JP7399125B2 - Electromagnetic brake motion compensation device - Google Patents

Description

Embodiments of the present invention relate to an electromagnetic brake operation compensation device that compensates for the operation of an electromagnetic brake device that brakes an industrial motor such as a plant equipment.

In electromagnetic brake devices for plant equipment such as steel equipment, when the brake is released when the equipment is in operation, an inrush current is applied to the coil and it is strongly excited to release the brake and make the motor ready for operation. Make it. While the equipment is in operation, the brake is maintained in an open state by constantly passing a holding current through the coil. To put the brake in a braking state, the current flowing through the coil is cut off.

If the brake cannot be released even if the coil is strongly excited, the motor cannot be operated, which may have a significant impact on equipment operation. Furthermore, if an abnormality occurs in the brakes while the equipment is in operation and the brakes cannot be kept in an open state, the equipment will be stopped, affecting operations and potentially causing large losses.

In such an electromagnetic brake device, it is necessary to rely on regular or irregular inspections to determine whether or not an abnormality has occurred in the brake, and it is desired to detect abnormalities in the electromagnetic brake device in real time.

Japanese Patent Application Publication No. 1-285558

Embodiments of the present invention aim to obtain an electromagnetic brake operation compensation device that can detect the state of an electromagnetic brake device in real time and continue operating equipment in a more appropriate state.

An electromagnetic brake operation compensation device according to an embodiment of the present invention compensates for the operation of an electromagnetic brake that brakes a disc with a set of brake pads and releases a braking state of the disc by passing a current through a coil. This electromagnetic brake operation compensator starts the operation of the set of brake pads from a first time when it receives a release signal output from a first sensor provided to detect that the set of brake pads has released the disc. Start receiving a gap signal from a second optical sensor provided to measure the gap between the brake pads, measure the gap based on the gap signal, and increase the holding current of the coil. A brake operation determination section that sets a first compensation current is provided. The brake operation determination unit sets the first compensation current when the interval is smaller than a first threshold value set in advance, and sets the first compensation current when the interval is equal to or larger than the first threshold value. Set compensation current to zero.

In this embodiment, an electromagnetic brake operation compensation device is realized that can detect the state of the electromagnetic brake device in real time and continue operating the equipment in a more appropriate state.

FIG. 1 is a schematic block diagram illustrating an electromagnetic brake motion compensation device according to an embodiment. FIGS. 2(a) to 2(c) are schematic diagrams illustrating a part of the electromagnetic brake operation compensation device according to the embodiment.

Embodiments of the present invention will be described below with reference to the drawings.
Note that the drawings are schematic or conceptual, and the relationship between the thickness and width of each part, the size ratio between parts, etc. are not necessarily the same as those in reality. Furthermore, even when the same part is shown, the dimensions and ratios may be shown differently depending on the drawing.
Note that in the present specification and each figure, the same elements as those described above with respect to the existing figures are denoted by the same reference numerals, and detailed explanations are omitted as appropriate.

FIG. 1 is a schematic block diagram illustrating an electromagnetic brake operation compensation device according to an embodiment.
As shown in FIG. 1, the electromagnetic brake operation compensator 30 is connected to the brake control device 4. In this example, the electromagnetic brake operation compensator 30 is connected to the brake control device 4 via the IO board 20.

The brake control device 4 is connected via the transformer 1, the circuit breaker 2, and the reactor 3, and is provided to supply current to the coil 11 of the electromagnetic brake device 10. The brake control device 4 includes a current drive circuit 5, and the current drive circuit 5 is provided between the AC power supply supplied by the transformer 1 and the coil 11 of the electromagnetic brake device 10. The brake control device 4 is provided with a current detector 6 that detects the current flowing through the coil 11 via the current drive circuit 5 as a feedback current.

The feedback current IFBK detected by the current detector 6 is input to the calculator 7. A preset current command value IREF is input to the calculator 7. Arithmetic unit 7 supplies current drive circuit 5 with the difference between current command value IREF and feedback current IFBK. The current drive circuit 5 controls the output current so that the value of the feedback current IFBK follows the current command value IREF.

In this example, the calculator 7 is provided in the brake control device 4, and the current command value IREF is also set in the brake control device 4, but the present invention is not limited to this, and the electromagnetic brake operation compensator 30, which will be described in detail later, However, the difference between the current command value IREF and the feedback current IFBK may be supplied to the current drive circuit 5 via the IO board 20, for example.

