WO2018014145A1 - 电刷压力智能控制系统与电刷压力控制系统 - Google Patents

电刷压力智能控制系统与电刷压力控制系统 Download PDF

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Publication number
WO2018014145A1
WO2018014145A1 PCT/CN2016/000403 CN2016000403W WO2018014145A1 WO 2018014145 A1 WO2018014145 A1 WO 2018014145A1 CN 2016000403 W CN2016000403 W CN 2016000403W WO 2018014145 A1 WO2018014145 A1 WO 2018014145A1
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WIPO (PCT)
Prior art keywords
brush
pressure
control system
mover
intelligent control
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PCT/CN2016/000403
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English (en)
French (fr)
Inventor
田园
黄继林
张树民
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田园
黄继林
张树民
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Application filed by 田园, 黄继林, 张树民 filed Critical 田园
Priority to CN201680087125.XA priority Critical patent/CN109417259B/zh
Priority to PCT/CN2016/000403 priority patent/WO2018014145A1/zh
Publication of WO2018014145A1 publication Critical patent/WO2018014145A1/zh

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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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R39/00—Rotary current collectors, distributors or interrupters
    • H01R39/02—Details for dynamo electric machines
    • H01R39/44—Devices for shifting brushes

Definitions

  • the invention relates to a monitoring system and a monitoring method for a brush pressure of a motor in an electromechanical industry, in particular to a monitoring device and a monitoring method for a brush pressure of a large generator slip ring of a power system, which has reference significance for monitoring the brush pressure of a small motor. .
  • the main forms are torsion springs, coil springs, and constant pressure coil springs. According to different design concepts, there are the following forms: replaceable springs, riveted springs, pressure regulating springs, constant pressure springs, etc., but these compression springs have unsatisfactory conditions in use.
  • the spiral spring is mostly made into a pressure-regulating spring.
  • the pressure of the whole set of brushes is basically balanced by the artificial adjustment of the compression spring, which is realized according to the experience of each person. It is difficult to ensure the uniformity and suitability of the pressure; the spring can be replaced by a coil spring. Constant pressure coil springs can be made in two ways, mostly by the card slot card installation.
  • the bayonet is loose during operation, which not only causes the brush to lose pressure (even if a brush loses pressure, it will cause Sparks, destroying the oxide film, causing brush failure), and the occurrence of the spring of the compression spring also poses a threat to the safety of the human body and equipment;
  • the so-called constant pressure of the constant pressure spring refers to the new constant pressure spring during the use of the brush life length.
  • the pressure change is small, within 10% and less, it can meet the requirements of the whole set of brush pressure difference, but in actual use, the weight of the brush installed on the upper part and the lower part has an influence on the pressure, so some power generation units are in pursuit of brush pressure.
  • the brush is replaced by one-third of the brush, resulting in wasted brush;
  • the riveted spring is mostly made of constant-pressure coil spring, which is difficult to replace due to riveting and fixing, and fatigue caused by long-term use (use fatigue , Vibration fatigue, temperature fatigue, stress fatigue, fretting fatigue, etc.), leads to a pressure reduction, the brush sliding contact unstable, causing severe bad brush, or even a spark.
  • the distance between the brush holder and the slip ring is different.
  • the brush pressure is affected.
  • the distance between the brush holder and the slip ring is artificially adjusted.
  • the actual production site cannot be adjusted consistently. Some units have different unit differences. It is still large or even many times, which further causes inconsistency in brush pressure.
  • the self-vibration frequency of the coil spring and the constant-pressure coil spring is close to the electromagnetic and mechanical vibration frequency of the high-speed unit, which easily causes the compression spring to resonate, causing the compression spring to be damaged.
  • the object of the present invention is to provide a brush pressure intelligent control system, which uses a controllable power device to apply pressure to the brush to realize intelligent monitoring, adjustment and control of the brush pressure.
  • the present invention provides a brush pressure intelligent control system, characterized in that: a force sensor is arranged on the pulling end of the brush, and a mover of a controllable power device is connected with the force sensor, The force sensor transmits a thrust to the brush, and the force sensor is connected to the controllable power device through a controller to form a closed loop control system, and the pressure between the brush and the slip ring is controlled at a predetermined time.
  • a force sensor is arranged on the pulling end of the brush, and a mover of a controllable power device is connected with the force sensor, The force sensor transmits a thrust to the brush, and the force sensor is connected to the controllable power device through a controller to form a closed loop control system, and the pressure between the brush and the slip ring is controlled at a predetermined time.
  • the brush pressure intelligent control system wherein: a linear position sensor is connected to the mover, or a linear position sensor is integrated in the controllable power device, and the linear position sensor is used for recording the telescopic expansion and contraction The distance and the remaining length of the brush can be calculated, the linear position sensor being coupled to the controller.
