Method for controlling the working gap of a high-precision electromagnetic brake

Abstract

The application discloses a kind of high-precision electromagnetic brake working gap control method, belong to the production technical field of electromagnetic brake, comprising the following steps: measuring part size;The part size data measured is entered into database, and is grouped according to preset grouping interval value respectively;Theoretical working gap minimum value and theoretical working gap maximum value are calculated by the exhaustive combination of a group of each part;The calculation result is compared with the standard working gap minimum value and the standard working gap maximum value of the standard working gap range of preset, to judge whether the combination is qualified;All armatures, brake discs and bushings in qualified combination are marked as qualified, as the related parts of assembling high-precision electromagnetic brake.The application changes the control of working gap from passive, empirical "later remedy" to active, accurate "early design", fundamentally guarantees the consistency and reliability of product.

Description

Technical Field

[0001] This invention belongs to the field of electromagnetic brake manufacturing technology, specifically relating to a method for controlling the working gap of a high-precision electromagnetic brake. Background Technology

[0002] High-precision electromagnetic brakes are key safety and positioning components in servo systems, industrial robots, and precision transmission equipment. The uniformity and size of their working gap (also known as air gap or simply gap) directly determine the brake's response time, braking torque stability, noise level, and service life.

[0003] like Figure 1 As shown, the basic structure of the electromagnetic brake includes a slotted plate 1, an armature 2, a brake disc 3, and a cover plate 4. The armature 2 is located between the slotted plate 1 and the brake disc 3, and the brake disc 3 is located between the armature 2 and the cover plate 4. An electromagnetic coil (not shown in the figure) and a reset spring (not shown in the figure) are installed in the slotted plate 1, and one end of the reset spring presses against the armature 2. The slotted plate 1 and the cover plate 4 are connected by connecting screws 6. The bushing 5 is installed outside the connecting screws 6 and is located between the slotted plate 1 and the cover plate 4, and is located outside the outer periphery of the brake disc 3 and the armature 2. During operation, when the electromagnetic coil is energized, it generates electromagnetic attraction, which overcomes the elastic force of the reset spring and pulls the armature 2 towards the slot 1 and close to the slot 1, thereby separating the armature 2 from the brake disc 3. At this time, the brake disc 3 can rotate normally, and the electromagnetic brake is in the released braking state. When the electromagnetic coil is de-energized, the electromagnetic attraction disappears, and the elastic force of the reset spring causes the armature 2 to press the brake disc 3 tightly onto the cover plate 4, preventing the brake disc 3 from rotating, and the electromagnetic brake is in the braking state.

[0004] When the electromagnetic brake is in braking state, the distance between the slot 1 and the armature 2 is the working clearance G of the electromagnetic brake. This working clearance G is also the maximum moving distance of the armature 2. Its value is within a reasonable range, such as 0.015mm to 0.03mm. If the value is too large or too small, it will be difficult to achieve good braking and release functions at the same time, and the brake volume can be minimized as much as possible.

[0005] The working clearance G of the electromagnetic brake is determined by the thickness of the armature 2, the thickness of the brake disc 3, and the length of the bushing 5. To ensure the accuracy of the working clearance G, the traditional approach is to improve the machining accuracy of the armature 2, brake disc 3, and bushing 5 and reduce machining tolerances. However, this approach makes it difficult to ensure that the working clearance of the assembled product meets the accuracy requirements. The specific drawbacks are as follows:

[0006] Tolerance accumulation is difficult to control: Even if the machining accuracy of a single part is very high (such as ±0.01mm), the accumulation of tolerances of the three parts, armature 2, brake disc 3 and bushing 5, may cause the final working clearance G to deviate from the ideal value, resulting in problems such as "large clearance on one side and small clearance on the other side" or the overall working clearance G being too small / too large.

[0007] Limited post-adjustment methods: Some manufacturers use methods such as adjusting shims or grinding the brake disc 3 / bulb 5. However, adding shims introduces new fit errors and the risk of loosening; grinding the brake disc 3 destroys its surface flatness and friction coefficient consistency, and is inefficient, failing to meet the requirements of high-efficiency and clean production of high-end products; grinding the bushing 5 damages its surface and causes corrosion, and the parallelism of the thickness after grinding is low, causing the working clearance G to change again after the brake is powered on.

