WO2020063163A1 - 一种实时监测碟簧力的盘式制动器及监测方法 - Google Patents

一种实时监测碟簧力的盘式制动器及监测方法 Download PDF

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WO2020063163A1
WO2020063163A1 PCT/CN2019/100514 CN2019100514W WO2020063163A1 WO 2020063163 A1 WO2020063163 A1 WO 2020063163A1 CN 2019100514 W CN2019100514 W CN 2019100514W WO 2020063163 A1 WO2020063163 A1 WO 2020063163A1
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Prior art keywords
disc spring
disc
brake
sensor
monitoring
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PCT/CN2019/100514
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English (en)
French (fr)
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张晓光
孙正
徐桂云
刘珍
蒋奇
孙佳胜
张然
张春梅
卢纪丽
Original Assignee
枣庄学院
徐州大恒测控技术有限公司
中国矿业大学
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Application filed by 枣庄学院, 徐州大恒测控技术有限公司, 中国矿业大学 filed Critical 枣庄学院
Priority to RU2021102073A priority Critical patent/RU2756142C1/ru
Publication of WO2020063163A1 publication Critical patent/WO2020063163A1/zh

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D66/00—Arrangements for monitoring working conditions, e.g. wear, temperature
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D55/00—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D66/00—Arrangements for monitoring working conditions, e.g. wear, temperature
    • F16D2066/005—Force, torque, stress or strain

