1. Introduction to the Disc Brake Online Detection System
The disc brake online detection system is an intelligent safety monitoring solution developed specifically for key equipment such as mine hoists, port machinery, and rail transit. The system uses multi-sensor fusion and AI analysis technology to monitor key parameters in real time, including brake friction coefficient, brake pad wear, and hydraulic pressure, enabling fault warning, performance evaluation, and life prediction. It effectively prevents brake failure accidents and ensures equipment operation.
2. System Composition
1. Core Detection Unit
Detection Module
Friction Coefficient Monitoring: Real-time measurement of the friction coefficient between the brake disc and brake pad to identify performance degradation.
Brake Pad Wear Detection: Laser ranging plus thickness sensor for precise measurement of remaining wear.
Hydraulic Pressure Monitoring: High-precision pressure sensor to monitor fluctuations in brake oil pressure.
Temperature Monitoring: Infrared temperature measurement plus contact sensors to prevent brake overheating.
Vibration Analysis: Accelerometer sensors detect abnormal vibrations to warn of mechanical faults.
2. Intelligent Analysis Platform
Edge Computing Terminal: On-site real-time data processing with response speed under 50ms.
AI Diagnostic Algorithm: Machine learning-based brake performance degradation model.
Cloud Platform: Supports data storage, remote access, and multi-device management.
3. Human-Machine Interface
Local HMI Touchscreen: Real-time display of brake status and alarm information.
Remote Monitoring Center: View data via Web/APP, supports report export on PC.
3. Core Functions
1. Real-time Status Monitoring
7×24 hours continuous monitoring of 12 key parameters.
Sampling frequency up to 1000Hz (dedicated to vibration analysis).
2. Intelligent Warning System
Alarm Type, Trigger Conditions, Response Measures.
Emergency Brake: Friction coefficient <0.35 or abnormal oil pressure triggers automatic backup brake and shutdown.
Level 1 Warning: Brake pad wear reaches 80% or temperature exceeds limit, prompting planned replacement.
Level 2 Warning: Performance drops by 20% or abnormal vibration, recommending maintenance inspection.
3. Diagnostic Functions
Remaining Life Prediction: Calculates brake pad replacement cycle based on wear rate.
Brake Efficiency Evaluation: Generates brake distance-speed characteristic curves.
Fault Tree Analysis: Automatically locates fault sources (hydraulic/mechanical/electrical).
4. Data Management
10 years of data storage (expandable).
Supports automatic generation of compliance reports for ISO 12100 safety standards.
4. Technical Advantages
Traditional Detection Methods vs. This Online Detection System
Manual periodic measurement with long intervals vs. real-time continuous monitoring with no blind spots.
Reliance on experience with large errors vs. AI quantitative analysis with accuracy up to ±1%.
Unexpected failures cannot be predicted vs. early warning of potential risks 3-7 days in advance.
No historical data to support decision-making vs. full lifecycle data traceability.
Shutdown inspections affect production vs. online detection with zero production interference.
5. Typical Applications
Brake Monitoring of a Metal Mine Main Shaft Hoist.
Problem: Overwinding accident caused by brake pad failure.
Solution: Installed an 8-channel online detection system.
Effect: Achieved 3 early warnings, avoided major accidents, and extended brake pad replacement cycle by 30%.
Technical Services
✔ Customized solutions—compatible with various disc brakes (single/multiple brakes, hydraulic/pneumatic).
✔ Rapid deployment—installation of a single device completed within 2-4 hours.
✔ Intelligent upgrades—supports 5G and digital twin expansion.
Keywords
Previous: Full digital low-voltage variable frequency feedback
Disc Brake Online Detection System
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Contact Us
No.99 Hengshan Road, Jianxi District, Luoyang City, Henan Province
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