  • the brush pressure intelligent control system wherein: the controllable power device has a self-locking function; or, the mover is provided with a self-locking mechanism, and the self-locking mechanism is defined by a positioning concave and a mover on the mover Composed of a spring pin on one side.
  • the brush pressure intelligent control system wherein: a lifting mechanism is arranged at a pulling end of the brush, the brushing mechanism is made of an elastic material, and the middle part is connected to the mover, and the two ends are connected with The recessed holes on the pulling end of the brush are movably connected.
  • the brush pressure intelligent control system wherein: the brush is connected to each of the generators Brush pressure intelligent control system.
  • the brush pressure intelligent control system wherein: the control information of the controllable power device connected to each brush eliminates the influence of the weight of components other than the brush on the working face pressure, and the control information also follows The length of the brush wears and changes accordingly.
  • the present invention also provides a brush pressure control system, characterized in that a mover of a power device outputs a fixed thrust to the brush.
  • the present invention has the following beneficial effects:
  • the compression spring exerts pressure on the brush.
  • the main work of the duty officer has two aspects: one is to adjust the pressure, and the other is to replace the compression spring; Factors and components related to the feelings, experience, skills, etc. of the duty personnel, especially in emergency situations, are very difficult to adjust and replace, which inevitably causes negative emotions such as “resistance and avoidance” by the duty personnel.
  • the invention is completed by computer analysis for the brush pressure adjustment, and is controlled in an ideal range, which reduces the workload of the on-duty personnel and eliminates the negative psychological influence of the on-duty personnel.
  • the computer automatically prints out the replacement brush work ticket, operation ticket: the unit increases the total number of installed brushes The amount of the brush is used to realize the standby.
  • the backup brush is self-operated.
  • the computer records and can be checked in real time.
  • the computer automatically prints out the replacement work ticket and operation ticket, and corresponds to the name, position and number of the brush work.
  • the operator realizes the three-check, even Including the model and quantity of the brush, the specific number of each brush in the unit is also in the operation ticket, can not be changed more, can not be changed less, can not be replaced, can not be replaced, the change is not changed according to personal judgment and change.
  • the computer automatically generates a brush for the maintenance and replacement of the work ticket, which avoids the problem of the quality of the work due to the large workload and the serious consequences of the fatigue caused by the fatigue of the personnel. At the same time, it avoids the random emotional factors of artificial assignment, and avoids the emotional factors of the shifting and arguing work of the duty staff. Realizing technology to contribute to scientific management.
  • FIG. 1 is a schematic structural view of an embodiment of a brush pressure intelligent control system provided by the present invention
  • FIG. 2 is a schematic structural view of another embodiment of a brush pressure intelligent control system provided by the present invention.
  • Figure 3 is a flow chart of the control method of the present invention.
  • FIG. 1 is a schematic structural view of an embodiment of a brush pressure intelligent control system provided by the present invention.
  • one end of the brush 1 in contact with the slip ring 2 is a contact end, and the other end of the brush 1 has a brush.
  • the brush is a prior art, not shown) and is called a pulling end.
  • a force sensor 3 is provided through a recess, and a force motor 4 (a linear motor with a target output thrust) is a mover.
  • a closed loop control system controls the pressure between the brush 1 and the slip ring 2 within a predetermined range.
  • the mover 5 After the force motor 4 is energized, the mover 5 outputs pressure to the force sensor 3 and the brush 1. When the pressure reaches a predetermined value, the force sensor 3 senses the pressure value and feeds back to the controller, so that the thrust output by the force motor 4 is no longer generated. Raise to maintain the predetermined value of the pressure constant, to achieve constant pressure of the brush 1.
  • a linear position sensor 6 is also connected to the extension end of the mover 5 for recording the telescopic distance of the mover 5, thereby calculating the remaining length of the brush 1, and at the same time facilitating the inspection personnel to visually see the length of the brush.
  • the linear position sensor 6 is connected to the controller.
  • the force motor 4 is integrated with the linear position sensor 6 if the sensor element carried by the force motor 4 itself is capable of realizing the position sensor function. If the force motor 4 does not have a position sensor function, the linear position sensor 6 can be separately provided as shown in FIG.
  • the controller receives the feedback signal of the linear position sensor 6, and returns the mover 5 of the force motor 4 to return the brush 1 to run. .
  • the standby brush (also having the brush pressure intelligent control system) is automatically put into operation, the structure of the standby brush and the structure of the working brush 1 The same, will not be described here.
  • the controller will cut off the power of the force motor 4 to save electric energy, and at the same time, if the force motor 4 has the power-off self-locking function, the mover 5 will be self-locking by the force motor 4, and cannot be freely stretched. If the force motor 4 does not have the power-off self-locking function, as shown in FIG. 1, a self-locking mechanism is provided on the mover 5, and the self-locking mechanism is provided by the positioning concave 51 and the mover 5 on the mover 5.