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  • the invention relates to a sensor, in particular to a disc spring sensor and a method for monitoring the force of a disc spring, which are suitable for implementing on-line monitoring of disc spring fatigue.
  • the disc brake is an important braking unit on the hoist equipment and is very important for the braking action of the hoist.
  • the disc brake uses the butterfly spring to generate braking force and releases the brake by oil pressure.
  • the hydraulic pressure pushes the piston, which drives the cylinder, the brake shoe moves, compresses the butterfly spring, and the brake shoe leaves the brake disc, showing a brake release state.
  • the butterfly spring returns to the original compression and deformation state, and the cylinder and the brake shoe are pressed against the brake disc by the spring force to generate a braking force, thereby achieving the purpose of the elevator braking.
  • the butterfly spring is one of the most critical parts to achieve braking.
  • the disc spring In the coal mine safety regulations, if the disc spring is found to be fatigued and worn, it should be replaced immediately. Generally, the inspection of the disc spring is half-year maintenance and one-year overhaul. During disc spring braking, if the disc spring is fatigued, it will lead to a reduction in the positive pressure of the brake, which will cause long braking time, long sliding distance during braking, and small braking torque. Fracture of the reed will cause the brake shoe components to become stuck in the hydraulic cylinder and cannot be released, which can not be found in time, causing serious wear of the brake shoes, and causing the elevator drum to move axially, affecting the braking performance and lifting performance of the elevator.
  • the purpose of the present invention is to overcome the shortcomings of the prior art and provide a butterfly spring sensor with a simple structure and capable of implementing online monitoring of disc spring fatigue.
  • a disc brake for monitoring the force of a disc spring includes a brake disc, a brake shoe assembly, a disc spring, a disc spring seat, a disc spring snap ring, and a hydraulic cylinder.
  • a disc spring sensor is arranged between the disc spring sensors.
  • the outer dimensions of the disc spring sensors are the same as those of the disc springs.
  • the opposite ends of the two sides of the disc spring sensors are provided with annular grooves in the grooves facing the end face of the disc spring seat.
  • a plurality of strain gauges arranged in pairs, the strain gauges arranged in pairs are closely and oppositely attached to the inner diameter and the outer diameter of the annular groove, and the disc spring sensor has radial openings for drawing out a plurality of strain gauge wires.
  • the number of the plurality of strain gauges arranged in pairs is 6-10.
  • the deflection angle ⁇ between the paired strain gauges is 5-10 °.
  • a monitoring method for a disc brake using the above-mentioned disc spring force When the brake is in operation, the disc spring force acts on the disc spring sensor. After the disc spring sensor is pressed, the strain gauge resistance changes, and the bridge will lose its balance. A constant current or voltage power supply is added to the bridge. The bridge will output a voltage signal corresponding to the pressure. The resistance change of the disc spring sensor is converted into a pressure signal output by the bridge. The change in resistance value is detected by the bridge and amplified by the amplifier circuit. After that, the voltage-current converter is used to transform the corresponding current signal. The current signal is compensated by the non-linear correction loop to generate a standard output signal.
  • the data acquisition device is used to connect the disc spring sensor to the multi-lead and the multi-lead.
  • the data of the disc spring sensor is collected and sent to the upper computer for monitoring and monitoring by the staff, so as to realize the online monitoring of the disc spring fatigue condition.
  • the brake completes a braking, When the brake is released, if the value of the disc spring force is less than 90 of the value of the disc spring force in one cycle, When the monitoring device issues a warning that the staff needed to carry out repair and maintenance of disc springs.
  • the present invention utilizes a disc spring sensor without a disc spring seat and a cylinder cylinder cover, and uses the limited space of the existing mine hoist disc brake structure,
  • a disc spring sensor composed of a custom-made disc spring with the same outer dimensions as the original disc spring and a plurality of strain gauges arranged in pairs inside was used to replace the original disc spring near the disc spring seat.
  • the disc spring sensor has the same installation dimensions as the original disc spring, which is convenient for direct replacement on site. It does not need to change the existing performance parameters of the existing brake and the structural dimensions of other parts. It has the dual functions of disc spring force and sensor monitoring.
  • the disc spring force is directly measured to monitor the disc spring fatigue, which greatly improves the reliability of the hoist disc brake. Because the disc spring force can be directly monitored online, the disc spring can be judged to be fatigued and broken to ensure that the disc spring applied with positive braking pressure is intact. Its simple structure, convenient installation and maintenance, high measurement accuracy, and wide practicability.
  • FIG. 1 is a structural diagram of the present invention.
  • FIG. 2 is a front view structural view of a disc spring sensor of the present invention
  • FIG. 3 is a left-side view of a disc spring sensor according to the present invention.
  • the disc brake for monitoring the disc spring force of the present invention is mainly composed of a brake disc 1, a brake shoe assembly 2, a disc spring 3, a disc spring seat 4, a disc spring snap ring 5 and a hydraulic cylinder 6.
  • a disc spring sensor 7 is provided between the disc spring seat 4 and the disc spring 3.
  • the outer dimensions of the disc spring sensor 7 are the same as those of the disc spring 3.
  • a ring-shaped groove is formed on the opposite end surfaces, and a plurality of strain gauges 7-1 are arranged in pairs in the groove facing the end surface of one side of the disc spring seat 4, and the plurality of strain gauges arranged in pairs are 7-1.
  • the number is 6-10 pieces. It is determined according to the actual situation.
  • the a, b, and c shown in Figure 2 indicate the width of the large, medium, and small rings.
  • the openings are slightly smaller than the thickness of the disc spring rings, and the width is 5-8mm.
  • the strain gauges in the examples in the drawings are eight.
  • the strain gauges arranged in pairs are opposite to each other and have an off-angle ⁇ that closely adheres to the inner and outer diameters of the annular groove, and the off-angle ⁇ between the pairs of strain gauges is 5-10 °.
  • the disc spring sensor 7 is a thin and uneven ring strain beam from the structural point of view. It is divided into three rings according to thickness and force.
  • the small ring c is supported on the small diameter of the disc spring 3.
  • the large ring a is supported on the disk.
  • the small ring c is thicker and bears the positive braking pressure P generated by the disc spring 3.
  • the large ring C is also thicker and bears the supporting force P ′ of the disc spring seat 4.
  • the middle ring b is thinner, and the middle ring b is at Strain occurs under the action of the braking positive pressure P and the reaction force P ′.
  • the coil spring sensor 7 is radially opened with a wire hole 7-2 for drawing out a plurality of strain gauge wires, and a large wire a is provided with a wire hole 7-2 that is the same as a ring groove for installing the strain gauge.
  • the disc brake monitoring method for monitoring the disc spring force of the present invention a circle groove is arranged on the side of the disc spring sensor 7 on the side of the disc spring seat 4, and eight strain gauges 7-1 arranged in pairs at the bottom of the groove are biased.
  • the angle ⁇ is 5-10 °, which is closely attached to the inner and outer diameters of the annular groove.
  • the strain gauge 7-1 is subjected to the combined stress of radial bending and axial shear.
  • the combined strain value is proportional to the forces P and P ′. In this way, even if the width of the middle ring b is small, the measurement accuracy is high, and the wire is led out through the cable hole 7-2, thereby obtaining the value of the disc spring force.
  • the strain gauge on the sensor has no external pressure, and the electric bridge is in a balanced state, which is called the zero position;
  • the disc spring force acts on the disc spring sensor 7.
  • the resistance of the strain gauge changes, the bridge will lose balance, a constant current or voltage power supply will be applied to the bridge, and the bridge will output
  • the voltage signal corresponding to the pressure the resistance change of the disc spring sensor 7 is converted into a pressure signal output by the electric bridge, and the change in the resistance value is detected by the electric bridge.
  • a current signal which is compensated by a non-linear correction loop, that is, a standard output signal of 4 to 20 mA in which the input voltage corresponds linearly;
  • a data acquisition device is connected to the coil spring sensor and is led out from the cable hole 7-2.
  • the wires connected to multiple strains collect the data of the disc spring sensor 7 and send it to the upper computer for the staff to observe and monitor.
  • the brake completes a braking and releasing action. If the value of the disc spring force is less than 90% of the initial value of the disc spring in one cycle, the monitoring device issues a warning to remind the staff To repair and maintenance of disc springs.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)
  • Springs (AREA)