[0008] Poor performance consistency: Due to the reliance on the precision of the equipment of the parts manufacturing suppliers to ensure the precision of the parts, the performance (such as the pull-in voltage) of the same batch of brakes may vary significantly, which cannot meet the stringent consistency requirements of high-end applications. Summary of the Invention

[0009] The purpose of this invention is to provide a high-precision electromagnetic brake working clearance control method to solve the above problems. This method can actively and accurately predict and control the final working clearance before assembly.

[0010] The present invention achieves the above objectives through the following technical solutions:

[0011] A method for controlling the working clearance of a high-precision electromagnetic brake, the high-precision electromagnetic brake comprising a slotted disc, an armature, a brake disc, and a cover plate, wherein the armature is located between the slotted disc and the brake disc, the brake disc is located between the armature and the cover plate, the slotted disc and the cover plate are connected by connecting screws, and a bushing is installed outside the connecting screws and located between the slotted disc and the cover plate, and outside the outer peripheral edges of the brake disc and the armature. The method for controlling the working clearance of the high-precision electromagnetic brake includes the following steps:

[0012] Step 1: Before assembling the armature, the brake disc, and the bushing, measure the thickness Ha of the multiple armatures, the thickness Hb of the multiple brake discs, and the length L of the multiple bushings, respectively.

[0013] Step 2: Enter the measured part size data into the database. According to the preset grouping interval value, divide the multiple armatures into m groups according to the thickness range, namely X1, X2, ..., Xm; divide the multiple brake discs into n groups according to the thickness range, namely Z1, Z2, ..., Zn; and divide the multiple bushings into p groups according to the length range, namely C1, C2, ..., Cp.

[0014] Step 3: Exhaustively combine one group from X1, X2, ..., Xm, one group from Z1, Z2, ..., Zn, and one group from C1, C2, ..., Cp. For each combination of three sets of dimensional data, calculate the theoretical minimum working clearance G' using the following formula. min The maximum theoretical working gap G' max :

[0015] G' min =L min -(Ha max +Hb max ),

[0016] G' min =L max -(Ha min +Hb min ),

[0017] Among them, L min L is the minimum length of the bushing in the corresponding combination. max Ha is the maximum length of the bushing in the corresponding combination. max It is the maximum thickness of the armature in the corresponding combination, Ha min It is the minimum thickness of the armature in the corresponding assembly, Hb max It is the maximum thickness of the brake disc in the corresponding combination, Hb min It is the minimum thickness of the brake disc in the corresponding combination;

[0018] Step 4: Calculate the minimum theoretical working clearance G' in the corresponding combination. min The maximum theoretical working gap G' max The minimum standard working clearance G within the preset standard working clearance range. min and the maximum standard working clearance G max Compare, if G' min Not less than G min And G' max Not greater than G max If the condition is met, the combination is considered a valid combination; otherwise, it is considered an invalid combination.

[0019] Step 5: Mark all armatures, brake discs and bushings in the qualified assembly as qualified parts for assembling the high-precision electromagnetic brake.

[0020] Preferably, to avoid wasting qualified products due to irrational grouping leading to missed qualified combinations, in step 4, if the number of unqualified combinations exceeds the set number, the grouping interval value is reduced, and then steps 2-4 are repeated. The minimum interval value can be zero, meaning no further grouping is performed, and all parts are combined exhaustively according to their dimensions. The advantage of this is avoiding the waste of any qualified product; the disadvantage is the high computational cost. However, this method is preferred when relying on a computer and the number of products is not too large.

[0021] Preferably, in order to optimize the product by using parts that can achieve the best results first, in step 5, G' is compared among the qualified combinations. min +G' max The results and G min +G max The smaller the result, the earlier the combination is ranked. According to this principle, the combinations are sorted, and then all the armatures, brake discs and bushings in the top-ranked combinations are selected as the relevant parts for assembling the high-precision electromagnetic brake.

