CN112010219A - Elevator brake real-time state monitoring/early warning system - Google Patents

Abstract

The invention provides a real-time state monitoring/early warning system of an elevator brake, which comprises: a tractor, a brake, a sensor subsystem, a logic subsystem and a final element subsystem; the sensor subsystem is connected with the logic subsystem; the logic subsystem is connected with the final element subsystem; the sensor subsystem includes: a sensor component; the elevator brake real-time status monitoring/early warning system comprises: the elevator system, the elevator brake, the sensor component, the input module, the logic processing module and the early warning/output module; the final element subsystem can cut off the power supply of the brake in time when a fault or danger occurs. The invention solves the control of the system power supply by connecting the output switch of the monitoring system into the safety loop, and ensures the safety of personnel and equipment.

Description

Elevator brake real-time condition monitoring/early warning system

technical field

The invention relates to the technical field of real-time state monitoring, in particular to a real-time state monitoring/early warning system of an elevator brake.

Background technique

For a long time, elevator brakes have widely used electrical testing, factory equipment testing and mechanical testing, as well as regular random inspections to ensure the normal operation of the brakes. This detection method still has obvious shortcomings: (1) If there is a fault in the detection, an accident has already occurred; (2) It is difficult to control the interval time for regular random inspection time. If the interval is too long, the safety between detections cannot be guaranteed. Intervals that are too short are wasteful. At the same time, in the process of data analysis, information data from a single source is mostly used, and diagnosis and early warning are based on expert experience, which lacks accurate quantitative analysis.

Patent document CN107814288A discloses a method for intelligent monitoring and early warning of elevator brakes, which adopts a non-contact measurement method to collect key parameters and gives the running state of the machine based on SVM cluster analysis. The shortcomings of the existing technology are: the main function of the monitoring system is to monitor the running state of the brake and record the relevant operating data, relying on expert experience to analyze and judge according to the change curve of the physical parameters, lack of research on the fault early warning algorithm; at the same time, the monitoring system itself Without functional safety certification, the reliability and safety during operation cannot be effectively guaranteed, so it cannot meet the functional safety requirements of the elevator itself.

SUMMARY OF THE INVENTION

In view of the defects in the prior art, the purpose of the present invention is to provide a real-time state monitoring/early warning system for elevator brakes.

A real-time state monitoring/early warning system for an elevator brake provided according to the present invention includes: a traction machine, a brake, a sensor subsystem, a logic subsystem and a final element subsystem;

the sensor subsystem is connected to the logic subsystem;

the logic subsystem is connected to the final element subsystem;

The sensor subsystem includes: a sensor component;

The elevator brake real-time state monitoring/early warning system includes: an elevator system, an elevator brake, a sensor component, an input module, a logic processing module, and an early warning/output module;

The elevator system and the elevator brake are respectively connected with the sensor components;

the input module is connected with the sensor component;

the input module is connected with the logic processing module;

The logic processing module is connected with the early warning/output module;

the final element subsystem is connected to the brake;

The final element subsystem can cut off the power supply of the brake in time in case of failure or danger.

Preferably, the sensor component includes: an AC voltage sensor, an AC current sensor;

The AC voltage sensor and the AC current sensor are respectively connected with the elevator system;

The AC voltage sensor and the AC current sensor are respectively connected with the input module.

Preferably, the sensor component includes: a displacement sensor, a temperature sensor, a DC voltage sensor, a DC current sensor and a noise sensor;

The displacement sensor, temperature sensor, DC voltage sensor, DC current sensor and noise sensor are respectively connected with the elevator brake;

The displacement sensor, temperature sensor, DC voltage sensor, DC current sensor and noise sensor are respectively connected with the input module.

Preferably, the sensor subsystem further comprises: a rotary encoder;

the rotary encoder is connected with the elevator system;

The rotary encoder is connected with the input module.

Preferably, the sensor subsystem further comprises: a micro switch;

the micro switch is connected with the elevator brake;

The micro switch is connected with the input module.

Preferably, it also includes: a DC current transmitter, a perforated AC current transmitter;

The AC voltage sensor, the AC current sensor, the DC voltage sensor, and the DC current sensor are connected in parallel on the positive and negative poles of the brake coil to monitor the brake coil voltage;

The DC current transmitter is connected in series on the circuit of the brake to monitor the current;

The perforated AC current transmitter monitors the output current of the traction machine.

Preferably, the temperature sensor adopts a J-type linear thermocouple.

Preferably, the displacement sensor adopts a laser displacement sensor.

Preferably, the rotary encoder adopts a HEIDENHAIN absolute value encoder.

Preferably, the logic subsystem includes: an MCU component, a power supply module, a power supply monitoring module, a watchdog module and a storage module.