Abstract

一种实时监测碟簧力的盘式制动器及监测方法，盘式制动器包括制动盘（1）、闸瓦组件（2）、碟簧（3）、碟簧座（4）、碟簧卡环（5）和液压缸（6），在碟簧座（4）和碟簧（3）之间设有碟簧传感器（7），碟簧传感器（7）的外型尺寸与碟簧（3）相同，碟簧传感器（7）两侧相对的端面上均开有环形凹槽，面向碟簧座（4）一侧端面的凹槽内设置成对排列的多个应变片（7-1）。

Description

一种实时监测碟簧力的盘式制动器及监测方法 技术领域
本发明涉及一种传感器，尤其是一种适用于实现在线监测碟簧疲劳的监测碟簧力的碟簧传感器及方法。
背景技术
矿井提升系统安全、可靠运行将会对国家经济发展以及人民生活水平有积极的意义。煤矿安全事故的引发包括人、提升机、环境等多方面的因素，其中盘式制动器正压力不足是一个比较典型的原因。在煤矿安全生产中，盘式制动器制动的正压力不足是导致提升运输问题的主要原因之一。
盘式制动器是提升机设备上的重要的制动单元，对提升机制动动作非常重要。盘形制动器是由蝶形弹簧产生制动力，靠油压松闸。当液压油进入液压单元时，液压力推动活塞，带动筒体，闸瓦移动，压缩蝶形弹簧，闸瓦离开制动盘，呈松闸状态。当液压单元泄压时，蝶形弹簧回到原始压缩变形状态，筒体、闸瓦在弹簧力作用下压向制动盘产生制动力，实现了提升机制动的目的。从制动器动作过程看，蝶簧是实现制动最关键的零件之一。在煤矿安全规程中，若发现碟簧疲劳和磨损应立即更换，一般碟簧检查为半年检修、一年大修。在碟簧制动过程中，若碟簧片疲劳会导致制动正压力减小，使制动时间长，制动时滑行距离长、制动力矩小等问题，无法实现及时制动；若碟簧片断裂会使闸瓦组件在液压缸中卡死不能松闸，不能及时发现导致闸瓦严重磨损，以及导致提升机滚筒轴向移动，影响提升机制动性能和提升性能。由此可见碟簧的疲劳、磨损或断裂都会给生产带来极大的人员和财产损害。若能够实现直接在线监测碟簧力可及时发现碟簧片疲劳和断裂。现在技术中均是监测制动正压力来监测制动安全，但是盘式制动器的正压力监测与盘式制动器的实际制动正压力存有很大误差，无法实现准确监测制动正压力。从而可以考虑监测碟簧疲劳来达到监测制动安全的问题。
发明内容
技术问题：本发明的目的是克服已有技术的不足之处，提供一种结构简单、能够实现在线监测碟簧疲劳的蝶簧传感器。
技术方案：本发明的一种监测碟簧力的盘式制动器，包括制动盘、闸瓦组件、碟簧、碟簧座、碟簧卡环和液压缸，在所述碟簧座和碟簧之间设有碟簧传感器，所述碟簧传感器的外型尺寸与碟簧相同，碟簧传感器的两侧相对的端面上均开有环形凹槽，面向碟簧座一侧端面的凹槽内成对排列的多个应变片，成对排列的应变片相对且呈偏角α分别紧贴在环形槽内外径上，碟簧传感器的径向开有引出多个应变片导线的排线孔。
所述成对排列的多个应变片个数为6-10片。
所述成对排列的应变片之间的偏角α为5-10°。
一种利用上述监测碟簧力的盘式制动器的监测方法：当制动器工作时，碟簧力作用在碟簧传感器上，碟簧传感器受压后应变片电阻发生变化，电桥将失去平衡，给电桥加一个恒定电流或电压电源，电桥将输出与压力对应的电压信号，碟簧传感器的电阻变化通过电桥转换成压力信号输出，通过电桥检测出电阻值的变化，经过放大电路放大后，再经过电压电流转换器，变换成相应的电流信号，该电流信号通过非线性校正环路的补偿，即产生标准输出信号；利用数据采集装置连接碟簧传感器从排线孔引出的与多个应变相连的导线，采集碟簧传感器的数据并发送至上位机，供工作人员观察监测，从而实现在线监测碟簧疲劳状况；当在一个碟簧力监测周期内，即制动器完成一个制动、松闸动作，若监测到碟簧力数值小于碟簧使用初始值一个周期内碟簧力的90％时，监测设备发出警告，提示工作人员需要对碟簧进行检修与维护。