  • the spring pin 52 of one side is composed. When the mover 5 is retracted to the predetermined position, the spring pin 52 is snapped into the positioning recess 51 by the elastic force to realize the self-locking position.
  • a brush lifting mechanism 11 is provided at the pulling end of the brush 1, the brushing mechanism 11 is made of an elastic material, and the middle portion is connected to the mover 5, and the two ends are connected with a brush.
  • the recessed holes 12 in the pulling end of the 1 are movably connected, and under the action of an external force (such as pinching both ends), the brushing mechanism 11 can be disengaged from the pulling end of the brush to facilitate the replacement of the brush 1.
  • a hydrogen gas sensor 15 may be disposed above the brush 1, and the hydrogen gas sensor 15 is connected to the controller. Once the hydrogen sensor 15 detects that the hydrogen concentration reaches the set value, an alarm signal is issued and the brush lifting action is blocked, and ventilation is enhanced to prevent hydrogen explosion.
  • the brush pressure intelligent control system is connected to each of the brushes 1 of the generator, the pressure values of all the brushes 1 in the generator can be intelligently controlled.
  • the force motor 4 in the foregoing embodiment can also be replaced by a push-pull electromagnet, as shown in FIG. 2, which is a schematic structural view of another embodiment of the brush pressure intelligent control system provided by the present invention, and the push-pull electromagnet 7 is preferably A slow long stroke (for example: solenoid type) electromagnet is used to output the thrust to the mover 5. At this time, it is generally required to connect the spring 71 to the mover 5, and the spring 71 pulls the mover 5 back under normal conditions. Or push forward to cooperate with the push-pull electromagnet 7 to provide push-pull force.
  • a slow long stroke for example: solenoid type
  • the force motor 4 in the foregoing embodiment may also be replaced by an electric push rod or an electro-hydraulic push rod, and the electric push rod or the electro-hydraulic push rod outputs a thrust, considering the brush working in a vibrating environment, the output of the electric push rod
  • the power motor can be equipped with a hollow cup motor to achieve fast action and output flexibility.
  • an elastic material such as an elastic gasket
  • an elastic material can be installed at the pulling end of the brush, and the rest of the structure and The working principles are similar and will not be repeated here.
  • the force motor 4 such as an electric push rod, an electro-hydraulic push rod, and a hydraulic cylinder.
  • the force motor 4 can be applied to the present invention.
  • the brush 1 is arranged in the horizontal direction as an example to introduce the brush pressure intelligent control system.
  • the pressure between the brush 1 and the slip ring 2 does not follow the brush. 1
  • the change of self-weight changes, and the pressure control is relatively simple.
  • the brush 1 above the slip ring 2 is composed of the thrust of the force motor 4 (or the push-pull electromagnet 7 plus the spring 71) plus the weight of the brush 1; the brush 1 below the slip ring 2,
  • the pressure is composed of the thrust of the force motor 4 (or the push-pull electromagnet 7 plus the spring 71) minus the self-weight of the brush 1; the pressure calculation method of the brush 1 on the side of the slip ring 2 varies with the inclination angle; If the pressure values of the respective brushes 1 are required to be as equal as possible, it is also necessary to consider the arrangement position of the brushes 1 and the wear of the brushes 1.
  • the angle of inclination of each brush 1 during use is constant. Therefore, the influence of the weight of the components other than the brush 1 on the pressure of the working surface is constant, and can be regarded as a constant and can be passed in advance.
  • the measurement adds the influencing factors to the control information of the controller to eliminate the influence of the constant; while the weight of the brush 1 is a variable, and the weight varies with the wear and tear, but the weight of the brush 1 varies with the length of the brush 1
  • the change of the law changes regularly, so the controller can also change the thrust of the force motor 4 (or the push-pull electromagnet 7 plus the spring 71) by the information fed back by the linear position sensor 6 to eliminate the influence of the variable to achieve a more accurate constant Pressure control.
  • the present invention also provides a simplified brush pressure control system (ie, a simplified solution), and the power device outputs a fixed thrust to the brush 1 through the mover 5, without the feedback of the force sensor 3, Compared with the prior art, the constant pressure spring is used to apply a pressure to the brush.
  • the above-mentioned simplified scheme is introduced by taking the brush 1 arranged in the horizontal direction as an example.
  • the pressure between the brush 1 and the slip ring 2 does not change with the change of the weight of the brush 1, and the power device
  • the fixed thrust is output, so the pressure between the brush 1 and the slip ring 2 is fixed throughout the life of the brush.
  • the pressure change between the brush 1 and the slip ring 2 reaches 7% according to the experimental data of the manufacturer during the entire service life of the brush.
