CN112326263A - Wet brake life estimation system and method - Google Patents
Wet brake life estimation system and method Download PDFInfo
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- CN112326263A CN112326263A CN202011169448.8A CN202011169448A CN112326263A CN 112326263 A CN112326263 A CN 112326263A CN 202011169448 A CN202011169448 A CN 202011169448A CN 112326263 A CN112326263 A CN 112326263A
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- 238000000034 method Methods 0.000 title claims abstract description 20
- 238000006073 displacement reaction Methods 0.000 claims abstract description 28
- 238000012360 testing method Methods 0.000 claims abstract description 26
- 239000002184 metal Substances 0.000 claims abstract description 17
- 238000012545 processing Methods 0.000 claims abstract description 14
- 230000008878 coupling Effects 0.000 claims description 6
- 238000010168 coupling process Methods 0.000 claims description 6
- 238000005859 coupling reaction Methods 0.000 claims description 6
- 230000017525 heat dissipation Effects 0.000 claims description 6
- 238000004364 calculation method Methods 0.000 claims description 5
- 238000007789 sealing Methods 0.000 claims description 5
- 238000005299 abrasion Methods 0.000 abstract description 9
- 230000008569 process Effects 0.000 abstract description 7
- 230000008859 change Effects 0.000 abstract description 4
- 238000010998 test method Methods 0.000 description 9
- 238000010586 diagram Methods 0.000 description 4
- 238000001514 detection method Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 238000005259 measurement Methods 0.000 description 2
- 238000001228 spectrum Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000002783 friction material Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012806 monitoring device Methods 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 238000011056 performance test Methods 0.000 description 1
- 239000012945 sealing adhesive Substances 0.000 description 1
- 238000010561 standard procedure Methods 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M17/00—Testing of vehicles
- G01M17/007—Wheeled or endless-tracked vehicles
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
Abstract
The invention discloses a system and a method for estimating the service life of a wet brake, which comprises a tested brake, a power unit, a pressure unit, an acquisition unit, a control unit and a signal processing unit, wherein the power unit is used for supplying power to the tested brake; the tested brake comprises a shell, and a friction plate assembly and a piston which are arranged in the shell; the end face of the friction plate assembly is provided with a metal sheet, the piston compresses the friction plate assembly when braking is carried out, the piston is in contact with the metal sheet, and a gap is reserved between the piston and the friction plate assembly when the braking is not carried out; the power unit is connected with an input shaft in the tested brake; the pressure unit is connected with the piston; the acquisition unit comprises a displacement sensor and an acquisition card; the displacement sensor is arranged in the piston; the signal processing unit is respectively connected with the control unit and the acquisition unit; the control unit is respectively connected with the power unit and the pressure unit. The invention can visually monitor the change condition of the thickness of the friction plate in the test process, and can obtain the accurate abrasion loss of the friction plate without disassembling the device.
Description
Technical Field
The invention belongs to the technical field of friction plate wear testing, and particularly relates to a service life estimating system and method for a wet brake.
Background
The friction plate of the brake is a key actuating element for braking of the brake, the performance and reliability of the friction plate are directly related to the performance and reliability of the brake, and the service life of the friction plate also determines the service life of the wet brake. The wet brake friction plate is affected by a plurality of factors such as temperature, pressure, oil and the like in the action process, the abrasion process of the friction plate changes in a nonlinear mode, the friction plate is a quick-wear part and a safety part, and the change trend of the performance of the friction plate is important to accurately grasp. The domestic wet friction plate performance test methods such as GB/T15141, GB/T13826 and JB/T7268 are suitable for testing clutch friction plates and are not matched with the use working conditions of the friction plates of the complete machine brake. How to match the test device and the test method and accurately estimate the service life and the service state of the wet brake friction plate on the whole machine according to the test result is a technical problem.
At present, the performance and reliability of the wet brake friction plate are detected by adopting the existing standard, or the wet brake friction plate is braked for a certain number of times according to the common rotating speed and inertia of the brake, which is proposed by a customer. According to the existing standard method, the performance detection is static and dynamic friction coefficient, maximum energy power and the like of the friction plate, the reliability detection is carried out durability test by specific working conditions (setting parameters are speed and pressure) specified by the standard, whether the reliability of the friction plate can meet the standard requirement is judged by monitoring the change condition of the friction coefficient in the durability test process, and parameters corresponding to the working condition of the whole machine and a test method corresponding to the parameters are absent. The measurement of the abrasion loss of the friction plate needs to disassemble the test device and measure the abrasion loss after cleaning. It can be seen that the existing method has the following disadvantages:
(1) the existing wet brake friction plate test device and system are lack of a friction plate abrasion loss monitoring device and a feedback signal, and cannot form closed-loop detection on the friction plate in real time.
