CN107271165B - Variable-frequency loading intelligent brake test system and test method thereof - Google Patents
Variable-frequency loading intelligent brake test system and test method thereof Download PDFInfo
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- CN107271165B CN107271165B CN201710485613.2A CN201710485613A CN107271165B CN 107271165 B CN107271165 B CN 107271165B CN 201710485613 A CN201710485613 A CN 201710485613A CN 107271165 B CN107271165 B CN 107271165B
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Abstract
The invention provides a variable-frequency loading intelligent brake testing system and a testing method thereof, wherein the testing system comprises an installation pedestal, a transmission middle shaft, a limit switch and an intelligent brake to be tested are arranged on the installation pedestal, a brake disc, a motor, an angle encoder and a torsion limiting type coupling which are in transmission connection are arranged on the transmission middle shaft, the brake disc is braked by the intelligent brake, the rotating speed of the transmission middle shaft is controlled by the motor, the rotating speed of a shaft is collected by the angle encoder, when the shaft rotating torque generated after the brake disc is braked is greater than a limit value, the torsion limiting type coupling generates shaft rotating slip, whether the torsion limiting type coupling slips or not is collected and judged by the limit switch, and an external control end sends a command and generates an alarm. During the whole test process, the torque sensor records the torque between the brake disc and the load all the time. The invention solves the problem of how to test the braking performance of the intelligent brake.
Description
Technical Field
The invention belongs to the technical field of test systems, and relates to a test system and a test method thereof for an intelligent brake based on variable frequency loading.
Background
At present, a normally closed type electro-hydraulic brake is a common safety device in the industrial field, is usually used for braking of a crane trolley, a crane, a lifting device and a luffing device, braking of wind power equipment, preventing anchor chain from drooping when a ship is anchored, and the like, and has the function of braking a moving part according to an instruction of a driver.
Conventional normally closed brakes have only an opening and closing function and no controllable intermediate state. This causes the brake to directly lock the brake disc during braking, which may generate a large impact force and cause a local rapid temperature rise and damage of the brake. In certain applications, such as emergency stop situations, damage to weak parts of the drive train, wheel wear, etc. may even result.
In the prior art, an intelligent brake utilizes a frequency conversion technology and a computer to intelligently modify a traditional normally closed electro-hydraulic or electromagnetic brake, so that the traditional brake only with an opening state and a closing state becomes the intelligent brake with controllable braking force and braking time and adjustable according to requirements. The intelligent brake can stabilize the braking process and relieve the impact when the brake is too urgent (particularly when the brake is stopped), thereby protecting each mechanism (reduction gearbox, coupling and the like) on a transmission chain at the front end of the brake and achieving the effects of prolonging the maintenance period and the service life of each mechanism.
A test object of a conventional brake test system is a traditional industrial brake, an inertia load is driven to rotate at a certain rotating speed by a variable frequency motor, then a brake to be tested brakes the load, and information such as braking torque, braking time, load speed and brake disc temperature is collected to evaluate the braking capacity of the brake. However, the intelligent brake test system cannot simulate the damage of braking impact on a mechanical system in actual working conditions, and cannot show the advantages of controllable and adjustable braking force of the intelligent brake, so that the intelligent brake test system cannot meet the functional requirements of the intelligent brake test system.
Disclosure of Invention
The invention is designed for testing and demonstrating the braking performance of the intelligent brake based on variable-frequency loading. In order to achieve the above purpose and overcome the defects in the prior art, the invention provides a variable-frequency loading intelligent brake testing system and a testing method thereof, so as to solve the problem of how to test the braking performance of an intelligent brake.
