CN114235431B - Wet brake testing method and test bed for long-distance heavy-gradient working condition - Google Patents
Wet brake testing method and test bed for long-distance heavy-gradient working condition Download PDFInfo
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- CN114235431B CN114235431B CN202111326647.XA CN202111326647A CN114235431B CN 114235431 B CN114235431 B CN 114235431B CN 202111326647 A CN202111326647 A CN 202111326647A CN 114235431 B CN114235431 B CN 114235431B
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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
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
- G01L5/28—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes for testing brakes
- G01L5/288—Measuring the force necessary to rotate a braked wheel
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/72—Electric energy management in electromobility
Abstract
The invention belongs to the field of brake testing, and particularly relates to a method and a test bed for testing the safety performance of a wet brake under a long-distance heavy-gradient working condition, wherein the method comprises a tested piece fixing platform, a driving motor, a diaphragm coupler, a speed reducer, a first transition disc and a universal transmission shaft; the output shaft of the driving motor is connected with the input shaft of the speed reducer through the diaphragm coupler, the output shaft of the speed reducer is connected with the first transition disc through the torque sensor, the first transition disc is connected with the tested brake through the universal transmission shaft, and the base of the tested brake is fixedly arranged on the tested piece fixing platform. The invention can simulate the long-distance large-gradient working condition of the underground coal mine and test the decay performance of the brake under the action of a small braking moment for a long time.
Description
Technical Field
The invention belongs to the field of brake testing, and particularly relates to a wet brake safety performance testing method and a test bed under a long-distance heavy-gradient working condition.
Background
Compared with a dry brake, the wet brake has the advantages of strong heat radiation capability, good tightness, stable braking capability, high safety coefficient and the like. At present, because the number of vehicles adopting wet brakes in the market is small, wet brake manufacturers are not yet scaled, so that no perfect inspection equipment exists before delivery, and the improvement period of the brakes is long. Most of the existing brake test stands are used for testing the dry braking performance of road vehicles, and related technical requirements are not applicable to wet brakes. The invention patent disclosed by Jilin university 'an inertia test stand for wet brakes of mine cars' mainly simulates various braking working conditions of the vehicle through flywheel inertia and electric inertia, and does not describe the aspect of checking the reliability performance of the brakes aiming at underground long-distance large-gradient working conditions, so that the safety performance of the wet brakes under extremely severe working conditions cannot be reflected.
Because the underground working condition is bad, the safety performance detection of the wet brake has important significance for underground safety production, and therefore, the wet brake testing method and the test bed are required to be invented, and the safety performance test of the wet brake under the underground long-distance heavy-gradient working condition is realized.
Disclosure of Invention
The invention overcomes the defects existing in the prior art, and solves the technical problems that: the wet brake testing method and the test bed for the long-distance heavy-gradient working condition are provided, so that the safety performance test of the wet brake is realized, and the safety accidents caused by braking faults are reduced.
In order to solve the technical problems, the invention adopts the following technical scheme: a wet brake test bed for long-distance heavy-gradient working conditions comprises a tested piece fixing platform, a driving motor, a diaphragm coupler, a speed reducer, a first transition disc and a universal transmission shaft; the output shaft of the driving motor is connected with the input shaft of the speed reducer through the diaphragm coupler, the output shaft of the speed reducer is connected with the first transition disc through the torque sensor, the first transition disc is connected with the tested brake through the universal transmission shaft, the base of the tested brake is fixedly arranged on the tested piece fixing platform, and the torque sensor is arranged between the first transition disc and the universal transmission shaft.
The wet brake test stand for the long-distance heavy-gradient working condition further comprises a motor fixing platform, and the base of the driving motor is fixedly arranged on the motor fixing platform.
The wet brake test bed for the long-distance heavy-gradient working condition further comprises an electric control system, wherein the input end of the electric control system is connected with the torque sensor, the output end of the electric control system is connected with the electro-hydraulic proportional servo valve of the tested brake, and the electric control system is used for adjusting the outlet pressure value of the electro-hydraulic proportional servo valve of the tested brake according to the rotating speed and the real-time torque value of the driving motor so as to maintain the constant braking torque of the brake in the test process.
The tested brake is a drive axle integrated brake or a wheel-side independent brake;
when the tested brake is a drive axle integrated brake, the brake is fixedly connected with the drive axle fixing base through a drive axle transition seat;
when the tested brake is a wheel-side independent brake, the brake is connected with a brake fixing frame through a transition flange plate;
the driving axle fixing base and the brake fixing frame are fixedly connected with the tested piece fixing platform.