(2) The wear amount of the friction plate needs to be measured by disassembling the test device, and the thickness of the friction plate is measured by using a measuring tool after the friction plate is cleaned, or the wear amount of the friction plate is judged by weighing before and after the test. The friction plate surface is porous, the physical characteristics of the material are influenced by oil, the size of the influence is different due to the material, the friction plate is disassembled from the device, the service environment of the friction plate is damaged, the material of the friction plate is flexible, the measurement error of the abrasion loss of the friction plate by using a measuring tool is large, and the process of disassembling and assembling the test device is time-consuming and labor-consuming.
(3) The existing test method is not suitable for friction plates with the use conditions out of the standard, and the service life of the friction plates in an engineering vehicle cannot be estimated;
(4) the existing test method lacks parameters and related relation related to the actual braking condition of the whole vehicle.
Disclosure of Invention
Aiming at the problems, the invention provides a system and a method for estimating the service life of a wet brake, which can visually monitor the change condition of the thickness of a friction plate in the test process and can obtain the accurate abrasion loss of the friction plate without disassembling the device.
In order to achieve the technical purpose and achieve the technical effects, the invention is realized by the following technical scheme:
in a first aspect, the invention provides a wet brake life estimation system, which comprises a tested brake, a power unit, a pressure unit, an acquisition unit, a control unit and a signal processing unit, wherein the power unit is connected with the pressure unit;
the tested brake comprises a shell, and a friction plate assembly and a piston which are arranged in the shell; the end face of the friction plate assembly is provided with a metal sheet, the piston compresses the friction plate assembly when braking is carried out, the piston is in contact with the metal sheet, and a gap is reserved between the piston and the friction plate assembly when the braking is not carried out;
the power unit is connected with an input shaft in the tested brake to provide power;
the pressure unit is connected with the piston and provides pressure;
the acquisition unit comprises a displacement sensor and an acquisition card which are connected; the displacement sensor is arranged in the piston and used for measuring the displacement of the metal sheet;
the signal processing unit is respectively connected with the control unit and the acquisition unit; the control unit is respectively connected with the power unit and the pressure unit; the signal processing unit sends a parameter setting signal to the control unit; the control unit controls the power unit and the pressure unit to output corresponding power signals and pressure signals based on the received parameter setting signals; and the signal processing unit also estimates the service life of the friction plate of the wet brake based on the received displacement of the metal plate and the parameter setting signal.
Optionally, a through groove is formed in the piston, and the displacement sensor is located in the through groove; and a sealing gasket connected with the displacement sensor is also arranged on the outer end face of the piston.
Optionally, the piston is in threaded connection with the displacement sensor.
Optionally, the power unit comprises: the variable frequency motor, the adjustable inertia disc and the gearbox are arranged on the base; the variable frequency motor is connected with the adjustable inertia disc through an elastic coupling, the adjustable inertia disc is connected with a gearbox through the elastic coupling, and the output end of the gearbox is connected with an input shaft in a tested brake through a torque sensor; the variable frequency motor and the adjustable inertia disc are also respectively connected with the control unit.
Optionally, the pressure unit includes a hydraulic pump and a servo valve, and the servo valve is connected to the piston, receives a parameter setting signal sent by the control unit, and controls the pressure delivered to the tested brake.
Optionally, the wet brake life estimation system further comprises a heat dissipation unit connected with the control unit; the acquisition unit further comprises a temperature sensor, the temperature sensor is connected with the tested brake, the output end of the temperature sensor is connected with the control unit, when the temperature sensor monitors that the temperature of the tested brake is higher than a set threshold value, the control unit starts the heat dissipation unit to cool the tested brake.