Compared with the prior art, the present invention has the following beneficial effects:

1. The present invention solves the problem of identifying too small braking distance and air gap by using the encoder reading, brake gap, friction noise, brake voltage, brake current, coil temperature and micro switch response time as the data objects collected by the monitoring system. Too large, the friction plate is worn, the coil voltage is too low, the coil current is too low, the coil is overheated, the residual voltage, current and spring force of the coil are insufficient and other physical phenomena;

2. The present invention solves the control of the power supply of the system by connecting the output switch of the monitoring system into the safety circuit and ensures the safety of personnel and equipment;

3. The present invention solves the problem that the system will enter a safe state when a random failure occurs in one of the two channels by using the master and slave systems to simultaneously complete the function of monitoring the running state of the brake.

Description of drawings

Other features, objects and advantages of the present invention will become more apparent by reading the detailed description of non-limiting embodiments with reference to the following drawings:

FIG. 1 is a schematic diagram of the overall structural framework of the present invention.

FIG. 2 is a schematic diagram of an overall hardware framework of an elevator brake monitoring system in an embodiment of the present invention.

FIG. 3 is a schematic diagram of an overall frame diagram of a sensor subsystem in an embodiment of the present invention.

FIG. 4 is a schematic diagram of an overall layout of a sensor in an embodiment of the present invention.

FIG. 5 is a schematic diagram of a design block diagram of an output circuit module in an embodiment of the present invention.

6 is a schematic diagram of an elevator safety circuit in an embodiment of the present invention.

In the picture:

K- elevator brake monitoring system output switch; BRAKE- elevator brake

M-tractor KM1-tractor contactor

Detailed ways

The present invention will be described in detail below with reference to specific embodiments. The following examples will help those skilled in the art to further understand the present invention, but do not limit the present invention in any form. It should be noted that, for those skilled in the art, several changes and improvements can be made without departing from the inventive concept. These all belong to the protection scope of the present invention.

A real-time state monitoring/early warning system for an elevator brake provided according to the present invention includes: a traction machine, a brake, a sensor subsystem, a logic subsystem, and a final element subsystem;

the sensor subsystem is connected to the logic subsystem;

the logic subsystem is connected to the final element subsystem;

The sensor subsystem includes: a sensor component;

The elevator brake real-time state monitoring/early warning system includes: an elevator system, an elevator brake, a sensor component, an input module, a logic processing module, and an early warning/output module;

The elevator system and the elevator brake are respectively connected with the sensor components;

the input module is connected with the sensor component;

the input module is connected with the logic processing module;

The logic processing module is connected with the early warning/output module;

the final element subsystem is connected to the brake;

The final element subsystem can cut off the power supply of the brake in time in case of failure or danger.

Preferably, the sensor component includes: an AC voltage sensor, an AC current sensor;

The AC voltage sensor and the AC current sensor are respectively connected with the elevator system;

The AC voltage sensor and the AC current sensor are respectively connected with the input module.

Preferably, the sensor component includes: a displacement sensor, a temperature sensor, a DC voltage sensor, a DC current sensor and a noise sensor;

The displacement sensor, temperature sensor, DC voltage sensor, DC current sensor and noise sensor are respectively connected with the elevator brake;

The displacement sensor, temperature sensor, DC voltage sensor, DC current sensor and noise sensor are respectively connected with the input module.

Preferably, the sensor subsystem further comprises: a rotary encoder;

the rotary encoder is connected with the elevator system;

The rotary encoder is connected with the input module.

Preferably, the sensor subsystem further comprises: a micro switch;

the micro switch is connected with the elevator brake;

The micro switch is connected with the input module.

Preferably, it also includes: a DC current transmitter, a perforated AC current transmitter;

The AC voltage sensor, the AC current sensor, the DC voltage sensor, and the DC current sensor are connected in parallel on the positive and negative poles of the brake coil to monitor the brake coil voltage;

The DC current transmitter is connected in series on the circuit of the brake to monitor the current;

The perforated AC current transmitter monitors the output current of the traction machine.

Preferably, the temperature sensor adopts a J-type linear thermocouple.

Preferably, the displacement sensor adopts a laser displacement sensor.

Preferably, the rotary encoder adopts a HEIDENHAIN absolute value encoder.

Preferably, the logic subsystem includes: an MCU component, a power supply module, a power supply monitoring module, a watchdog module and a storage module.

The elevator brake monitoring system can monitor the temperature, noise, electrical signal, encoder signal and micro-switch signal in real time, and realize the random fault judgment of the elevator brake and the fault early warning of brake failure. Comply with the design requirements of hardware safety integrity for SIL2 (safety integrity level, SIL 2).