The wet brake test bed for the long-distance heavy-gradient working condition is characterized by further comprising a second transition disc, wherein one end of the second transition disc is connected with the universal transmission shaft, and the other end of the second transition disc is of an imitation hub structure and is connected with a movable shell of a tested brake.
The driving motor is a direct current motor, and the maximum power of the driving motor meets the following conditions:wherein v represents the vehicle speed, m represents the mass of the full-load whole vehicle, g represents the gravitational acceleration, N represents the number of brake wheels, and a represents the gradient;
the reduction ratio of the reduction gear satisfies:wherein M is the theoretical braking torque of the tested brake, T n Is the maximum overload torque of the drive motor.
In addition, the invention also provides a wet brake test method for long-distance heavy-gradient working conditions, which is realized by adopting the test bed and comprises a maximum static braking moment test, a hauling test and a decay rate test;
the maximum static braking torque test comprises the following steps:
s101, controlling the tested brake to rotate under the complete braking state, controlling the driving motor to forcibly drag the tested brake to rotate through the speed reducing device (4), simultaneously recording the rotating speed of the driving motor and the reading of the torque sensor, and recording the numerical value recorded by the torque sensor at the starting time of the driving motor, namely the maximum static braking moment of the tested brake;
the haulage test comprises the following steps:
s201, calculating theoretical braking moment required to be maintained when deceleration corresponding to the gradient is generated;
s202, controlling a driving motor to forcibly drag the tested brake to rotate through a speed reducing device, periodically repeating a drag test at intervals of fixed time, and adjusting the outlet pressure of an electric proportional pressure reducing valve in the drag time period to enable the actual braking moment of the tested brake to be consistent with the theoretical braking moment, and enabling the tested brake to be in a complete release state in the interval time period;
the decay rate test comprises the following steps:
and S301, after the drag test is finished, testing the maximum static braking moment of the tested brake at the moment, comparing the maximum static braking moment with the original maximum static braking moment, and calculating the decay rate.
In step S202, when the driving motor is controlled to forcibly drag the tested brake to rotate through the speed reducing device, the tested brake is rotated at a constant speed with the actual maximum rotation speed.
In the step S201, a calculation formula of the theoretical braking torque is:
；
wherein M represents a theoretical braking torque, F represents a braking force,the method comprises the steps of carrying out a first treatment on the surface of the r0 represents the tire rolling radius, m represents the full vehicle mass, g represents the gravitational acceleration, N represents the number of braked wheels, and a represents the gradient.
The gradient is 8 °.
Compared with the prior art, the invention has the following beneficial effects:
1. the invention provides a wet brake testing method and a test bed for long-distance heavy-gradient working conditions, which can simulate the long-distance heavy-gradient working conditions under a coal mine well and test the degradation performance of a brake under the action of a small braking torque for a long time;
2. the invention realizes double closed-loop control of the motor rotating speed and the braking torque, and can ensure reliable test data;
3. the invention can test the safety performance of the wet brake under the severe working condition of the polar end, can confirm the reliability of the brake before installation, and is beneficial to reducing the safety accidents caused by braking faults; meanwhile, the development period of the wet brake is obviously shortened, the failure rate of the brake in the whole vehicle running-in process and the user use process is reduced, and the quality assurance cost is reduced. The method has good guiding function for improving the safety performance of the wet brake, guaranteeing the safety of underground operation and improving the reliability of the whole vehicle brake.
Drawings
FIG. 1 is a schematic top view of a wet brake test stand for long distance heavy grade conditions according to an embodiment of the present invention;
FIG. 2 is a schematic diagram showing the fixing of a tested actuator to a test piece fixing platform according to a first embodiment of the present invention;
FIG. 3 is a schematic diagram illustrating the fixing of a test actuator to a test piece fixing platform according to a second embodiment of the present invention.
In the figure: 1. a driving motor; 2. a motor fixing platform; 3. a diaphragm coupling; 4. a speed reducing device; 5. a torque sensor; 6. a first transition disc; 7. a universal drive shaft; 8. a second transition disc; 9. a drive axle integrated brake; 10. a drive axle fixed base; 11. a drive axle transition seat; 12. a test piece fixing platform; 13. wheel-side independent brake; 14. a transition flange; 15. a brake mount; 16. a hydraulic pump station; 17. an electric control system.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments; all other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Example 1
As shown in fig. 1, the first embodiment of the invention provides a wet brake test stand for long-distance heavy-gradient working conditions, which comprises a tested piece fixing platform 12, a driving motor 1, a diaphragm coupler 3, a speed reducer 4, a first transition disc 6 and a universal transmission shaft 7; the output shaft of driving motor 1 passes through the input shaft that diaphragm shaft coupling 3 connects decelerator 4, the output shaft of decelerator 4 passes through torque sensor 5 and connects first transition dish 6, and first transition dish 6 passes through universal drive shaft 7 and connects the brake that is tested, the base of brake that is tested is fixed to be set up on the test piece fixed platform 12, be provided with torque sensor 5 between first transition dish 6 and the universal drive shaft 7.
