Brake Dynamic Monitoring System

I. Principle of the Brake Dynamic Monitoring System

The brake dynamic monitoring system dynamically tracks the operating condition of brakes by employing dedicated pressure sensors installed within the brake assembly, as well as displacement sensors that monitor brake shoe clearance and brake disc runout. Data exchange between the system and the main electrical control unit is facilitated via a PLC. Equipped with proprietary software, the system enables mine operators to access real-time information on equipment safety and operational status anytime, anywhere over the internet. The sensor components and critical subsystems of this brake dynamic monitoring system, independently developed by Jin Mining Group, are all sourced from overseas, thereby enhancing the overall reliability of the system.

II. The brake dynamic monitoring system complies with mandatory regulatory requirements.

1. The ratio of the brake’s total braking torque to the rotational torque of the actual maximum static load being lifted shall be no less than 3.

2. Under all operating conditions and loads, the safe braking deceleration shall be: 1.5 m/s² ≤ braking deceleration ≤ 5.0 m/s².

3. No-load operating time ≤ 0.3 s;

4. The coefficient of friction between the brake shoe and the brake disc is 0.30–0.35.

5. The clearance between the brake shoe and the brake disc shall not exceed 2 mm.

III. Functions of the Brake Dynamic Monitoring System

1. Online monitoring of braking force: Each brake is equipped with an internal pressure sensor that continuously measures the braking force, enabling the calculation of the total braking torque. An industrial PC records and stores the variation in braking force for each brake, allowing detection of disc-spring fatigue and failure. The ratio of the calculated total braking torque to the maximum static load‑induced rotational torque must be no less than 3; otherwise, an alarm is triggered. The pressure sensors are Siemens products, custom‑designed by our company.

2. Online monitoring of brake clearance: Displacement sensors installed on each brake enable real-time monitoring and recording, with pressure sensor data used to analyze the causes of changes in brake clearance; an alarm is triggered when the clearance exceeds 2 mm. The displacement sensors are manufactured by MIB, a German company, offering high accuracy and excellent repeatability.

3. Online monitoring of dead time: An alarm is triggered when the dead time exceeds 0.3 seconds.

4. Online monitoring of brake disc runout: An alarm is triggered when the runout exceeds 0.5 mm.

5. Mine managers can access, anytime and anywhere via the internet, real-time information on equipment safety status as well as the online monitoring processes for items 1 through 4.

IV. Electric Control Cabinet for Dynamic Brake Monitoring:

The electrical control cabinet employs a large‑screen touch panel, a high‑performance Siemens S7‑300 PLC, dedicated signal isolators, and a high‑speed A/D processor to store, process, and analyze real‑time data on brake shoe clearance, brake shoe wear, brake disc runout, and brake pressure. When any measured value exceeds the preset alarm threshold, the system automatically triggers an alarm and transmits this information to the main control unit, thereby ensuring the system’s safety and reliability.

The touchscreen provides monitoring and display functions for the braking system, featuring an excellent human–machine interface.

The braking system can communicate with the main electrical control system via a communication interface and is equipped with dedicated software, enabling mine operators to monitor the equipment’s safe operating status anytime, anywhere over the internet.