  • the weight of the brush and the pressure action mechanism at the upper part will increase the pressure between the brush 1 and the slip ring 2, and the weight of the brush and the pressure action mechanism at the lower part will decrease.
  • the weight of the brush pressure action mechanism component is 200g.
  • the large-scale graphite brush that is commonly used by the main power generation unit size: 25.4 ⁇ 38.1 ⁇ 100mm
  • the total weight of the new brush itself is about 150g
  • the brush End of service life The remaining weight is about 70g (this weight is the weight of the unusable part of the brush, can be regarded as a constant)
  • the available part of the brush weighs about 80g (only the weight of the available part of the brush is a variable), when the brush is working
  • the required pressure is 1500g.
  • the pressure deviation of each brush is basically not more than the required range (10%).
  • the force of the power unit output is fixed; when the power unit is manufactured and installed, the power device with different power is applied to the brush with different installation positions, for example, the upper mounted power unit
  • the pressures for the installation of the tilting angle and the horizontal installation of the brushes are similarly analyzed and understood, and will not be described again.
  • the scope of the request In the actual production of large generators, some units do not have brushes installed in the lower part, that The difference between the upper and horizontally mounted brushes is even smaller.
  • the pressure change in the whole process requires no more than 10%. According to the experimental data of the manufacturer, it is about 7%, that is, the pressure applied by the constant pressure spring to the new brush is large, and the pressure applied to the brush whose service life is coming to an end is small.
  • the upper mounted brush is a new brush
  • the horizontally mounted brush is the brush whose service life is coming to an end. Under the combined effect of the above two factors, the pressure difference also exceeds the brush pressure requirement of 10%. Even if the units are all horizontally mounted brushes, the pressure difference between the constant pressure springs and the brushes is about 7%, and the simplified solution of the present invention can also achieve a pressure difference of 5.4% for the upper and lower mounted brushes.