Optionally, the parameter setting signal includes a rotation speed, an inertia, a test period, a brake pressure and a test frequency;
the calculation formula of the rotating speed is as follows:
in the formula, m represents the mass of the whole vehicle; v represents a vehicle speed; j denotes the brake input moment of inertia: omega represents the input angular speed of the brake, E is the energy absorbed by the friction plate of the brake when the vehicle brakes;
the inertia is calculated by the following formula:
in the formula: a represents the total area of the friction plate; e is the energy absorbed by the friction plate of the brake when the vehicle brakes; rhoEIs energy density, i.e. the energy absorbed by the friction plate unit;
the calculation formula of the life estimation of the friction plate is as follows:
H1＝∑f(ρm)nm
in the formula, H1 is the thickness of the friction plate in the test period S; h0 is the thickness of the unused friction plate, nmAt an energy density pEThe number of times of braking, L, is the life of the wet brake.
In a second aspect, the invention provides a method based on the wet brake life estimation system of any one of the first aspect, comprising the following steps:
counting the energy density and the braking frequency of the whole vehicle in a period S, and according to H1 ═ Σ f (rho)m)nmObtaining the total wear rate H1 of the friction plate of the brake in the time S;
and calculating the service life L of the wet brake based on the formula H0/H1S, and completing prediction of the full service life of the wet brake.
Compared with the prior art, the invention has the beneficial effects that:
the method can obtain a relation between energy density and abrasion thickness, and not only can estimate the service life of the friction plate by calculating the abrasion thickness and the braking times under different energy densities, but also can investigate whether the friction plate can bear the highest energy density and the braking performance stability of the friction plate under the energy density from low to high. Provides basis for calculating accurate replacement period of friction plate and provides test method for type selection of friction plate
Drawings
In order that the present disclosure may be more readily and clearly understood, reference is now made to the following detailed description of the present disclosure taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic diagram of a wet brake life estimation system according to an embodiment of the present invention;
fig. 2 is an installation diagram of a wet brake to be tested and a displacement sensor according to an embodiment of the invention;
FIG. 3 is a schematic structural diagram illustrating a method for estimating the lifetime of a wet brake according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a plurality of displacement sensors according to one embodiment of the present invention;
wherein:
the device comprises a shell 1, a friction plate assembly 2, a piston 3, a metal sheet 4, a displacement sensor 5 and a sealing gasket 6.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and do not limit the scope of the invention.
The following detailed description of the principles of the invention is provided in connection with the accompanying drawings.
Example 1
The embodiment of the invention provides a wet brake service life prediction system, which comprises a tested brake, a power unit, a pressure unit, an acquisition unit, a control unit and a signal processing unit, wherein the power unit is used for providing power for the tested brake;
the tested brake comprises a shell 1, and a friction plate assembly 2 and a piston 3 which are arranged in the shell 1; the end face of the friction plate assembly 2 is provided with a metal sheet 4, the piston 3 compresses the friction plate set when braking, the piston 3 is in contact with the metal sheet 4, and a gap is reserved between the piston 3 and the friction plate set when not braking; in the actual use process, the metal sheet 4 can be a steel sheet;
the power unit is connected with an input shaft in the tested brake to provide power;
the pressure unit is connected with the piston 3 to provide pressure;
the acquisition unit comprises a displacement sensor 5 and an acquisition card which are connected; the displacement sensor 5 is arranged in the piston 3 and used for measuring the displacement of the metal sheet 4;
the signal processing unit is respectively connected with the control unit and the acquisition unit; the control unit is respectively connected with the power unit and the pressure unit; the signal processing unit sends a parameter setting signal to the control unit; the control unit controls the power unit and the pressure unit to output corresponding power signals and pressure signals based on the received parameter setting signals; the signal processing unit also estimates the service life of the friction plate of the wet brake based on the received displacement of the metal plate 4 and the parameter setting signal.
In a specific implementation manner of the embodiment of the present invention, a through groove is formed in the piston 3, the displacement sensor 5 is located in the through groove, so that the displacement sensor 5 can directly measure the position of the metal sheet 4 conveniently, and preferably, the piston 3 and the displacement sensor 5 are in threaded connection; and a sealing gasket 6 connected with the displacement sensor 5 is also arranged on the outer end face of the piston 3 or coated with a sealing adhesive to ensure the sealing of the wet brake to be tested. In order to detect the wear of the friction plates at different positions, a plurality of displacement sensors 5 may be arranged, and as shown in fig. 4, a plurality of sensors may be evenly distributed in the circumferential direction.