In order to achieve the above purpose, the solution of the invention is: the frequency conversion loading intelligent brake testing system comprises an installation pedestal, wherein a transmission center shaft, a limit switch and an intelligent brake to be tested are arranged on the installation pedestal, a brake disc, a motor, an angle encoder and a torsion limiting type coupling which are in transmission connection with each other are arranged on the transmission center shaft, the brake disc is braked by the intelligent brake, the rotating speed of the transmission center shaft is controlled by the motor, the rotating speed of a shaft is collected by the angle encoder, when the shaft rotating torque generated after the brake disc is braked is larger than a limit value, the torsion limiting type coupling generates shaft rotating slip, whether the torsion limiting type coupling slips or not is collected and judged by the limit switch, and an external control end sends a command and generates an alarm.
Preferably, a plurality of bearing seats are arranged on the mounting pedestal at intervals, the transmission middle shaft comprises a brake disc left shaft, a brake disc right shaft and an inertia wheel shaft which are coaxially connected, and bearings are respectively sleeved on the brake disc left shaft, the brake disc right shaft and the inertia wheel shaft and are respectively and correspondingly mounted on the bearing seats through the bearings.
Preferably, the angle encoder is in transmission connection with the left shaft of the brake disc through a first elastic coupling, a torque sensor is arranged on the mounting pedestal between the right shaft of the brake disc and the torque limiting type coupling, the right shaft of the brake disc is in transmission connection with the dynamic torque sensor through a second elastic coupling, and the torque sensor is in transmission connection with the inertia wheel shaft through the torque limiting type coupling.
Preferably, a flywheel is fixedly sleeved on the inertia wheel shaft, and the rotational inertia of the inertia wheel shaft is loaded through the flywheel.
Preferably, the flywheel shaft and the motor are connected through a third elastic coupling.
Preferably, the control end comprises a PLC controller, the PLC controller is used for respectively driving and controlling the frequency converter and the intelligent driver, the frequency converter is used for driving and controlling the rotating speed of the motor, and the intelligent driver is used for controlling and adjusting the braking torque and the braking time of the intelligent brake.
Preferably, the limit switch is used for detecting the axial displacement of the torque limiting type coupler when the torque exceeds the limit value, and the limit switch is in signal transmission connection with the PLC.
In order to better achieve the above object, the present invention further provides a method for testing a variable frequency loading intelligent brake, comprising the following steps:
arranging a mounting pedestal, and arranging a transmission middle shaft, a limit switch and an intelligent brake to be tested on the mounting pedestal;
a brake disc, a motor, an angle encoder and a torque limiting type coupler which are in transmission connection with each other are arranged on the transmission middle shaft, the brake disc is braked through the intelligent brake, the rotating speed of the transmission middle shaft is controlled through the motor, and the rotating speed of the shaft is acquired through the angle encoder;
the motor is started, when the shaft rotation torque generated after the brake disc is braked is larger than a limit value, the torque limiting type coupling generates shaft rotation slip, and whether the torque limiting type coupling slips or not is collected and judged through the limit switch;
if the torque limiting type coupler does slip, sending a preset signal to an external control end, sending a command through the control end and generating an alarm;
and acquiring and recording the time history of the rotating speed and the actual torque in the whole running and braking process, and evaluating the performance of the intelligent brake by analyzing the test phenomenon and the acquired information.
Preferably, the method comprises the following steps: the control end is provided with a PLC controller, the PLC controller is used for respectively driving and controlling the frequency converter and the intelligent driver, the frequency converter is used for driving and controlling the rotating speed of the motor and feeding back the running state of the motor to the PLC controller, and the intelligent driver is used for controlling and adjusting the braking torque and the braking time of the intelligent brake and feeding back the running state of the intelligent brake to the PLC controller.
Preferably, the method comprises the following steps: and detecting the axial displacement of the torque limiting type coupler when the torque exceeds the limit value through the limit switch so as to judge whether the torque limiting type coupler slips or not, and sending a signal to be fed back to the PLC.
