Elastic Wave Sensor for Hoisting Machine Brake State Estimation
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Solution Overview
Problem
The existing brake apparatus for hoisting machines in elevators lacks a reliable method to monitor and predict the deterioration of brake performance over time, leading to unpredictable torque changes and potential safety issues due to uneven wear, foreign matter, and surface roughness, which can result in inadequate braking torque.
Innovation Solution
A state estimation apparatus that uses sensors to acquire waveform information from the contact between brake materials and metal plates, estimating the surface states and contact conditions based on feature amounts of the waveform data to determine the necessary inspection and replacement timing of the brake apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the brake apparatus operates continuously without monitoring, then the elevator can maintain operational continuity, but the brake performance deteriorates unpredictably due to wear, foreign matter, and surface roughness
Solution Approach 1:
The elastic wave sensor detects changes in brake material surface state (roughness, wear, foreign matter) before they significantly degrade brake performance. By performing preliminary detection and issuing alerts, the system allows for proactive maintenance scheduling that prevents performance deterioration while maintaining operational continuity.
Solution Approach 2:
The system continuously monitors brake material conditions using elastic wave sensors and provides real-time feedback on surface state changes. This feedback loop enables dynamic adjustment of maintenance schedules and operational parameters, resolving the contradiction between continuous operation and performance reliability.
2Reliability
If the brake apparatus is inspected frequently to ensure safety, then the reliability of brake performance is improved, but the maintenance time and operational downtime increase
Solution Approach 1:
The system replaces manual visual inspection and physical measurement methods with automated elastic wave sensing technology. The sensor non-invasively detects surface state changes (roughness, wear, foreign matter) without requiring disassembly or operational shutdown, dramatically reducing maintenance time while improving detection accuracy and reliability.
Solution Approach 2:
The brake apparatus performs self-diagnosis through the elastic wave sensor that continuously monitors its own material surface state. The system automatically detects deterioration trends and generates maintenance alerts, eliminating the need for frequent manual inspections and reducing operational downtime while ensuring brake performance reliability.
3Reliability
If the brake material is replaced early to ensure safety, then the reliability is improved, but the loss of brake material and increased maintenance cost occur
Solution Approach 1:
The elastic wave sensor detects surface state changes (roughness, wear, foreign matter) at early stages before they lead to significant material loss or performance failure. By identifying deterioration trends early, the system enables precise timing of material replacement, maximizing material utilization while ensuring safety and avoiding premature replacement.
4Measurement precision
If the brake apparatus is monitored continuously with advanced sensors, then the detection precision of surface state is improved, but the device complexity increases
Solution Approach 1:
The system uses elastic wave sensing technology that naturally penetrates and interacts with the brake material structure, providing deep surface and subsurface defect detection without complex optical alignment or contact requirements. This physical principle-based approach achieves high measurement precision for surface state (roughness, wear, foreign matter) while avoiding the complexity of multi-component electronic sensing systems.
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
Enables timely inspection and replacement of the brake apparatus, preventing a drop in braking torque below safety levels, ensuring the safety and reliability of elevator operations by monitoring and predicting performance degradation.
Implementation Method 1
acquire waveform information of an elastic wave generated in a case where a brake material and a metal plate come into contact with each other using a sensor
Data Source
AI summary
According to an embodiment, a state estimation apparatus for a brake apparatus for a hoisting machine, includes a processor. The processor is configured to acquire waveform information of an elastic wave generated in a case where a brake material fixed to a brake plate connected to a rotation shaft of the hoisting machine and a metal plate holding the brake material and restraining movement of the brake plate come into contact with each other using a sensor provided on the metal plate; and estimate at least one of a surface state of the brake material, a surface state of the metal plate, and a contact state between the brake material and the metal plate based on a feature amount of the waveform information.