Specifically, in one embodiment, the elevator brake real-time state monitoring/early warning system is divided into three subsystems, namely the sensor subsystem, the logic subsystem and the final element subsystem, according to the functional requirements and reliability requirements of the monitoring system.

The sensor subsystem of the elevator brake monitoring system is mainly composed of thermocouples, voltage and current sensors, noise sensors, laser displacement sensors, encoders and micro-switch signals, which are used to measure the coil temperature, voltage and current during the brake holding and releasing process respectively. , brake noise, wear degree, braking distance and brake response time and other analog and digital changes.

1. Voltage and current sensor. The voltage and current sensors are connected in parallel on the positive and negative poles of the brake coil to monitor the voltage of the brake coil; the DC current transmitter is connected in series on the brake circuit to monitor the current; the perforated AC current transmitter monitors the output current of the traction machine.

2. Temperature sensor. The J-type linear thermocouple with high sensitivity, stability and uniformity is used as the temperature sensor, which is embedded in the coil to detect the high temperature generated by the coil under continuous power supply when the elevator brake is working.

3. Noise sensor. During the process from normal operation to failure of the brake, the brake pads will gradually wear out, and the sound produced by the brake will change. Install the noise sensor outside the electrical cabinet, with the mic port facing the brake, and set a distance of 5m, which can be monitored. The brake abnormality produces sound changes (sound intensity, audio frequency), so as to capture the abnormal situation of the brake.

4. Displacement sensor. A laser displacement sensor is used to indirectly measure the gap between the brake wheel and the brake shoe and the wear amount of the brake shoe.

5. Encoder. The elevator brake encoder is a HEIDENHAIN absolute encoder, and the incremental signal output is a quadrature sine and cosine signal. The quadrature analog signal is converted into a pulse signal, and the quadrature pulse signal we need is obtained as the output.

6. Micro switch. The 24V digital quantity of the micro switch is provided by PLC, and the signal is collected by the data acquisition and control board. The micro switch is mainly used for the following two functions: 1. When the coil in the electromagnetic coil is energized, the armature disk is pulled toward the coil Bracket, when the brake is in place, the micro switch sends a signal to judge the brake opening response time; 2. When the brake is powered off, the armature disk returns to the initial position, and the micro switch signal returns to a low level, according to the low level obtained by the chip. The closing response time is derived from the level time and the brake de-energization time.

The logic subsystem of the elevator brake monitoring system mainly includes high reliability MCU, power supply module, power supply monitoring module, watchdog module and storage module.

The function of the final component subsystem of the elevator brake monitoring system is to cut off the power supply of the traction machine and the brake in time when it is judged that there is a fault or danger, so it can be regarded as the output of the safety relay connected to the safety circuit. By connecting the relay output of the system to the safety circuit, the power supply of the traction machine and the brake is controlled.

In the elevator brake monitoring system, the system is divided into two modules, master and slave, and the master and slave modules can each complete the function of monitoring the running state of the brake. The MCU of the master-slave module performs data communication and interaction through SPI. Since the two modules have the same structure, the following describes the functions of each module according to the main module. The AD processing module is used to receive, collect and process the analog quantities measured by each sensor; the optocoupler input module is used to collect the signal of the micro switch to judge the brake opening action of the brake; the RTC module is used as a clock module to save records The time of failure; the watchdog module is used to detect the reset function when the MCU has a system error; the man-machine interface is used to display the fault code and the remaining life of the machine; the EEPROM is used to store the fault information and elevator brake related parameters; the power circuit Provide power for the system, and power monitoring ensures that the power supply voltage of the system remains normal; the relay is used as an output element and is connected in series in the safety circuit. When a relay of the master-slave module is disconnected, the safety circuit is automatically disconnected, and the system is powered off and enters a safe state.

The design module of the output circuit is shown in Figure 5. The two relays are controlled by their respective MCUs in the A and B modules. When the two MCUs are initialized and the exchange information is normal, the two relays are turned on at the same time, and the safety circuit is connected. Start the trial test. When one MCU cannot control the relay in time due to random failure, the other MCU will cut off the relay output according to the interactive information feedback, so as to keep the elevator in a safe state and ensure the functional safety of the overall system.

The chip of the minimum system module of the microcontroller is TMS570LC4357 from Ti company. The chip itself has a lock-step dual ARM Cortex-R5F floating-point core, which can meet the requirements of the IEC 61508SIL3 safety standard. It integrates 41 channels of ADC interfaces, 5 MibSPI communication interface, 4 UART interfaces, up to 168 GPIO interfaces, and I2C communication and EMIF communication interfaces can meet the connection with other circuits. The two MCUs use MibSPI to communicate. According to the PESSRAL circuit requirements, when one of the two channels fails randomly, the system will enter a safe state. In this paper, the main system sends a query request to the secondary MCU at the beginning and end of each cycle. Similarly, the secondary MCU waits for the MCU to send a query request at the beginning and end of each cycle. If the two information are inconsistent, or a MCU system is stuck If the cycle causes the communication to fail, the system is put in a safe state through the relay output. Through the method of real-time supervision of two MCUs, the probability of random failure can be greatly reduced, and the reliability can be improved.