The electromagnetic brake device 10 is connected to at least two sensors 12 and 13. One sensor 12 is a distance measurement sensor. As will be described in detail later, the sensor (second sensor) 12 is an optical sensor and measures the gap width L when the electromagnetic brake device 10 is released. The sensor 12 transmits data on the measured gap width L to the electromagnetic brake operation compensator 30 via the IO board 20. The other sensor 13 is a limit switch. The signal output from the sensor (first sensor) 13 is transmitted to the electromagnetic brake operation compensator 30 by the IO board 20. The sensor 13 is used to measure the opening time from when a release command to drive the coil 11 of the electromagnetic brake device 10 to release the brake is output until the electromagnetic brake device 10 operates and the brake is released. It will be done.

The electromagnetic brake operation compensation device 30 includes a brake operation determination section 31. The brake operation determination unit 31 inputs data on the gap width L from the IO board 20, and outputs a compensation current ICOM based on the data on the gap width L. The output compensation current ICOM is added to the difference between the current command value IREF and the feedback current IFBK by the arithmetic unit 7.

Further, the brake operation determination unit 31 inputs the release command from the IO board 20 and the release signal output from the sensor 13, and calculates the release time T, which is the time difference between the release command and the release signal. The brake operation determination unit 31 generates and outputs an alarm signal based on the calculated release time T.

After receiving the release signal, the brake operation determining unit 31 starts measuring and determining the gap width L using the sensor 12. In the electromagnetic brake device 10, the brake starts to be released from the braking state of the brake, that is, from the stopped state of the electric motor, in response to a release command, and the released state of the brake is determined by the operation of the sensor 13, making it possible to measure the effective gap width L. Because it will be.

The electromagnetic brake operation compensator 30 includes a database section 32, and in this example, a threshold value ΔL of the gap width L is set in the database section 32. When the brake operation determination unit 31 receives the data on the gap width L, it accesses the database unit 32 and determines the compensation set in the database unit 32 when the received value of the gap width L is larger than the threshold value ΔL. The current ICOM is read out and output to the IO board 20. The database unit 32 stores data on the gap width L and data on the compensation current ICOM for the gap width L, for example, in a table format.

For example, the relationship between the gap width L and the compensation current ICOM is such that when the gap width L is greater than or equal to the threshold value ΔL, the compensation current ICOM is constant, and when the gap width L is smaller than the threshold value ΔL, the compensation current ICOM is constant. , the compensation current ICOM is set to zero. The present invention is not limited to this, and when the gap width L becomes equal to or larger than the threshold value ΔL, the larger the gap width L, the larger the compensation current ICOM may be.

In the database section 32, a threshold value ΔT of the open time T is set. After calculating the opening time T, the brake operation determining unit 31 accesses the database unit 32 and generates and outputs an alarm signal when the calculated value of the opening time T is equal to or greater than the threshold value ΔT. The warning signal can include text data, audio data, image data, etc., and the output warning signal is displayed on the display device 40 via the brake operation management section 33 and the brake state display section 34. The threshold value ΔT of the open time T may be set over multiple stages so that as the calculated open time T becomes longer, the alarm signal includes different test data and the like.

The brake operation determination unit 31 collects data on the gap width L at a cycle set on the IO board 20 side. The collected gap width L data is stored in the database section 32 together with the time of collection. In the gap width L data and the acquisition time data stored in the database unit 32, the time when the compensation current ICOM is applied and the data of the applied compensation current ICOM are also recorded.

Further, the brake operation determination section 31 stores data on the calculated release time T in the database section 32 together with the generation time of the release command and the reception time of the release signal from the sensor 13. The database unit 32 also records the fact that the alarm signal regarding the opening time T was generated and the time.

The brake operation management section 33 accesses the database section 32, reads out the data on the gap width L and its acquisition time, converts the time series data into a graph, etc., and analyzes changes over time and statistical analysis. It can be output as data for The data to be analyzed can include the time when the compensation current ICOM is applied, and can be used to confirm whether or not the application of the compensation current ICOM is effective.

Further, the brake operation management section 33 can access the database section 32, convert time-series data regarding the opening time T into a graph, etc., and output the same. The time series data of the open time T can be set to be displayed simultaneously with the time series data of the gap width L, and can also be data representing the correlation between the gap width L and the open time T.

In addition to the time series data stored in the database unit 32, the brake operation management unit 33 can simultaneously output and display data on the gap width L acquired in real time and the calculated value of the opening time T. It is also possible to observe the status in real time.

The brake state display unit 34 converts the data output by the brake operation management unit 33 into data corresponding to a preset display method and outputs the data. The output data is displayed on the display device 40.