[0022] Preferably, in order to improve measurement accuracy and achieve automated control, in step 1, in a clean environment, a high-precision measuring device is used to measure the thickness Ha of multiple armatures, the thickness Hb of multiple brake discs, and the length L of multiple bushings, and then an automated device is used to complete the warehousing of the relevant parts; in steps 2-4, a computer is used to complete data entry, grouping, calculation, and combination division; in step 5, an automated device is used to complete the warehousing of the relevant parts.

[0023] The beneficial effects of this invention are as follows:

[0024] This invention measures, groups, combines, calculates, and compares all armatures, brake discs, and bushings before assembling the product, pre-screening qualified combinations before assembly. This ensures that the working clearance of the assembled electromagnetic brake meets precision requirements, transforming the control of the working clearance from a passive, experience-based "post-remediation" to a proactive, precise "pre-design," fundamentally guaranteeing product consistency and reliability. Through refined grouping, the minute tolerances of the parts themselves are transformed into usable "resources" rather than accumulated "errors," truly transforming high-cost precision parts into high-performance products. This method achieves a high degree of process and data integration, easily integrating with MES (Manufacturing Execution System) and automated assembly lines to achieve fully automated selection and assembly, significantly improving production efficiency and achieving 100% traceability.

[0025] The electromagnetic brake produced using the control method of this invention can significantly improve the core performance of the electromagnetic brake in the following aspects: Faster response: Uniform and precise gap ensures rapid brake engagement and release; Hysteresis-free: Precisely controlled working gap ensures complete brake disengagement, eliminating accidental friction loss and heat generation; Longer lifespan: Uniform contact avoids uneven wear, extending the service life of the armature and brake disc; Lower noise: Eliminates abnormal engagement impact noise caused by uneven working gap; Achieves high performance with zero break-in period: Traditional brakes may require a short break-in period to reach their optimal state, while products produced using this invention are in optimal working condition upon leaving the factory. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the front cross-sectional structure of the electromagnetic brake described in this invention.

[0027] In the diagram, 1-slotted plate, 2-armature, 3-brake disc, 4-cover plate, 5-bulb, 6-connecting screw. Detailed Implementation

[0028] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0029] like Figure 1 As shown, the high-precision electromagnetic brake of the present invention includes a slotted disc 1, an armature 2, a brake disc 3, and a cover plate 4. The armature 2 is located between the slotted disc 1 and the brake disc 3, and the brake disc 3 is located between the armature 2 and the cover plate 4. The slotted disc 1 and the cover plate 4 are connected by connecting screws 6. A bushing 5 is installed outside the connecting screws 6 and is located between the slotted disc 1 and the cover plate 4, outside the outer peripheral edges of the brake disc 3 and the armature 2. The present invention does not improve the structure of the electromagnetic brake, so it is the same as the structure of the electromagnetic brake in the prior art.

[0030] Combination Figure 1 The high-precision electromagnetic brake working gap control method of the present invention includes the following steps:

[0031] Step 1: Before assembling the armature 2, brake disc 3, and bushing 5, or before assembling the entire electromagnetic brake, measure the thickness Ha of multiple armatures 2, the thickness Hb of multiple brake discs 3, and the length L of multiple bushings 5 ​​respectively, thus obtaining the dimensional data of these parts. In this step, in order to improve measurement accuracy and achieve automated control, in a clean environment, use high-precision measuring equipment to measure the thickness Ha of multiple armatures 2, the thickness Hb of multiple brake discs 3, and the length L of multiple bushings 5, and then use automated equipment to complete the warehousing of the relevant parts.

[0032] Step 2: Enter the measured part size data into the database. Based on the preset grouping interval, divide the multiple armatures 2 into m groups according to the thickness range, namely X1, X2, ..., Xm; divide the multiple brake discs 3 into n groups according to the thickness range, namely Z1, Z2, ..., Zn; and divide the multiple bushings 5 ​​into p groups according to the length range, namely C1, C2, ..., Cp. In this step, in order to achieve automated control, a computer is used to complete the data entry and grouping.