The beneficial effects of the invention include:
1) the structure is simple, the number of parts is small, the layout is reasonable, the installation is convenient, and the maintenance and the repair can be conveniently carried out;
2) the brake performance of the intelligent brake based on variable frequency loading can be tested under the condition of least energy consumption, the actual working condition of an industrial reducer is completely simulated, the brake effect of the intelligent brake is compared with that of a traditional brake, the damage of brake impact on a mechanical system can be visually shown through the slipping of a torque limiting type coupling and sound-light alarm, and the brake impact is relieved and improved after the intelligent brake is adopted;
3) the controllable and adjustable braking torque of the intelligent brake is demonstrated by changing the limiting torque of the torque limiting type coupling and correspondingly adjusting the braking torque of the intelligent brake;
4) the change relation between the braking torque and the load rotating speed of the intelligent brake along with the braking time can be quantitatively tested, the driving frequency of the intelligent driver can be adjusted accordingly, the change process of the braking torque of the intelligent brake is adjusted, the braking process is more stable and has no impact, and therefore a data basis is provided for quantitatively determining an intelligent braking strategy of actual equipment.
Drawings
FIG. 1 is a schematic diagram of the overall top view structure of the variable frequency loading intelligent brake test system of the present invention;
FIG. 2 is a schematic cross-sectional front view corresponding to FIG. 1;
FIG. 3 is a schematic layout diagram of an electrical control terminal in the variable frequency loading intelligent brake test system of the present invention.
Reference numbers in the figures: 1- -pedestal; 2-encoder support; 3- -absolute value encoder; 4- -a first elastic coupling; 5- -brake disc left axle; 6- -brake disc; 7- -brake disc right axle; 8- -a second elastic coupling; 9- -dynamic torque sensor; 10-torque force limiting type coupling; 11- -flywheel shaft; 12- -a flywheel; 13- -third elastic coupling; 14- -AC motor; 15- -bearing seat; 16- -round nut; 17- -a bearing; 18- -circlip; 19- -limit switch; 20- -ordinary flat bond; 21- -Intelligent brake tested.
Detailed Description
The invention will be further described with reference to examples of embodiments shown in the drawings.
Referring to fig. 1 and 2, the present invention first provides a variable frequency loading intelligent brake testing system, which includes: a pedestal 1; an encoder support 2; an absolute value angle encoder 3; a first elastic coupling 4; a brake disc left shaft 5; a brake disk 6; a brake disc right shaft 7; a second elastic coupling 8; a dynamic torque sensor 9; a torque-limiting coupling 10; an inertia wheel shaft 11; a flywheel 12; a third elastic coupling 13; an alternating current motor 14; a bearing housing 15; a round nut 16; a bearing 17; a circlip 18; a limit switch 19; a generally flat key 20; the smart brake 21 being tested for several parts.
Specifically, the pedestal 1 is connected with the encoder support 2, the dynamic torque sensor 9, the alternating current motor 14, the bearing seat 15, the limit switch 19 and the intelligent brake 21 by high-strength bolts, and the encoder support 2 is connected with the absolute value angle encoder 3 by common bolts. The absolute value angle encoder 3 is connected with a left shaft 5 of a brake disc through a first elastic coupling 4, and motion and power are transmitted through a common flat key. The brake disk 6 is connected with the brake disk left shaft 5 and the brake disk right shaft 7 by adopting flat keys to transmit motion and power, and forms a transmission middle shaft whole body without relative displacement, and is supported and positioned by a pair of bearings 17. The brake disc right shaft 7 and the dynamic torque sensor 9 are connected by a second elastic coupling 8, and transmit motion and power through a common flat key. The dynamic torque sensor 9 and the inertia wheel shaft 11 are connected by a torsion limiting type coupling 10, and the motion and the power are transmitted through a common flat key. The limit switch 19 is switched to abut against the torque limiting coupling 10 to detect whether it slips. The flywheel 12 is splined to the flywheel shaft 11 and is axially positioned by a round nut 16. The flywheel shaft 11 is supported and positioned by a pair of bearings 17. The inertia wheel shaft 11 and the alternating current motor 14 are connected by a third elastic coupling 13, and the motion and the power are transmitted through a common flat key. The elastic couplings all function as a conventional connection.