In a particular implementation of the embodiment of the invention, the power unit comprises: the variable frequency motor, the adjustable inertia disc and the gearbox are arranged on the base; the variable frequency motor is connected with the adjustable inertia disc through an elastic coupling, the adjustable inertia disc is connected with a gearbox through the elastic coupling, and the output end of the gearbox is connected with an input shaft in a tested brake through a torque sensor; the variable frequency motor and the adjustable inertia disc are also respectively connected with the control unit.
In a specific implementation manner of the embodiment of the present invention, the pressure unit includes a hydraulic pump and a servo valve, and the servo valve is connected to the piston 3, receives a parameter setting signal sent by the control unit, and controls the pressure delivered to the tested brake.
In a specific implementation manner of the embodiment of the present invention, the system for estimating the lifetime of the wet brake further includes a heat dissipation unit connected to the control unit; the acquisition unit further comprises a temperature sensor, the temperature sensor is connected with the tested brake, the output end of the temperature sensor is connected with the control unit, when the temperature sensor monitors that the temperature of the tested brake is higher than a set threshold value, the control unit starts the heat dissipation unit to cool the tested brake.
In a specific implementation manner of the embodiment of the invention, the invention discloses a life estimation test and calculation method of a friction plate, which comprises the following steps: the energy absorbed by the brake lining during braking of the vehicle is calculated according to equation (1).
In the formula, m represents the mass of the whole vehicle, and the unit is kg; v represents the driving speed, and the unit is m/s; j denotes the brake input moment of inertia, unit: ω represents the brake input angular velocity in units: rad/s.
Where A represents the total friction pad area in units: cm2(ii) a E is the energy absorbed by the friction plate of the brake when the vehicle brakes, and the unit is as follows: kJ; rhoEIs the energy density, i.e. the energy absorbed by the friction plate in kJ/cm2。
According to the formula (1) and the formula (2), the energy density (mass and driving speed) of the vehicle is converted to obtain equivalent test bed input parameters (rotating speed and inertia).
Calculating the best of the vehicleThe energy density of the large gear is rhomaxDividing the maximum energy density into a plurality of grades rho according to the maximum energy density and combining the vehicle gearmM is determined according to the experimental requirements. The test method of the invention determines the times according to the energy density.
When rhom＝ρmax/2, is the medium energy density ρi1Medium energy density class brake 2000
When rhom<ρmaxPer 2, low energy density ρi2Low energy density grade brake 5000
When rhom>ρmaxPer 2, high energy density ρi3Low energy density graded braking 800
The test method comprises the following steps:
the test method is used for testing to obtain a test curve with the abscissa as the energy density and the ordinate as the single braking wear thickness, and H is fitted into a mathematical relation of f (rho).
According to the load spectrum of the engineering vehicle, the types and the proportion of the brake energy densities of the friction plates in the time period of the load spectrum test period S are counted, and the thickness H1 of the friction plates in the period S is calculated according to the mathematical relation H-f (E). The thickness of the friction material of the unused friction plate is H0, and the life prediction formula of the friction plate is shown in the formula (4).
H1＝∑f(ρm)nm (3)
Wherein n ismAt an energy density pmNumber of brakes down.
H1 is the wear thickness of the friction plate in the test period S of the whole vehicle;
h0 is the thickness of the friction plate when not worn;
s is the test period of the whole vehicle, generally about one month
The prediction method comprises the following steps:
(1) the life estimation system was tested to obtain the energy density-wear thickness relationship, i.e., H1 ═ Σ f (ρ)m)nm。
(2) Counting the type and frequency of energy density of the whole vehicle in a period of time S (generally one month), and obtaining the total wear rate H1 of the brake friction plate in the time S according to the relation of the energy density and the wear thickness;
(3) in the time period S, the service life L of the wet brake is H0/H1S when the friction plate is abraded by H1
And according to the short-time test, the prediction of the whole service life of the wet brake is realized.
Example 2
An embodiment of the present invention provides a method for estimating a lifetime of a wet brake based on the system in embodiment 1, including:
counting the energy density and the braking frequency of the whole vehicle in a period S, and according to H1 ═ Σ f (rho)m)nmObtaining the total wear rate H1 of the friction plate of the brake in the time S;
and calculating the service life L of the wet brake based on the formula H0/H1S, and completing prediction of the full service life of the wet brake.