  • the constant pressure spring applies pressure to the brush, and it is difficult to achieve a range of 10% of the sliding working surface pressure of the brush for the brush having the weight factor.
  • the power device used in the brush pressure control system may be a force motor, or may be replaced by: a push-pull electromagnet, an electric push rod, an electro-hydraulic push rod or a hydraulic cylinder.
  • a push-pull electromagnet a push-pull electromagnet
  • an electric push rod a push rod that is pressed for different installation positions.
  • a power unit that requires a fixed thrust output can be applied to the above simplified solution.

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  • Motor Or Generator Current Collectors (AREA)

Abstract

一种电刷（1）压力智能控制系统与电刷（1）压力控制系统。该电刷（1）压力智能控制系统包括：在电刷（1）的提拉端上设置力传感器（3），一个可控动力装置的动子（5）与力传感器（3）连接，通过力传感器（3）向电刷（1）传递推力，力传感器（3）再通过控制器与可控动力装置相连，以构成一个闭环控制系统，将电刷（1）与滑环（2）之间的压力控制在预定范围内。

Description

电刷压力智能控制系统与电刷压力控制系统 技术领域
本发明涉及机电行业电机用电刷压力的监控系统以及监控方法，特别是涉及电力系统大型发电机滑环用电刷压力的监控装置以及监控方法，对于小型电机用电刷压力的监控有参考意义。
背景技术
原始电机诞生时就有电刷，电刷压力是电刷运行的重要指标之一。现在发电行业大型主力发电机组，使用一、两百个大型电刷，承担着传递励磁电流的任务，电刷与滑环相对滑动运行时的可靠接触是靠压簧的压力实现的，压簧的形式主要有扭力簧、螺旋弹簧、恒压卷片簧。根据设计理念不同又有如下形式：可更换簧、铆接簧，调压簧、恒压簧等，但这些压簧使用过程中都有不令人满意的情况存在。
螺旋弹簧多做成调压簧，靠人为调节压簧使整组电刷压力基本均衡，是依各人的经验感觉实现的，难以保证压力的均匀性与合适性；可更换簧由螺旋弹簧、恒压卷片簧两种都可做成，多是靠卡口卡位安装，运行中都偶尔有卡口松脱的情况发生，不仅造成电刷失压(哪怕一个电刷失压，将造成火花，破坏氧化膜，导致电刷故障)，而且压簧发生跳出还对人身和设备的安全构成威胁；恒压簧所谓的恒压，是指新的恒压簧在电刷寿命长度使用过程中压力变化小，在10％及以内，能够满足整组电刷压力差别的要求，但实际使用时在上部、下部安装电刷自身重量对压力是有影响的，所以一些发电单位为了追求电刷压力尽可能一致，规定电刷使用三分之一即更换，造成电刷浪费；铆接簧多由恒压卷片簧做成，由于铆接固定造成更换困难，长久使用造成疲劳(使用疲劳、振动疲劳、温度疲劳、应力疲劳、微动磨损疲劳等)，导致压力降低，电刷滑动接触不稳定，严重时造成电刷接触不良，甚至产生火花。
各种压簧制造时实际不可能压力一致，使用后又造成疲劳，严重的情况如：在上部的电刷是新换电刷自身最重且是较大压力的压簧，此时电刷滑动运行工作面压力较大；而下部是新换电刷自身最重将抵消部分压簧的压力，若压簧已 经使用疲劳没有及时更换，这时电刷滑动运行工作面压力将较小；造成上、下部电刷滑动运行工作面压力超出压力差距范围，甚至下部电刷动作不灵活，电刷又工作在振动的环境中，可能有的电刷发生时接触时断开产生火花的恶劣情况。
刷握与滑环的距离不同，对于恒压簧而言是影响电刷压力的，刷握与滑环的距离间隙是人为调整的，实际生产现场不可能调整一致，有的单位有的机组差别还很大甚至许多倍，这更加造成了电刷压力的不一致。
螺旋弹簧、恒压卷片簧自振频率与高速机组电磁、机械振频接近，易引起压簧共振，造成压簧损坏。