Furthermore, after having the above structural features, the present invention further discloses a method for testing an intelligent brake by variable frequency loading, and the above testing system of the present invention can also be implemented by the method, and with reference to fig. 1 to 2, the method specifically includes the following processes:
during testing, the alternating current motor 14 drives the brake disc 6, the inertia load 12, the torque limiting type coupling 10 and other devices to rotate, the absolute value angle encoder 3 collects the current rotating speed, and when the set rotating speed is reached, the control end controls the brake 21 to brake. The torque limiting type coupler 9 is normally connected when the torque does not exceed a limit value, and slips when the torque exceeds the limit value, the limit switch 19 collects whether the torque limiting type coupler 10 slips, if the torque limiting type coupler slips, a preset signal is sent to the control end, and the control end sends a command to the audible and visual alarm to enable the audible and visual alarm to give out audible and visual alarm; if not, the whole test system is braked normally. In the whole operation process, the time history of the rotating speed and the actual torque is collected and recorded, and the braking performance of the intelligent brake can be obtained by analyzing the test phenomenon and the collected information.
As shown in fig. 3, for the electrical control part, the PLC is a main controller, and the upper controller thereof is an industrial tablet computer, and is responsible for driving the frequency converter and the intelligent driver, collecting feedback signals, and completing functions such as speed control of the motor 14, brake on/off control, data collection and storage, and the like.
The frequency converter is used for driving the motor, inputting proper frequency to the motor 14 according to a master control instruction of the PLC, enabling the motor 14 to rotate at a certain rotating speed, and meanwhile, feeding back the running state of the frequency converter to the PLC.
The intelligent driver is a driving device of the intelligent brake, adjusts the braking torque and the braking time of the brake 21 according to a preset program, and simultaneously feeds back the running state of the brake to the PLC.
The encoder 3 collects the rotation speed of the inertial load of the transmission center shaft and feeds the rotation speed back to the PLC.
The limit switch 19 monitors whether the torque limiting type coupler slips or not, the working principle is that the coupler has axial displacement when the torque exceeds a limit value, signals are fed back to the PLC by detecting the axial displacement, and the signals are used for realizing acousto-optic alarm.
The torque sensor is used for collecting torque data in the test process and feeding back the torque data to the PLC for recording and analyzing. During the whole test process, the torque sensor records the torque between the brake disc and the load all the time.
After the implementation process is completed, the following characteristics of the invention can be embodied:
1) the structure is simple, the number of parts is small, the layout is reasonable, the reliability is high, the efficiency is high, and the installation, the maintenance and the repair are convenient;
2) the intelligent brake based on frequency conversion loading can be tested under the least energy consumption, the actual working condition of the industrial reducer is completely simulated, the intelligent brake is compared with the braking effect of the traditional brake, the impact damage caused by the braking of the traditional brake is vividly shown, and after the intelligent brake is adopted, the impact of the braking is relieved and improved, and the specific performance is as follows:
a. simulating an inertial load in the operation of industrial equipment, and enabling the inertial to stably rotate at a set rotating speed;
b. the system can automatically or manually give a braking signal after the tested object reaches the preset initial braking speed, and starts the testing process;
c. in the test process, the brake can be switched to a traditional braking mode and an intelligent braking mode at will, and whether the brake impact can damage a transmission chain or not is distinguished according to the preset torque limiting type coupling slipping torque; if the braking torque is smaller, normal braking is performed, if the braking torque exceeds a limit value, the torque force limits the coupler to slip, and the test system gives out sound and light alarm;
d. the test system can automatically reset after slipping to prepare for the next test;
e. the limiting torque of the torque limiting coupling can be changed, and the braking torque of the intelligent brake can be correspondingly adjusted, so that the controllable and adjustable braking force of the intelligent brake can be demonstrated;
f. in the test experiment, the time history of the rotating speed and torque data can be automatically stored and exported to a computer.