The operation of the electromagnetic brake motion compensation device 30 of the embodiment will be described in detail.
The configuration and operation of the electromagnetic brake device 10 will be explained.
FIGS. 2(a) to 2(c) are schematic diagrams illustrating a part of the electromagnetic brake operation compensation device according to the embodiment.
FIG. 2A is a diagram showing a state in which the electromagnetic brake device 10 is operating, that is, the brake is applied and the electric motor is stopped. In this example, FIG. 2(a) represents a front view of the electromagnetic brake device 10.
FIG. 2(b) schematically shows the shape of the coil 11, with the left figure being a side view of the coil 11, and the right figure being a front view of the coil 11.
FIG. 2(c) is a diagram showing a state in which the coil 11 of the electromagnetic brake device 10 is energized and the brake is released.

As shown in FIG. 2(a), the electromagnetic brake device 10 has a pair of brake calipers 15a, 15b, and brake pads Pa, which are disposed opposite to each other, are provided at the tips of the brake calipers 15a, 15b. Pb is provided. When the electromagnetic brake device 10 is in a braking state, the disc 16 is sandwiched between the brake pads Pa and Pb. The disk 16 is a circular member mechanically connected to the rotating shaft of the electric motor, and rotates as the electric motor rotates.

The coil 11 is provided between the brake calipers 15a, 15b, and supports the brake calipers 15a, 15b by a support member provided at the other end of the brake calipers 15a, 15b. The brake calipers 15a and 15b each have a fulcrum Sa and Sb fixed between one end and the other end, and when the other end fixed to the coil 11 is open, the one end is closed and the brake pad Pa and Pb sandwich and hold the disk 16. In the braking state in which the coil is not energized, the coil 11 is maintained in a vertically extending state in the figure by the elastic member indicated by diagonal lines in the right figure of FIG. 2(b), and the brake pads Pa, Pb maintains a state in which the disc 16 is sandwiched and held.

One ends of angles 14a, 14b are coupled to the other ends of brake calipers 15a, 15b, respectively. The angles 14a, 14b are members having a longitudinal direction along substantially the same direction as the brake calipers 15a, 15b.

The sensor 12 is provided to measure the distance between the other ends of the two opposing angles 14a, 14b.

When the brake is applied, the angles 14a and 14b are subjected to force in the direction of the arrow in the figure due to the action of the elastic member of the coil 11. Therefore, the other ends of the angles 14a and 14b provided with the sensor 12 are maintained in an open state.

The sensor 13 is provided on the coil 11 so as to be in contact with the angle 14b when the angles 14a and 14b approach a predetermined position. In this figure, angles 14a and 14b are far enough apart that sensor 13 is off.

As shown in FIG. 2(b), in this example, the sensor 13 is provided on the coil 11. The sensor 13 is provided at a position facing the angle 14b. Further, the coil 11 is provided with a support portion 11a, and is coupled to brake calipers 15a, 15b via the support portion 11a. In the right diagram of FIG. 2(b), the coil 11 operates so as to be compressed in the vertical direction in the diagram when energized by the elastic member shown by diagonal lines. As a result, the brake calipers 15a and 15b operate to open the space between the brake pads Pa and Pb using the fulcrums Sa and Sb.

As shown in FIG. 2(c), the coil 11 compressed in the vertical direction by the energization operates to shorten the distance between the brake calipers 15a and 15b. Therefore, the brake pads Pa and Pb open in the vertical direction in the figure so as to release the disc 16. Since the angles 14a and 14b are connected to the other ends of the brake calipers 15a and 15b, they move in the direction of the arrow in the figure together with the other ends of the brake calipers 15a and 15b, and the distance between the angles 14a and 14b becomes narrower. The spacing between the brake pads Pa, Pb is substantially measured by measuring the spacing between the narrowed angles 14a, 14b. That is, the sensor 12 substantially measures the distance between the brake pads Pa and Pb by measuring the distance between the angles 14a and 14b.

On the angle 14a, 14b side, when the sensor 13 contacts the angle 14b, the sensor 13, which is a limit switch, outputs an open signal. The sensor 12 measures the gap width L and outputs the measured data.

By providing the sensors 12 and 13 in this manner, the distance between the brake pads Pa and Pb can be substantially measured, and it can be substantially determined whether the brakes are sufficiently released. The sensors 12 and 13 provided in such an electromagnetic brake device 10 transmit detected data, signals, etc. to the electromagnetic brake operation compensation device 30.