电刷使用压簧施加压力的形式难以实现现代化的调节控制要求。
发明内容
本发明的目的在于，提供一种电刷压力智能控制系统，采用可控动力装置对电刷施加压力，以实现对电刷压力的智能监测、调节与控制。
为实现上述目的，本发明提供一种电刷压力智能控制系统，其特征在于：在电刷的提拉端上设置有力传感器，一个可控动力装置的动子与所述力传感器连接，通过所述力传感器向所述电刷传递推力，所述力传感器再通过控制器与可控动力装置相连，以构成一个闭环控制系统，将所述电刷与所述滑环之间的压力控制在预定范围内。
所述的电刷压力智能控制系统，其中：在动子上还连接有直线位置传感器，或者在所述可控动力装置内集成有直线位置传感器，所述直线位置传感器用于记录动子的伸缩距离，并能够计算电刷的剩余长度，所述直线位置传感器与所述控制器相连。
所述的电刷压力智能控制系统，其中：所述可控动力装置具有自锁功能；或者，在动子上设有自锁机构，所述自锁机构由动子上的定位凹和动子一侧的弹簧销组成。
所述的电刷压力智能控制系统，其中：在所述电刷的提拉端设有提刷机构，所述提刷机构是由弹性材料制成，其中部连接在动子上，两端与电刷的提拉端上的凹孔活动连接。
所述的电刷压力智能控制系统，其中：在发电机的每个电刷上都连接所述 电刷压力智能控制系统。
所述的电刷压力智能控制系统，其中：各个电刷上连接的可控动力装置的控制信息中消除了电刷之外的元件的重量对工作面压力的影响，所述控制信息还随着电刷的长度磨损而相应变化。
为实现上述目的，本发明还提供一种电刷压力控制系统，其特征在于：一个动力装置的动子向电刷输出固定的推力。
与现有技术相比较，本发明具有的有益效果是：
1、停机时：方便将电刷提起来，以防止钢质滑环上出现重象伤痕、白浊化、电刷影子。
2、实时监测各电刷在运、备用、提刷、待检、待更换等状态。电刷长度、压力、磨损量与时间的关系，电脑记录并分析，还可以间接判断滑环(光洁度、不平度、不圆度及污染等)问题。
3、实现电刷恒压力或所需的压力：使用的时候，动力装置的动子对力传感器和电刷输出压力，当压力达到预定值时，根据力传感器感受压力值再反馈至所述控制器，使可控动力装置输出的推力不再升高，以维持压力预定值不变，实现电刷恒压力；还可以根据电刷或机组运行的需要，设定和调节电刷需要的压力。
4、物尽其用：传统的电刷定期维护制度，往往会存在这样情况：电刷剩余可用部分已经不多，维护人员不敢让其“物尽其用”而更换，有的单位规定电刷使用三分之一必须更换以保持在线运行电刷的长度基本一致达到压力基本均衡的目的，有的单位规定电刷进入刷握3毫米更换，这都将造成电刷浪费；本发明直线位置传感器与控制器配合可以准确判断电刷长度使其“充分利用”，节约电刷。
5、减轻值班人员的工作量，消除值班人员的负面心理影响：压簧对电刷施加压力，值班人员的主要工作有两方面，一是调整压力，二是更换压簧；这两项工作都涉及值班人员的感觉、经验、技能等因素和成分，尤其在紧急情况下调整、更换都有很大困难，难免造成值班人员“抵触、躲避”等负面的情绪。本发明对于电刷压力调整由电脑分析完成，并控制在理想范围，减轻了值班人员的工作量，消除了值班人员的负面心理影响。
6、电脑自动打印出更换电刷工作票、操作票：机组增加安装电刷的总数 量，实现部分电刷明备用，当有电刷退出运行时备用电刷自投运，当少量电刷达到使用寿命或不能正常运行而退出时，电脑记录并实时可查，当备用电刷大多已投运或退出运行的电刷达到设定的数量时，电脑自动打印出更换电刷工作票、操作票，将电刷工作的名称、位置、编号对应，操作人员实现三核对，甚至包括电刷的型号、数量、本单位每个电刷的具体编号也在操作票中，不能多换也不能少换更不能该换的不换不该换的随个人判断认识不同而更换的情况；电脑自动生成一台机的电刷维护更换工作票，避免了因工作量大工作质量下降的问题以及人员疲劳造成严重后果的隐患。同时也避免了人为指派工作的随意性感情因素，避免了值班人员推诿、扯皮工作的感情因素。实现科技为科学管理做出贡献。
附图说明
图1是本发明提供的电刷压力智能控制系统的一个实施例的结构示意图；
图2是本发明提供的电刷压力智能控制系统的另一实施例的结构示意图；
图3是本发明的控制方法流程图。
附图标记说明：电刷1；提刷机构11；凹孔12；氢气传感器15；滑环2；力传感器3；力电机4；动子5；定位凹51；弹簧销52；直线位置传感器6；推拉电磁铁7；弹簧71。
具体实施方式
如图1所示，是本发明提供的电刷压力智能控制系统的一个实施例的结构示意图，在此称电刷1与滑环2接触的一端为接触端，电刷1另一端具有刷辫(刷辫为现有技术，未予图示)而称为提拉端，在提拉端上通过凹部设置有力传感器3，一个力电机4(以输出推力为目标任务的直线电机)的动子5与所述力传感器3连接，通过所述力传感器3向所述电刷1传递推力，所述力传感器3再通过控制器(未予图示)与所述力电机4相连，以构成一个闭环控制系统，将所述电刷1与所述滑环2之间的压力控制在预定范围内。
力电机4通电后，动子5对力传感器3和电刷1输出压力，当压力达到预定值时，力传感器3感受压力值再反馈至所述控制器，使力电机4输出的推力不再升高，以维持压力预定值不变，实现电刷1恒压力。