有益效果：由于采用了上述技术方案，本发明通过在无碟簧座和油缸后盖的碟簧传感器，利用现有的矿井提升机盘式制动器结构的有限空间，在碟簧座与碟簧之间用由一片定制的与原有盘式制动器内碟簧外形尺寸相同且在内部贴有成对排列的多个应变片构成的碟簧传感器替换原有的靠近碟簧座的那片碟簧，碟簧传感器与原有碟簧安装尺寸相同，便于现场直接更换，不需改变现有制动器原有性能参数和其它零件的结构尺寸，具有碟簧受力以及传感器监测的双重作用，碟簧传感器能够直接在测碟簧力，从而监测碟簧疲劳，大大提高了提升机盘式制动器的可靠性。由于可在线直接监测碟簧力，因此可判断碟簧疲劳和断裂情况，确保施加制动正压力的碟簧完好，其结构简单，安装维修方便，测量精度高，具有广泛的实用性。
附图说明
图1为本发明的结构图。
图2为本发明的碟簧传感器主视结构图；
图3为本发明的碟簧传感器左视结构图。
图中：1—制动盘；2—闸瓦组件；3—碟簧；4—碟簧座；5—碟簧卡环；6—液压缸；7—碟簧传感器，7—1—应变片，7-2—排线孔，α—成对排列应变片之间的夹角，P—碟簧制动正压力，P′—碟簧座支反力。
具体实施方式
下面结合附图中的实施例对本发明作进一步的描述：
如图1所示，本发明的监测碟簧力的盘式制动器，主要由制动盘1、闸瓦组件2、碟 簧3、碟簧座4、碟簧卡环5和液压缸6构成，在所述碟簧座4和碟簧3之间设有碟簧传感器7，所述碟簧传感器7的外型尺寸与碟簧3相同，如图2图3所示，碟簧传感器7的两侧相对的端面上均开有环形凹槽，面向碟簧座4一侧端面的凹槽内成对排列的多个应变片7-1，所述成对排列的多个应变片7-1个数为6-10片，根据实际情况确定，图2中所示的a、b、c表示大中小环的宽度，开设的凹槽比碟簧环厚度稍小，宽度为5-8mm。附图实例中的应变片为8片。成对排列的应变片相对且呈偏角α分别紧贴在环形槽内外径上，成对排列的应变片之间的偏角α为5-10°。所述的碟簧传感器7从结构上看是一个薄厚不等的圆环应变梁，按厚度和受力不同分成三环，小环c支撑在碟簧3的小径上，大环a支撑在碟簧座4上，小环c较厚承受碟簧3产生的制动正压力P，大环C也较厚承受碟簧座4的支反力P′,中间环b较薄，中间环b在制动正压力P与支反力P′的作用下产生应变。所述碟簧传感器7的径向开有引出多个应变片导线的排线孔7-2，在大环a上开有与安装应变片环形凹槽相同的排线孔7-2。
本发明的监测碟簧力的盘式制动器监测方法：将碟簧传感器7靠碟簧座4一侧设置一圈环形凹槽，凹槽底部成对排列的八个应变片7-1，以偏角α为5-10°分别紧贴在环形槽内外径上，应变片7-1上受径向弯曲和轴向剪切的复合应力，复合应变值与所受力P和P′成正比，这样可达到即使中间环b的宽度较小,测量精度也较高，并由排线孔7-2引出导线，由此得出碟簧力数值。
当盘式制动器不工作时，传感器上的应变片没有外加压力作用，电桥处于平衡状态，称为零位；
当制动器工作时，碟簧力作用在碟簧传感器7上，碟簧传感器7受压后应变片电阻发生变化，电桥将失去平衡，给电桥加一个恒定电流或电压电源，电桥将输出与压力对应的电压信号，碟簧传感器7的电阻变化通过电桥转换成压力信号输出，通过电桥检测出电阻值的变化，经过放大电路放大后，再经过电压电流转换器，变换成相应的电流信号，该电流信号通过非线性校正环路的补偿，即产生了输入电压成线性对应关系的4～20mA的标准输出信号；利用数据采集装置连接碟簧传感器从排线孔7-2引出的与多个应变相连的导线，采集碟簧传感器7的数据并发送至上位机，供工作人员实进观察监测；当在一个碟簧力监测周期内，即制动器完成一个制动、松闸动作，若碟簧力监测数值小于碟簧使用初始值一个周期内碟簧力的90％时，监测设备发出警告，提示工作人员需要对碟簧进行检修与维护。

