Elevator Brake Moment Detection via Automated Torque Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing elevator brake detection methods are cumbersome, requiring manual operation and additional devices, and fail to accurately predict brake wear trends, leading to potential safety hazards due to insufficient braking moments.
Innovation Solution
An automated detection system utilizing a controller, motor encoder, and frequency converter to detect brake moment changes by gradually increasing torque output, allowing for accurate assessment of brake reliability and wear trends without manual intervention, enabling periodic and convenient monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual hydraulic device and pressure sensor are used for brake moment detection, then detection function is provided, but operation complexity increases and convenience decreases
Solution Approach 1:
The system performs self-detection of brake moment automatically without requiring manual operation. The controller initiates detection sequences, applies test torques through the frequency converter, and evaluates brake performance autonomously, eliminating the need for manual hydraulic device operation while maintaining detection reliability
Solution Approach 2:
The manual hydraulic detection device is replaced with an automated electrical control system. The frequency converter electronically controls motor torque output, and the controller automatically processes detection data, substituting mechanical manual operations with electrical automation to improve ease of operation while preserving detection functionality
2Measurement precision
If single-point brake moment detection is performed, then current brake status is detected, but wear trend prediction capability is lost
Solution Approach 1:
The system performs preliminary detection at multiple time points throughout brake operation. By conducting repeated brake moment detections and storing the results in the controller, the system builds a historical data set that enables prediction of wear trends before critical failure occurs, while maintaining precise measurement of current brake status
Solution Approach 2:
The controller continuously monitors brake moment detection results and compares them against predetermined thresholds and historical data. This feedback mechanism identifies degradation trends over time, providing early warning of brake wear while maintaining accurate measurement of current brake performance through continuous comparison and analysis
3Reliability
If additional detection devices are installed, then detection function is enhanced, but device complexity increases
Solution Approach 1:
Existing elevator components are made multi-functional to perform both their primary functions and brake moment detection. The frequency converter, already present for motor control, is used to apply test torques during detection. The motor encoder, already installed for position feedback, provides rotation detection during brake testing. This eliminates the need for separate dedicated detection devices while maintaining detection accuracy
Solution Approach 2:
The brake moment detection system is merged with the existing motor control system. The controller integrates both motor control and brake detection functions, the frequency converter handles both normal operation torque control and detection torque application, and the motor encoder serves both position feedback and rotation detection during detection. This consolidation reduces device complexity while preserving detection capabilities
Data Source
Figure 1
Figure 2
AI summary
A detection method for elevator brake moment solves the problems that operation of the brake detection device in the prior art is required to be manually executed, the brake detection device is not convenient and facilitative to operate, the function is singular and the brake moment change trend and the brake wear trend cannot be reflected. In the method, by inputting stagewise torque current to the motor and determine whether the torque during rotation of a motor is within the design moment range of a brake, whether torque of the brake is enough can be determined and the brake wear trend can be analyzed according to torque recorded at each time. The method has advantages that the automatic detection is performed periodically, the functions are diversified, the detection accuracy is high, the brake moment change trend can be reflected and the brake wear trend can also be reflected.