Specifically, the test stand of the embodiment further comprises a motor fixing platform 2, and the base of the driving motor 1 is fixedly arranged on the motor fixing platform 2.
Further, the wet brake test stand for long-distance heavy-gradient working conditions further comprises an electric control system 17, wherein the input end of the electric control system is connected with the torque sensor 5, the output end of the electric control system is connected with the electro-hydraulic proportional servo valve of the tested brake, and the electric control system is used for adjusting the outlet pressure value of the electro-hydraulic proportional servo valve of the tested brake according to the rotating speed and the real-time torque value of the driving motor 1 so as to maintain the constant braking torque of the brake in the test process.
Specifically, as shown in fig. 2, in the present embodiment, when the brake to be tested is a brake with an integral drive axle, the brake is fixedly connected to the drive axle fixing base 10 through the drive axle transition seat 11.
Specifically, as shown in fig. 1, the embodiment further includes a second transition disc 8, one end of the second transition disc 8 is connected with the universal transmission shaft 7, and the other end is in a hub-like structure and is connected with the movable shell of the tested brake.
Because the running speed of the mining rubber-tyred vehicle is generally lower, and meanwhile, the torque of the wet brake is large, the current maximum torque can reach 140000 nm, so that the driving motor 1 selects a direct current motor with low rotation speed and large torque, and the driving motor 1 is fixed on the motor fixing platform 2 through bolts. The maximum power of the drive motor 1 should be such that:i.e. the motor power should be able to cover the maximum drag test requirement of the wet brake, where v denotes the vehicle speed, the maximum operating speed of the different vehicles is different, the maximum rotational speed of the corresponding brake is not.
Because the braking torque of the tested wet brake is large, in order to meet the testing requirement of the maximum braking torque, a speed reduction device 4 is added between the driving motor 1 and the tested piece, and the speed ratio of the speed reduction device should meet:wherein M is the theoretical braking torque of the wet brake, T n Is the maximum overload torque of the motor. The speed reducing device 4 is fixed on a tested piece fixing platform, and the input end of the speed reducing device is connected with the driving motor 1 through a diaphragm coupler 3; the maximum test torque of the torque sensor 5 should be slightly greater than that of the wet brake under testOne end of the maximum braking torque is connected with the output end of the speed reducer 4 through a flange, and the other end of the maximum braking torque is connected with the first transition disc 6 through a flange. The first transition disc 6 is connected with the tested brake through the universal transmission shaft 7, and the universal transmission shaft 7 can reduce the coaxiality requirement of the tested piece and the whole transmission chain, so that the operation is convenient. A second transition disc 8 is added between the tested drive axle integrated brake 9 and the universal transmission shaft 7, one end of the second transition disc 8 is connected with the universal transmission shaft 7, the other end is connected with the movable shell of the tested drive axle integrated brake 9 in a hub-like structure, and the tested drive axle integrated brakes 9 in different types are connected with the universal transmission shaft 7 through different second transition discs 8.
In this embodiment, the tested driving axle integrated brake 9 is connected and fixed with the tested piece fixing platform 12 through the driving axle fixing base 10 and the driving axle transition seat 11, wherein when the tested driving axle integrated brakes of different types are fixed, the connection between the driving axle fixing base 10 and the tested piece fixing platform 12 can be realized only by replacing the driving axle transition seat 11.
The test bed of the embodiment can simulate the long-distance heavy-gradient working condition of the underground coal mine, and the wet brake has the braking performance declining condition after long-time use under the condition of smaller braking moment. According to the relevant regulations of the coal safety regulations (2016), the gradient of a coal mine underground roadway is basically no more than 6 degrees, but the currently known maximum gradient is 7.5 degrees and the length is 2 kilometers, so that the maximum gradient which can be simulated by the test bed is considered to be 8 degrees and the length is considered to be 2 kilometers.