Claims (4)

  1. 一种实时监测碟簧力的盘式制动器，包括制动盘(1)、闸瓦组件(2)、碟簧(3)、碟簧座(4)、碟簧卡环(5)和液压缸(6)，其特征在于：在所述碟簧座(4)和碟簧(3)之间设有碟簧传感器(7)，所述碟簧传感器(7)的外型尺寸与碟簧(3)相同，碟簧传感器(7)的两侧相对的端面上均开有环形凹槽，面向碟簧座(4)一侧端面的凹槽内成对排列的多个应变片(7-1)，成对排列的应变片相对且呈偏角α分别紧贴在环形槽内外径上，碟簧传感器(7)的径向开有引出多个应变片导线的排线孔(7-2)。
  2. 根据权利要求1所述的一种实时监测碟簧力的盘式制动器，其特征在于：所述成对排列的多个应变片(7-1)个数为6-10片。
  3. 根据权利要求1所述的一种实时监测碟簧力的盘式制动器，其特征在于：所述成对排列的应变片之间的偏角α为5-10°。
  4. 一种利用权利要求1所述实时监测碟簧力的盘式制动器的监测方法，其特征在于：当制动器工作时，碟簧力作用在碟簧传感器(7)上，碟簧传感器(7)受压后应变片电阻发生变化，电桥将失去平衡，给电桥加一个恒定电流或电压电源，电桥将输出与压力对应的电压信号，碟簧传感器(7)的电阻变化通过电桥转换成压力信号输出，通过电桥检测出电阻值的变化，经过放大电路放大后，再经过电压电流转换器，变换成相应的电流信号，该电流信号通过非线性校正环路的补偿，即产生标准输出信号；利用数据采集装置连接碟簧传感器从排线孔(7-2)引出的与多个应变相连的导线，采集碟簧传感器(7)的数据并发送至上位机，供工作人员观察监测，从而实现在线监测碟簧疲劳状况；当在一个碟簧力监测周期内，即制动器完成一个制动、松闸动作，若监测到碟簧力数值小于碟簧使用初始值一个周期内碟簧力的90％时，监测设备发出警告，提示工作人员需要对碟簧进行检修与维护。
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