在动子5外伸端还连接有直线位置传感器6，用于记录动子5的伸缩距离，从而计算电刷1的剩余长度，同时便于巡检人员直观地看到电刷长度。所述直线位置传感器6与所述控制器相连。若力电机4自身带有的传感元件能够实现位置传感器功能，则所述力电机4集成有所述直线位置传感器6。若力电机4不带位置传感器功能，则可以如图1所示，单独设置直线位置传感器6。随着电刷1使用磨损，当电刷1使用到设定长度时，所述控制器接收到直线位置传感器6的反馈信号，将指令力电机4的动子5退回，使电刷1退出运行。
磨损到设定长度的电刷1(工作电刷1)退出运行以后，备用电刷(同样具有电刷压力智能控制系统)自动投入运行，备用电刷的结构与工作电刷1的结构相同，在此不予赘述。
当直线位置传感器6获知动子5退回到预定位置后，所述控制器将断开力电机4的电源以节约电能，同时，若所述力电机4具有断电自锁功能，所述动子5将被所述力电机4自锁限制，不能自由伸缩。若所述力电机4不具有断电自锁功能，则如图1所示，在动子5上设有自锁机构，所述自锁机构由动子5上的定位凹51和动子5一侧的弹簧销52组成，当动子5退回到预定位置时，弹簧销52在弹力作用下卡入定位凹51中，实现自锁定位。
如图1所示，在所述电刷1的提拉端设有提刷机构11，所述提刷机构11是由弹性材料制成，其中部连接在动子5上，两端与电刷1的提拉端上的凹孔12活动连接，在外力作用下(如捏紧两端)，提刷机构11能够与电刷的提拉端处脱离，以方便更换电刷1。
此外，为了防止发生氢爆事故，在电刷1的上方可以设置氢气传感器15，所述氢气传感器15与所述控制器相连。一旦所述氢气传感器15探测出氢气浓度达到设定值，则发出报警信号并闭锁提刷动作，并加强通风，以防氢爆。
由上述内容可知，若在发电机的每个电刷1上都连接所述电刷压力智能控制系统，可使发电机中的所有的电刷1的压力值得到智能控制。
前述实施例中的力电机4还可以用推拉电磁铁来替代，如图2所示，是本发明提供的电刷压力智能控制系统的另一实施例的结构示意图，所述推拉电磁铁7优选采用慢速长行程(例如：螺管式)电磁铁来给动子5输出推力，此时，一般需要在动子5上连接弹簧71，所述弹簧71在常态下将动子5往回拉或往前推，以配合推拉电磁铁7提供推拉合力。图2所示的实施例，与图1所示的 实施例相比，当推拉电磁铁7断开电源，由弹簧71将动子5退回并保持在退回状态，自锁机构也可以不再装设，其余结构以及工作原理均类同，在此不予赘述。
前述实施例中的力电机4还可以用电推杆或电液推杆来替代，所述电推杆或电液推杆输出推力，考虑电刷工作在振动的环境中，电推杆的输出动力电机可选用空心杯电机，以实现动作的快速性及输出柔性力；此时，为了吸收振动的影响，可以在电刷的提拉端装设弹性材料(如弹性垫片)，其余结构以及工作原理均类同，在此不予赘述。
此外，所述力电机4的替代方式还有很多，例如电推杆、电液推杆、液压缸，总之，只要是可控动力装置，都能够应用到本发明中来。
在上述两个实施例中，是以水平方向布置的电刷1为例来介绍电刷压力智能控制系统，此种情况下，电刷1与滑环2之间的压力不会随着电刷1自重的改变而改变，其压力控制较为简单。而在滑环2上方的电刷1，其压力由力电机4(或者推拉电磁铁7加弹簧71)的推力加上电刷1的自重而组成；在滑环2下方的电刷1，其压力由力电机4(或者推拉电磁铁7加弹簧71)的推力减去电刷1的自重而组成；滑环2侧面的电刷1，其压力计算方法随着倾斜角度的不同而不同；若要求各个电刷1的压力值尽量相等，则还需要考虑电刷1的布置位置以及电刷1的磨损。
而每个电刷1在使用过程中的倾斜角度是不变的，因此，除了电刷1之外的元件，其重量对工作面压力的影响是不变的，可以视作为常量，能够通过事先测量将影响因素加入到控制器的控制信息中，来消除常量的影响；而电刷1重量是变量，其重量是随着使用磨损而变化，但电刷1的重量会随着电刷1长度的改变而有规律变化，因此控制器也可以通过直线位置传感器6反馈的信息来改变力电机4(或者推拉电磁铁7加弹簧71)的推力，来消除变量的影响，以实现更精确的恒压控制。
通过上述分析可知，在电刷1的滑动工作面达到恒压力无级调节是可以实现的。但这是理论分析的理想境界，由于电刷1是不可避免地工作在振动的环境中，各传感器、控制系统和动作机构将频繁地感受、反馈、指令、动作，为了电刷1工作在较稳定的状态，同时避免各装置频繁动作，应当将力电机4(或者推拉电磁铁7加弹簧71)的推力幅度作阶梯调节。
此外，本发明还提供一种简化了的电刷压力控制系统(即简化方案)，动力装置通过动子5向所述电刷1输出固定的推力，不需要力传感器3的反馈，也能够实现比现有技术中采用恒压簧对电刷施加压力更优的效果。
首先以水平方向布置的电刷1为例来介绍上述简化方案，此种情况下，电刷1与滑环2之间的压力不会随着电刷1自重的改变而改变，又由于动力装置输出固定的推力，所以在电刷的整个使用寿命过程中，电刷1与滑环2之间的压力都是固定不变的。而在采用恒压簧的现有技术中，在电刷的整个使用寿命过程中，随着电刷长度变化，根据厂家实验数据，电刷1与滑环2之间的压力变化达到7％。
再考虑电刷安装位置对压力的影响，处于上部的电刷以及压力动作机构的自重会增加电刷1与滑环2之间的压力，处于下部的电刷以及压力动作机构的自重会减小电刷1与滑环2之间的压力。