Example two
The second embodiment of the present invention provides a wet brake test stand for long-distance heavy-gradient working conditions, which has the same structure as the first embodiment, but the difference is that in the present embodiment, the structure of the tested piece is a wheel-side independent brake 13. As shown in fig. 3, the wheel-side independent brake 13 is connected and fixed with the tested piece fixing platform 12 through the transition flange 14 and the brake fixing frame 15, and likewise, the wheel-side independent brake 13 with different types can be connected by replacing the transition flange 14 when the wheel-side independent brake 13 with the same structural form needs to be tested, so that the number and weight of tools are effectively reduced.
Example III
The third embodiment of the invention provides a wet brake test method for long-distance heavy-gradient working conditions, which is realized by adopting the test bed in the first embodiment and comprises a maximum static braking torque test, a drag test and a decay rate test;
the maximum static braking torque test comprises the following steps:
s101, controlling the tested brake to rotate under the complete braking state, controlling the driving motor 1 to forcibly drag the tested brake to rotate through the speed reducing device 4, simultaneously recording the rotating speed of the driving motor 1 and the reading of the torque sensor 5, and recording the numerical value recorded by the torque sensor 5 at the starting time of the driving motor 1, namely the maximum static braking moment of the tested brake;
the haulage test comprises the following steps:
s201, calculating theoretical braking moment required to be maintained when the required deceleration is generated.
In the step S201, a calculation formula of the theoretical braking torque is:
；
wherein M represents a theoretical braking torque, F represents a braking force,the method comprises the steps of carrying out a first treatment on the surface of the r0 represents the tire rolling radius, m represents the full vehicle mass, g represents the gravitational acceleration, N represents the number of braked wheels, and a represents the gradient. In this example, the slope is 8 °, and the corresponding required deceleration is 0.14g.
S202, controlling the driving motor 1 to forcibly drag the tested brake to rotate through the speed reducing device 4, periodically repeating a drag test at fixed intervals, and adjusting the outlet pressure of the electric proportional pressure reducing valve in the drag time period to enable the actual braking moment of the tested brake to be consistent with the theoretical braking moment, and enabling the tested brake to be in a complete release state in the interval time period. Wherein, when the driving motor 1 is controlled to forcibly drag the tested brake to rotate through the speed reducing device 4, the tested brake is enabled to rotate at a constant speed with the actual maximum rotation speed. Specifically, the drag time was 40s, the interval time was 60s, and the total test time test period was determined by the test distance and the test speed. In the process of hauling, the outlet pressure of the electric proportional pressure reducing valve is regulated to ensure that the value of the torque sensor is consistent with the theoretical braking torque M.
The decay rate test comprises the following steps:
and S301, after the drag test is finished, testing the maximum static braking moment of the tested brake at the moment, comparing the maximum static braking moment with the original maximum static braking moment, and calculating the decay rate. In order to ensure reliable braking of the whole vehicle, the decay rate should be less than 15%.
In this embodiment, the hydraulic pump station uses a gear pump as a power source, so as to provide braking/releasing pressure of the tested wet brake (the braking mode of the wet brake can be divided into two modes of spring braking hydraulic release and hydraulic braking spring release), and meanwhile, the pressure adjustment is performed by adopting an electrohydraulic proportional servo valve with high frequency response, the pressure adjustment range of the electrohydraulic proportional servo valve covers the braking/releasing pressure requirements of all brakes, the remote adjustable overflow valve performs pressure adjustment according to the pressure value of the current tested brake, and when the outlet pressure value of the electrohydraulic proportional servo valve reaches the requirement, the gear pump is controlled to unload. The electro-hydraulic proportional servo valve is used for adjusting the braking pressure, when the braking pressure reaches a target value, the electro-hydraulic proportional servo valve is closed, the outlet of the gear keeps high pressure until the opening pressure value of the overflow valve is reached, and therefore the system can generate heat. And a remote adjustable overflow valve is added, and when the braking pressure reaches a target value, the electronic control system can control the valve to unload at a smaller opening pressure. When the brake pressure needs to be adjusted again, the electronic control system can control the pressure value of the valve to be larger than the current brake pressure.
In the test process, the electric control system 17 collects the rotating speed value of the rotating speed 1 of the driving motor in real time, realizes rotating speed closed loop, and ensures that the brake moves at uniform rotating speed in the test process; meanwhile, the electric control system 17 also collects the value of the torque sensor, and adjusts the outlet pressure value of the electro-hydraulic proportional servo valve in real time, so that the braking torque of the brake is ensured to be constant in the test process.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention.