Hereinafter, a series of operations of the electromagnetic brake operation compensator 30 after being output from the signals etc. from the sensors 12 and 13 will be explained.
(1) In the electromagnetic brake operation compensator 30, the brake operation determination section 31 receives a release command, and subsequently receives a release signal from the sensor 13. The brake operation determination unit 31 calculates the release time T and compares it with the threshold value ΔT of the database unit 32.

(2) If the value of the opening time T is smaller than the threshold value ΔT, the brake operation determination unit 31 continues the operation, and if the value of the opening time T is greater than or equal to the threshold value ΔT, the brake operation determination unit 31 issues an alarm. Output a signal.

(3) Upon receiving the release signal, the brake operation determining section 31 starts receiving and recording data on the gap width L sent periodically from the sensor 12 to the database section 32 . The brake operation determination section 31 compares the data on the gap width L with the threshold value ΔL of the database section 32 every time the data on the gap width L is received. The brake operation determination unit 31 continues the operation when the received gap width L data is equal to or greater than the threshold value ΔL. If the received gap width L data is smaller than the threshold value ΔL, the brake operation determination unit 31 reads out the compensation current ICOM corresponding to the gap width L data from the database unit 32 and sends it to the brake control device 4. Set against.

(4) If necessary, based on the operator's operation, the brake operation management unit 33 extracts past data from the database unit 32 and displays it on the display device 40 along with real-time data via the brake status display unit 34. to be displayed.

In step (4) above, if real-time data is not displayed, past data will be displayed even when the brake is being applied, that is, when no current is flowing through the coil 11 of the electromagnetic brake device 10. Needless to say, it can be executed for purposes such as data analysis.

In the above description, when the open time T detected by the sensor 13, which is a limit switch, is equal to or greater than the threshold value ΔT, the brake operation determination unit 31 outputs an alarm signal, but the present invention is not limited to this. For example, a compensation current ICOM' when the opening time T is equal to or greater than the threshold value ΔT is set in the database unit 32, and the brake operation determining unit 31 outputs the compensation current ICOM' according to the opening time T. You may also do so. Note that the threshold value of the open time T may be the same value or different values when outputting the alarm signal and when outputting the compensation current ICOM'. Further, the value of the compensation current ICOM' may be the same value as the compensation current ICOM, or may be a different value. These values can be any appropriate values depending on the equipment.

If the release time T becomes longer, the electromagnetic force generated by the coil 11 may be degraded, and in that case, the holding current after the brake is released may not be sufficient to maintain the release state. Therefore, the brake operation determination unit 31 can secure the electromagnetic force of the coil 11 by setting the compensation current (second compensation current) ICOM' at the time of entering the operation using the holding current. After that, if the data of the gap width L is not below the threshold value ΔL, the setting of the compensation current ICOM' is maintained, and if the gap width L becomes narrower, the compensation current ICOM is further added to the compensation current ICOM'. Alternatively, the coil 11 may be driven.

In the above description, the electromagnetic brake is provided with brake pads at one end of the brake caliper, and the distance between the brake pads is measured by the distance between the angles at the other end of the brake caliper, but the invention is not limited to this. Of course, the distance between the brake pads may be directly measured by using an optical sensor. With this configuration, the present invention can be applied to electromagnetic brakes that are not provided with an angle, and it is also possible to more accurately measure setting deviations between the brake pad and the disc.

The electromagnetic brake motion compensation device of the embodiment may be implemented, for example, by a computer device including an arithmetic processing unit. When the electromagnetic brake operation compensation device is expressed by a computer device, part or all of the functions of each block shown in FIG. 1 are realized by one or more steps sequentially executed by an arithmetic processing device. For example, a part of the brake operation determination section 31 is realized by a programmable logic controller (PLC) on the IO board 20 side, and the other part is realized by a program of a computer device.

The effects of the electromagnetic brake motion compensation device 30 of the embodiment will be explained.
The electromagnetic brake operation compensation device 30 of the embodiment can measure the gap width L between the angles 14a and 14b in real time using the sensor 12 attached to the angle 14a of the electromagnetic brake device 10, and can acquire data in real time.

When the coil 11 has no deterioration or the like, the electromagnetic force generated by the coil 11 is approximately constant when a holding current is passed through the coil 11. On the other hand, when the brake pads Pa, Pb are worn, the gap width L during braking is wider than when the brake pads Pa, Pb are not worn. When the brake is released in such a state, the gap width L at the time of release becomes narrower than the gap width L when the brake pads Pa and Pb are not worn. Depending on the wear status of the brake pads Pa and Pb, a threshold value ΔL of the gap width L can be set to allow additional compensation current ICOM to flow. Therefore, the electromagnetic force of the coil 11 is substantially improved, a sufficient distance between the brake pads Pa and Pb can be ensured when the brake is released, and unexpected braking can be avoided.

