copying approach reduces the perceived complexity increase, as the system architecture remains consistent and predictable, making the simultaneous modulation manageable through standardized design patterns.
4Length of moving object
If higher deceleration setpoint curve is used, then stopping distance is reduced, but risk of pulsation and instability increases
Solution Approach 1:
The modulation circuits incorporate feedback mechanisms that monitor the actual braking performance against the deceleration setpoint curve. This feedback allows the system to adjust the modulation signals dynamically, preventing pulsation and instability even when using higher deceleration curves that would otherwise reduce stopping distance.
Solution Approach 2:
The deceleration setpoint curve is applied dynamically during the braking process, allowing the system to optimize the balance between stopping distance and stability. By adjusting the deceleration parameter in real-time based on system response, the system achieves reduced stopping distance while maintaining braking stability and preventing pulsation through adaptive control.
Data Source
AI summary
The invention relates to a method for controlling a braking unit of a rope transport installation and braking unit. The command signals of a first brake are modulated, until the installation is stopped, by a first modulation circuit integrated in the control unit to automatically regulate the running speed of the rope according to a first predetermined deceleration setpoint curve activated by a braking order. The command signals of a second brake are simultaneously modulated by a second modulation circuit integrated in the control unit to automatically regulate the running speed of the rope according to a second predetermined deceleration setpoint curve activated by the braking order, the instantaneous value of the second setpoint curve being at all times greater than the value of the first setpoint curve.