The foregoing shows and describes the general principles and broad features of the present invention and advantages thereof. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (10)
1. A wet brake life estimation system, comprising: the device comprises a tested brake, a power unit, a pressure unit, an acquisition unit, a control unit and a signal processing unit;
the tested brake comprises a shell, and a friction plate assembly and a piston which are arranged in the shell; the end face of the friction plate assembly is provided with a metal sheet, the piston compresses the friction plate assembly when braking is carried out, the piston is in contact with the metal sheet, and a gap is reserved between the piston and the friction plate assembly when the braking is not carried out;
the power unit is connected with an input shaft in the tested brake to provide power;
the pressure unit is connected with the piston and provides pressure;
the acquisition unit comprises a displacement sensor and an acquisition card which are connected; the displacement sensor is arranged in the piston and used for measuring the displacement of the metal sheet;
the signal processing unit is respectively connected with the control unit and the acquisition unit; the control unit is respectively connected with the power unit and the pressure unit; the signal processing unit sends a parameter setting signal to the control unit; the control unit controls the power unit and the pressure unit to output corresponding power signals and pressure signals based on the received parameter setting signals; and the signal processing unit also estimates the service life of the friction plate of the wet brake based on the received displacement of the metal plate and the parameter setting signal.
2. A wet brake life estimation system as claimed in claim 1, wherein: a through groove is formed in the piston, and the displacement sensor is located in the through groove.
3. A wet brake life estimation system as claimed in claim 2, wherein: and a sealing gasket connected with the displacement sensor is also arranged on the outer end face of the piston.
4. A wet brake life estimation system as claimed in claim 1, wherein: the piston is in threaded connection with the displacement sensor.
5. A wet brake life estimation system as claimed in claim 1, wherein said power unit comprises: the variable frequency motor, the adjustable inertia disc and the gearbox are arranged on the base; the variable frequency motor is connected with the adjustable inertia disc through an elastic coupling, the adjustable inertia disc is connected with the gearbox through the elastic coupling, and the output end of the gearbox is connected with an input shaft in the tested brake through a torque sensor.
6. The system of claim 5, wherein the variable frequency motor and the adjustable inertia disc are further connected to the control unit, respectively.
7. A wet brake life estimation system as claimed in claim 1, wherein: the pressure unit comprises a hydraulic pump and a servo valve, the servo valve is connected with the piston, receives a parameter setting signal sent by the control unit and controls the pressure transmitted to the tested brake.
8. A wet brake life estimation system as claimed in claim 1, wherein: the wet brake service life prediction system also comprises a heat dissipation unit which is connected with the control unit; the acquisition unit further comprises a temperature sensor, the temperature sensor is connected with the tested brake, the output end of the temperature sensor is connected with the control unit, when the temperature sensor monitors that the temperature of the tested brake is higher than a set threshold value, the control unit starts the heat dissipation unit to cool the tested brake.
9. A wet brake life estimation system as claimed in claim 1, wherein: the parameter setting signal comprises a rotating speed, inertia, a test period, brake pressure and test times;
the calculation formula of the rotating speed is as follows:
in the formula, m represents the mass of the whole vehicle; v represents a vehicle speed; j denotes the brake input moment of inertia: omega represents the input angular speed of the brake, E is the energy absorbed by the friction plate of the brake when the vehicle brakes;
the inertia is calculated by the following formula:
in the formula: a represents the total area of the friction plate; e is the energy absorbed by the friction plate of the brake when the vehicle brakes; rhoEIs energy density, i.e. the energy absorbed by the friction plate unit;
the calculation formula of the life estimation of the friction plate is as follows:
H1＝∑f(ρm)nm
in the formula, H1 is the thickness of the friction plate in the test period S; h0 is the thickness of the unused friction plate, nmAt an energy density pEThe number of times of braking, L, is the life of the wet brake.
10. A method based on a wet brake life estimation system according to any one of claims 1-9, characterized by the steps of:
counting the energy density and the braking frequency of the whole vehicle in a period S, and according to H1 ═ Σ f (rho)m)nmObtaining the total wear rate H1 of the friction plate of the brake in the time S;
and calculating the service life L of the wet brake based on the formula H0/H1S, and completing prediction of the full service life of the wet brake.
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