举例来说，电刷压力动作机构元件重量为200g，现以发电行业主力机组较常用的大型石墨电刷为例(尺寸：25.4×38.1×100mm)，新电刷自身总重量约150g，电刷使用寿命终止剩余重量约70g(这个重量是电刷的不可使用部分的重量，可以视作常量)，即电刷可用部分重量约80g(仅电刷可用部分的重量是变量)，电刷工作时所需压力1500g，现仅以上、下部安装的电刷为例作一简要说明：为简便分析各考虑电刷可用重量的一半为40g，则基本实现各电刷压力偏差不超过要求范围(10％)的情况下尽可能接近，即动力装置输出固定不变的力就能够实现；在制造、安装动力装置时以不同功率的动力装置对安装位置不同的电刷施加压力，例如上部安装的动力装置输出固定不变的力为1190g(1500g-200g-70g-40g＝1190g)，下部安装的动力装置输出固定不变的力为1810g(1500g+200g+70g+40g＝1810g)。对于倾角安装、水平安装电刷的压力，也类同分析和理解，不再赘述。
电刷运行真正需要的是滑动工作面压力均衡，现在以简化方案动力装置对电刷施加压力与现技术中恒压簧对电刷施加压力，其差距大小对电刷运行滑动工作面影响作比较分析。
动力装置对电刷施加压力：上、下部安装的电刷不论新旧其电刷运行滑动工作面最大压力差距40+40＝80g，压力差80/1500≈5.4％，不超过电刷压力偏差10％的要求范围。实际生产中的大型发电机，有的机组下部不安装电刷，那 么上部安装与水平安装的电刷压力差距就更小。
恒压簧对电刷施加压力：上、下部安装均为新电刷时其电刷运行滑动工作面最大压力差距150+150＝300g，压力差300/1500＝20％。超过了电刷压力10％要求范围。实际生产中的大型发电机，有的机组下部不安装电刷，那么上部安装与水平安装的电刷，影响电刷运行滑动工作面压力差距的因素有两个：其一是电刷自身重量的影响，最大差距150g，影响电刷运行滑动工作面压力差10％，其二是恒压簧在电刷使用寿命过程中压力的变化，按恒压簧的定义，恒压簧在电刷使用寿命全过程中压力的变化要求不超过10％，根据产品厂家实验数据在7％左右，即恒压簧对新电刷施加的压力大，对使用寿命即将结束的电刷施加的压力小，这样，上部安装的电刷是新电刷、水平安装的电刷是使用寿命即将结束的电刷时，在上述两个因素共同作用下，其压力差距也超过了电刷压力10％要求范围。即便机组全部是水平安装的电刷，恒压簧对电刷施加压力差距在7％左右，而本发明简化方案对上、下部安装的电刷施加压力差距也能够实现在5.4％以内。通过分析，恒压簧对电刷施加压力，对有重量因素影响压力的电刷难以实现电刷运行滑动工作面压力10％的范围。
在现实生产中，有的单位规定电刷使用三分之一必须更换以保持在线运行电刷的长度基本一致达到压力基本均衡的目的，有的单位规定电刷进入刷握3毫米更换，这都将造成电刷浪费；这样的规定虽然造成电刷浪费，也是不得已而为之，况且，恒压簧实际运行中，使用疲劳影响可能更大，铆接簧更换也困难。
以发电行业主力机组较常用的大型石墨电刷为例(尺寸：25.4×38.1×100mm，产品标注使用寿命线约67～69mm)，按使用三分之一更换，浪费是很严重的，这样的浪费没有实现电刷压力均衡，也没有必然地带来电刷安全运行的目的。
此外，电刷压力控制系统采用的动力装置可以是力电机，也可以替代为：推拉电磁铁、电推杆、电液推杆或液压缸，总之，只要是能够对不同安装位置的电刷按要求输出固定的推力的动力装置，都能够应用到上述简化方案中来。
以上说明对本发明而言只是说明性的，而非限制性的，本领域普通技术人员理解，在不脱离权利要求所限定的精神和范围的情况下，可作出许多修改、变化或等效，但都将落入本发明的保护范围之内。

Claims (7)

  1. 一种电刷压力智能控制系统，其特征在于：在电刷的提拉端上设置有力传感器，一个可控动力装置的动子与所述力传感器连接，通过所述力传感器向所述电刷传递推力，所述力传感器再通过控制器与可控动力装置相连，以构成一个闭环控制系统，将所述电刷与所述滑环之间的压力控制在预定范围内。
  2. 根据权利要求1所述的电刷压力智能控制系统，其特征在于：在动子上还连接有直线位置传感器，或者在所述可控动力装置内集成有直线位置传感器，所述直线位置传感器用于记录动子的伸缩距离，并能够计算电刷的剩余长度，所述直线位置传感器与所述控制器相连。
  3. 根据权利要求1所述的电刷压力智能控制系统，其特征在于：所述可控动力装置具有自锁功能；或者，在动子上设有自锁机构，所述自锁机构由动子上的定位凹和动子一侧的弹簧销组成。
  4. 根据权利要求1所述的电刷压力智能控制系统，其特征在于：在所述电刷的提拉端设有提刷机构，所述提刷机构是由弹性材料制成，其中部连接在动子上，两端与电刷的提拉端上的凹孔活动连接。
  5. 根据权利要求1所述的电刷压力智能控制系统，其特征在于：在发电机的每个电刷上都连接所述电刷压力智能控制系统。
  6. 根据权利要求5所述的电刷压力智能控制系统，其特征在于：各个电刷上连接的可控动力装置的控制信息中消除了电刷之外的元件的重量对工作面压力的影响，所述控制信息还随着电刷的长度磨损而相应变化。
  7. 一种电刷压力控制系统，其特征在于：一个动力装置的动子向电刷输出固定的推力。
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