In order to ensure reliability and security, it is finally divided into three parts: A, B core board and backplane. Two identical core boards A and B are mainly composed of the smallest microcontroller module, ADC input module and storage module, and the backplane consists of the rest. There are two sets of interfaces on the bottom plate to connect with the two core boards A and B respectively.

By using the encoder reading, brake gap, friction noise, brake voltage, brake current, coil temperature and micro-switch response time as the data objects collected by the monitoring system, the invention solves the problem of identifying too small braking distance and too large air gap. , The friction plate is worn, the coil voltage is too low, the coil current is too low, the coil is overheated, the residual voltage, current and spring force of the coil are insufficient and other physical phenomena;

By connecting the output switch of the monitoring system into the safety circuit, the present invention solves the control of the power supply of the system and ensures the safety of personnel and equipment;

The invention solves the problem that the system will enter a safe state when a random failure occurs in one of the two channels by using the master and slave dual systems to simultaneously complete the function of monitoring the running state of the brake.

In the description of this application, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", The orientation or positional relationship indicated by "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the accompanying drawings, which is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying the indicated device. Or elements must have a particular orientation, be constructed and operate in a particular orientation, and therefore should not be construed as a limitation of the present application.

Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the above-mentioned specific embodiments, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essential content of the present invention. The embodiments of the present application and features in the embodiments may be arbitrarily combined with each other without conflict.

Claims (10)

1. An elevator brake real-time condition monitoring/warning system, comprising: a tractor, a brake, a sensor subsystem, a logic subsystem and a final element subsystem;

the sensor subsystem is connected with the logic subsystem;

the logic subsystem is connected with the final element subsystem;

the sensor subsystem includes: a sensor component;

the elevator brake real-time status monitoring/early warning system comprises: the elevator system, the elevator brake, the sensor component, the input module, the logic processing module and the early warning/output module;

the elevator system and the elevator brake are respectively connected with the sensor component;

the input module is connected with the sensor component;

the input module is connected with the logic processing module;

the logic processing module is connected with the early warning/output module;

the final element subsystem is connected with a brake;

the final element subsystem can cut off the power supply of the brake in time when a fault or danger occurs.

2. The elevator brake real-time condition monitoring/warning system of claim 1, wherein the sensor component comprises: an alternating voltage sensor, an alternating current sensor;

the alternating current voltage sensor and the alternating current sensor are respectively connected with an elevator system;

and the alternating current voltage sensor and the alternating current sensor are respectively connected with the input module.

3. The elevator brake real-time condition monitoring/warning system of claim 2, wherein the sensor component comprises: a displacement sensor, a temperature sensor, a direct current voltage sensor, a direct current sensor and a noise sensor;

the displacement sensor, the temperature sensor, the direct current voltage sensor, the direct current sensor and the noise sensor are respectively connected with the elevator brake;

and the displacement sensor, the temperature sensor, the direct-current voltage sensor, the direct-current sensor and the noise sensor are respectively connected with the input module.

4. The elevator brake real-time status monitoring/warning system of claim 1, wherein the sensor subsystem further comprises: a rotary encoder;

the rotary encoder is connected with an elevator system;

the rotary encoder is connected with the input module.

5. The elevator brake real-time status monitoring/warning system of claim 1, wherein the sensor subsystem further comprises: a microswitch;

the microswitch is connected with an elevator brake;

the micro switch is connected with the input module.

6. The elevator brake real-time condition monitoring/warning system of claim 3, further comprising: a direct current transmitter, a perforated alternating current transmitter;

the alternating current voltage sensor, the alternating current sensor, the direct current voltage sensor and the direct current sensor are connected in parallel to monitor the coil voltage of the brake on the coil positive electrode and the coil negative electrode of the brake;

the direct current transducer is connected in series on a circuit of the brake to monitor current;

and the perforated alternating current transmitter monitors the output current of the traction machine.

7. The elevator brake real-time condition monitoring/warning system of claim 3, wherein the temperature sensor employs a J-type wire thermocouple.

8. The elevator brake real-time condition monitoring/warning system of claim 3, wherein the displacement sensor is a laser displacement sensor.

9. The elevator brake real-time condition monitoring/warning system of claim 3, wherein the rotary encoder employs a Heidenhain absolute encoder.

10. The elevator brake real-time status monitoring/warning system of claim 1, wherein the logic subsystem comprises: MCU component, power module, power monitoring module, watchdog module and storage module.

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