The embodiments described above are intended to facilitate one of ordinary skill in the art in understanding and using the present invention. It will be readily apparent to those skilled in the art that various modifications to these embodiments may be made, and the generic principles described herein may be applied to other embodiments without the use of the inventive faculty. Therefore, the present invention is not limited to the above embodiments, and those skilled in the art should make improvements and modifications within the scope of the present invention based on the disclosure of the present invention.
Claims (8)
1. The utility model provides a frequency conversion loading intelligence stopper test system which characterized in that: the intelligent brake system comprises an installation pedestal, wherein a transmission middle shaft, a limit switch and an intelligent brake to be tested are arranged on the installation pedestal, a brake disc, a motor, an angle encoder and a torsion limiting type coupler are arranged on the transmission middle shaft, the motor is in transmission connection with the transmission middle shaft, the intelligent brake is used for braking the brake disc, the rotating speed of the transmission middle shaft is controlled through the motor, the rotating speed of a shaft of the transmission middle shaft is acquired through the angle encoder, when the rotating torque of the shaft generated after the brake disc is braked is larger than a limit value, the torsion limiting type coupler generates shaft slipping, the limit switch is used for acquiring and judging whether the torsion limiting type coupler slips or not, an external control end is used for sending a command and generating an alarm, the time history of the rotating speed and the actual torque is acquired and recorded in the whole operation process, and the limiting torque of the torsion limiting type coupler is changed, the braking torque of the intelligent brake is correspondingly adjusted, the damage of braking impact on a mechanical system is visually shown through the slipping of the torque limiting type coupling and the sound-light alarm, and the braking impact is relieved and improved after the intelligent brake is adopted; the control end comprises a PLC controller, a frequency converter and an intelligent driver are respectively driven and controlled by the PLC controller, the rotating speed of the motor is driven and controlled by the frequency converter, and the braking torque and the braking time of the intelligent brake are controlled and adjusted by the intelligent driver; the limit switch is used for detecting the axial displacement of the torque limiting type coupler when the torque exceeds the limit value, and the limit switch is in signal transmission connection with the PLC.
2. The variable frequency loading intelligent brake test system of claim 1, wherein: the installation pedestal is provided with a plurality of bearing seats at intervals, the transmission middle shaft comprises a brake disc left shaft, a brake disc right shaft and an inertia wheel shaft which are coaxially connected, and the brake disc left shaft, the brake disc right shaft and the inertia wheel shaft are respectively sleeved with a bearing and are respectively and correspondingly installed on each bearing seat through the bearing.
3. The variable frequency loading intelligent brake test system of claim 2, wherein: the angle encoder is in transmission connection with the left shaft of the brake disc through a first elastic coupling, a dynamic torque sensor is arranged on the mounting pedestal between the right shaft of the brake disc and the torque limiting type coupling, the right shaft of the brake disc is in transmission connection with the dynamic torque sensor through a second elastic coupling, and the dynamic torque sensor is in transmission connection with the inertia wheel shaft through the torque limiting type coupling.
4. The variable frequency loading intelligent brake test system of claim 3, wherein: the flywheel is fixedly sleeved on the inertia wheel shaft, and the rotational inertia of the inertia wheel shaft is loaded through the flywheel.
5. The variable frequency loading intelligent brake test system of claim 4, wherein: the inertia wheel shaft is connected with the motor through a third elastic coupling.
6. A variable frequency loading smart brake testing method using the variable frequency loading smart brake testing system of claim 1, comprising the steps of:
arranging a mounting pedestal, and arranging a transmission middle shaft, a limit switch and an intelligent brake to be tested on the mounting pedestal;
a brake disc, a motor, an angle encoder and a torque limiting type coupler which are in transmission connection with each other are arranged on the transmission middle shaft, the brake disc is braked through the intelligent brake, the rotating speed of the transmission middle shaft is controlled through the motor, and the rotating speed of the transmission middle shaft is acquired through the angle encoder;
the motor is started, when the shaft rotation torque generated after the brake disc is braked is larger than a limit value, the torque limiting type coupling generates shaft rotation slip, and whether the torque limiting type coupling slips or not is collected and judged through the limit switch;
if the torque limiting type coupler does slip, sending a preset signal to an external control end, sending a command through the control end and generating an alarm;
and acquiring and recording the time history of the rotating speed and the actual torque in the whole running and braking process, and evaluating the performance of the intelligent brake by analyzing the test phenomenon and the acquired information.