Furthermore, if the relative positional relationship between the brake calipers 15a, 15b and the disc 16 is shifted due to equipment vibration or the like, the distance between the disc 16 and one of the brake pads Pa, Pb becomes shorter. As a result, there is a risk of problems such as wearing out one of the brake pads, so by setting the compensation current ICOM, sufficient electromagnetic force is generated in the coil 11, and a sufficient distance between the brake pads Pa and Pb is ensured. can do.

The electromagnetic brake operation compensation device 30 of the embodiment uses a signal from a sensor 13 provided to detect that a sufficient distance between the angles 14a and 14b is secured when the brake is released, and the release operation of the electromagnetic brake device 10. Based on the start command at the time of start, the opening time T can be calculated and monitored in real time.

In industrial applications, the electromagnetic brake device 10 is often used under harsh environmental conditions such as high temperature and high humidity, and the electromagnetic force of the coil 11 may decrease due to deterioration of the magnetic material or the like. A problem that may occur due to deterioration in the performance of the coil 11 is that even if a rush current is applied to the coil 11 to strongly excite it during startup, the deteriorated coil 11 cannot be sufficiently excited, and the brake may not be released until the brake is released. For example, it takes a long time.

The electromagnetic brake operation compensator 30 of the embodiment calculates the opening time T, and if the opening time T is equal to or greater than a predetermined threshold value ΔT, an alarm signal is sent to the effect that the coil 11 may be deteriorated. It can be output. Therefore, the deterioration state of the coil 11 can be grasped in advance, parts can be replaced or repaired in advance, and the situation where the brake is not released and the operation has to be stopped when the equipment starts operation can be avoided. can do.

When a holding current is passed through the deteriorated coil 11, the electromagnetic force may also be reduced. In that case, by setting the compensation current ICOM', which is set according to the opening time T, regardless of the gap width L, sufficient electromagnetic force can be ensured, and the situation of unexpected braking operation can be avoided. It becomes possible.

According to the embodiment described above, it is possible to realize an electromagnetic brake operation compensation device that can detect the state of the electromagnetic brake device in real time and continue operation in a more appropriate state.

Although several embodiments of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and changes can be made without departing from the gist of the invention. These embodiments and their modifications are included within the scope and gist of the invention, as well as within the scope of the claimed invention and its equivalents. Further, each of the embodiments described above can be implemented in combination with each other.

1 Transformer, 2 Circuit breaker, 4 Brake control device, 5 Current drive circuit, 6 Current detector, 10 Electromagnetic brake device, 11 Coil, 12, 13 Sensor, 14a, 14b Angle, 15a, 15b Brake caliper, 20 IO panel , 30 electromagnetic brake operation compensation device, 31 brake operation determination section, 32 database section, 33 brake operation management section, 34 brake state display section, 40 display device

Claims (5)

An electromagnetic brake operation compensation device that compensates for the operation of an electromagnetic brake that brakes a disc with a set of brake pads and releases the braking state of the disc by passing current through a coil,
The interval between the one set of brake pads is measured from a first time when a release signal output from a first sensor provided to detect that the one set of brake pads has released the disc is received. Start receiving a gap signal from a second optical sensor provided at
measuring the interval based on the gap signal;
a brake operation determination unit that sets a first compensation current to increase a holding current of the coil;
The brake operation determination section includes:
setting the first compensation current when the interval is smaller than a preset first threshold;
An electromagnetic brake operation compensation device that sets the first compensation current to zero when the interval is equal to or greater than the first threshold value. The brake operation determination section includes:
calculating a difference between a second time when a release command generated to release the electromagnetic brake is received and the first time, and calculating a release time;
The electromagnetic brake operation compensator according to claim 1, wherein an alarm signal is output when the release time is equal to or greater than a second preset threshold. The brake operation determination section includes:
3. The electromagnetic brake operation compensator according to claim 2, wherein the second compensation current is set to increase the holding current when the opening time is equal to or greater than a third preset threshold. The brake operation determination section includes:
a database unit that collects the gap signal at regular intervals along with its acquisition time as first time series data, and stores the first time series data;
a brake operation management unit that extracts and outputs the first time series data from the database unit under preset conditions;
The electromagnetic brake operation compensation device according to any one of claims 1 to 3, further comprising: The electromagnetic brake includes a set of brake calipers provided with the set of brake pads at one end,
The electromagnetic brake operation compensation device according to claim 1, wherein the first sensor and the second sensor are provided at the other end of the set of brake calipers.

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