Claims (8)
1. The wet brake test bed for the long-distance heavy-gradient working condition is characterized by comprising a tested piece fixing platform (12), a driving motor (1), a diaphragm coupler (3), a speed reducer (4), a first transition disc (6) and a universal transmission shaft (7); an output shaft of the driving motor (1) is connected with an input shaft of a speed reducer (4) through a diaphragm coupler (3), the output shaft of the speed reducer (4) is connected with a first transition disc (6) through a torque sensor (5), the first transition disc (6) is connected with a tested brake through a universal transmission shaft (7), a base of the tested brake is fixedly arranged on a tested piece fixing platform (12), and the torque sensor (5) is arranged between the first transition disc (6) and the universal transmission shaft (7);
the driving motor (1) is a direct current motor, and the maximum power of the driving motor meets the following conditions:wherein V represents the vehicle speed, m represents the mass of the full-load whole vehicle, g represents the gravitational acceleration, and N represents the number of brake wheels;
the reduction ratio of the reduction gear (4) is as follows:wherein M is the theoretical braking torque of the tested brake, T n Is the maximum overload torque of the drive motor (1);
the calculation formula of the theoretical braking moment is as follows:
；
wherein M represents a theoretical braking torque, F represents a braking force,；/>the tire rolling radius is represented by m, the full-load whole vehicle mass is represented by g, the gravity acceleration is represented by g, the number of braked wheels is represented by N, and the gradient is represented by a.
2. The wet brake test stand for long-distance heavy-gradient working conditions according to claim 1, further comprising a motor fixing platform (2), wherein the base of the driving motor (1) is fixedly arranged on the motor fixing platform (2).
3. The wet brake test stand for long-distance heavy-gradient working conditions according to claim 1, further comprising an electric control system (17), wherein the input end of the electric control system is connected with the torque sensor (5), and the output end of the electric control system is connected with an electrohydraulic proportional servo valve of the tested brake, and is used for adjusting the outlet pressure value of the electrohydraulic proportional servo valve of the tested brake according to the rotating speed and the real-time torque value of the driving motor (1) so as to maintain the brake torque of the brake to be constant in the test process.
4. The wet brake test stand for long-distance heavy-duty conditions of claim 1, wherein said brake under test is a transaxle-integrated brake or a wheel-side independent brake;
when the tested brake is a drive axle integrated brake, the brake is fixedly connected with a drive axle fixing base (10) through a drive axle transition seat (11);
when the tested brake is an independent brake on the wheel side, the tested brake is connected with a brake fixing frame (15) through a transition flange (14);
the drive axle fixing base (10) and the brake fixing frame (15) are fixedly connected with the tested piece fixing platform (12).
5. The wet brake test stand for long-distance heavy-gradient working conditions according to claim 1, further comprising a second transition disc (8), wherein one end of the second transition disc (8) is connected with the universal transmission shaft (7), and the other end of the second transition disc is of a hub-like structure and is connected with a movable shell of a tested brake.
6. The wet brake test method for the long-distance heavy-gradient working condition is characterized by comprising a maximum static braking torque test, a hauling test and a decay rate test by adopting the test bed disclosed in claim 1;
the maximum static braking torque test comprises the following steps:
s101, controlling the tested brake to rotate under the complete braking state, controlling the driving motor (1) to forcibly drag the tested brake to rotate through the speed reducing device (4), simultaneously recording the rotating speed of the driving motor (1) and the reading of the torque sensor (5), and recording the numerical value recorded by the torque sensor (5) at the starting moment of the driving motor (1), namely the maximum static braking moment of the tested brake;
the haulage test comprises the following steps:
s201, calculating theoretical braking moment required to be maintained when deceleration corresponding to the gradient is generated;
s202, controlling a driving motor (1) to forcibly drag a tested brake to rotate through a speed reducing device (4), periodically repeating a drag test at fixed intervals, and adjusting the outlet pressure of an electric proportional pressure reducing valve to enable the actual braking moment of the tested brake to be consistent with the theoretical braking moment in the drag time period, wherein the tested brake is in a complete release state in the interval time period;
the decay rate test comprises the following steps:
and S301, after the drag test is finished, testing the maximum static braking moment of the tested brake at the moment, comparing the maximum static braking moment with the original maximum static braking moment, and calculating the decay rate.
7. The method according to claim 6, wherein in step S202, when the driving motor (1) is controlled to forcibly drag the tested brake to rotate through the speed reducing device (4), the tested brake is rotated at a constant speed with its actual maximum rotation speed.
8. The method of claim 7, wherein the grade is 8 °.
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| CN202111326647.XA CN114235431B (en) | 2021-11-10 | 2021-11-10 | Wet brake testing method and test bed for long-distance heavy-gradient working condition |
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