7. The variable frequency loading intelligent brake testing method according to claim 6, characterized by comprising the following steps:
the control end is provided with a PLC controller, the PLC controller is used for respectively driving and controlling the frequency converter and the intelligent driver, the frequency converter is used for driving and controlling the rotating speed of the motor and feeding back the running state of the motor to the PLC controller, and the intelligent driver is used for controlling and adjusting the braking torque and the braking time of the intelligent brake and feeding back the running state of the intelligent brake to the PLC controller.
8. The variable frequency loading intelligent brake testing method according to claim 7, characterized by comprising the following steps:
and detecting the axial displacement of the torque limiting type coupler when the torque exceeds the limit value through the limit switch so as to judge whether the torque limiting type coupler slips or not, and sending a signal to be fed back to the PLC.
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| CN201710485613.2A CN107271165B (en) | 2017-06-23 | 2017-06-23 | Variable-frequency loading intelligent brake test system and test method thereof |
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| CN201710485613.2A CN107271165B (en) | 2017-06-23 | 2017-06-23 | Variable-frequency loading intelligent brake test system and test method thereof |
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| CN107271165B true CN107271165B (en) | 2020-02-14 |
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| CN108646181A (en) * | 2018-08-15 | 2018-10-12 | 上海市特种设备监督检验技术研究院 | A kind of braking motor load test system and its test method |
| CN109163839B (en) * | 2018-08-30 | 2021-02-09 | 北京精密机电控制设备研究所 | Brake performance testing device and testing method |
| CN110132581A (en) * | 2019-06-27 | 2019-08-16 | 三一重能有限公司 | A kind of shaft coupling slipping monitoring system and method |
| CN111220379B (en) * | 2020-04-23 | 2020-07-31 | 湖南中车时代通信信号有限公司 | Fault diagnosis method and device for traction motor transmission system |
| CN113607411B (en) * | 2021-07-28 | 2024-03-08 | 三一重能股份有限公司 | Torque limiter test system and method |
| CN113776710B (en) * | 2021-08-24 | 2022-05-17 | 嘉兴恩碧技电气有限公司 | Coupler torsion testing device |
| CN114216661A (en) * | 2021-10-22 | 2022-03-22 | 盐城和阳驱动科技有限公司 | Service life detection device for traction machine brake |
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| CN202339241U (en) * | 2012-01-19 | 2012-07-18 | 康卓彬德电磁技术（苏州）有限公司 | Torsion-resistant test device of electromagnetic brake |
| CN102589883B (en) * | 2012-02-28 | 2014-07-02 | Bpw(梅州）车轴有限公司 | Bearing temperature, dynamic torque detection testing method and testing device |
| CN102706506B (en) * | 2012-06-21 | 2013-11-13 | 江苏省特种设备安全监督检验研究院无锡分院 | Comprehensive performance testing device for safety brake |
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| CN105043768B (en) * | 2015-06-30 | 2018-08-03 | 安徽协同轴承股份有限公司 | Unilateral bearing durability-testing machines |
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| CN105223015A (en) * | 2015-11-09 | 2016-01-06 | 江苏省特种设备安全监督检验研究院 | A kind of low-speed big inertia brake test unit with speed reduction unit |
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| CN105403397A (en) * | 2015-12-18 | 2016-03-16 | 海安县申菱电器制造有限公司 | Electromagnetic brake detection apparatus capable of simulating multiple loads |
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| CN205315539U (en) * | 2015-12-29 | 2016-06-15 | 武汉正通传动技术有限公司 | Take torque limiter of flexible sheet shaft coupling |
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