[0033] Step 3: Exhaustively combine one group from X1, X2, ..., Xm, one group from Z1, Z2, ..., Zn, and one group from C1, C2, ..., Cp. Each combination includes one set of armatures 2 (the number of each set depends on the actual interval division and the total number of armatures 2), one set of brake discs 3 (the number of each set depends on the actual interval division and the total number of brake discs 3), and one set of bushings 5 ​​(the number of each set depends on the actual interval division and the total number of bushings 5). For the three sets of dimensional data in each combination, calculate the minimum theoretical working clearance G' using the following formula. min The maximum theoretical working gap G' max :

[0034] G' min =L min -(Ha max +Hb max ),

[0035] G' min =L max -(Ha min +Hb min ),

[0036] Among them, L min L is the minimum length of the bushing in the corresponding combination. max Ha is the maximum length of the bushing in the corresponding combination. max It is the maximum thickness of the armature in the corresponding combination, Ha min It is the minimum thickness of the armature in the corresponding assembly, Hb max It is the maximum thickness of the brake disc in the corresponding combination, Hb min This refers to the minimum thickness of the brake disc in the corresponding combination; in this step, a computer is used to perform the calculation in order to achieve automated control; combination division.

[0037] Step 4: Calculate the minimum theoretical working clearance G' in the corresponding combination. min The maximum theoretical working gap G' max The minimum standard working clearance G within the preset standard working clearance range. min (A known value defined by the manufacturer or industry standards) and the maximum standard working clearance G max(Compare with known values ​​defined by the manufacturer or industry standards) if G' min Not less than G min And G' max Not greater than G max If the result is positive, the combination is considered a qualified combination; otherwise, it is considered an unqualified combination. In this step, to achieve automated control, a computer is used to perform the calculation and combination division. In this step, to avoid missing qualified combinations and wasting qualified products due to unreasonable grouping, if the number of unqualified combinations exceeds the set number, the grouping interval value is reduced, and then steps 2-4 are repeated. The minimum interval value can be zero, that is, no more grouping, but exhaustive combination of all parts dimensions. The advantage of this is to avoid wasting any qualified product, and the disadvantage is that the calculation is large. However, this method is preferred when it relies on a computer and the number of products is not too large.

[0038] Step 5: Mark all armatures 2, brake discs 3, and bushings 5 ​​in the qualified assembly as qualified parts, as they are the relevant parts for assembling the high-precision electromagnetic brake. In this step, in order to optimize the product by using the parts that can achieve the best results first, G' is compared among the qualified assemblies. min +G' max The results and G min +G max The smaller the result, the earlier the combination is ordered. According to this principle, the combinations are sorted, and then all the armatures 2, brake discs 3 and bushings 5 ​​in the first-ranked combinations are selected as the relevant parts for assembling the high-precision electromagnetic brake. In this step, in order to achieve automated control, automated equipment is used to complete the warehousing of the relevant parts.

[0039] The following example illustrates the specific control process of the present invention using a working gap control process applied in the production of a high-precision electromagnetic brake for an assistive robot:

[0040] Example:

[0041] Parts: armature, brake disc, bushing, made of conventional brake metals or composite materials.

[0042] Measurement equipment: High-precision measurement equipment (such as laser displacement sensors or contact micrometers with an accuracy better than 0.001 mm).

[0043] Standard working clearance range: 0.085mm~0.125mm.

[0044] Implementation steps:

[0045] 1. Precision measurement:

[0046] 1000 sets of parts were measured using a laser measuring instrument: the thickness Ha of the armature was found to be between 2.97 and 3.00 mm, the thickness Hb of the brake disc was found to be between 2.88 and 2.90 mm, and the length L of the bushing was found to be between 5.97 and 6.00 mm.

[0047] 2. Data grouping: Armatures and brake discs are spaced 0.01mm apart, and bushings are spaced 0.005mm apart. Armatures are divided into three groups: X1 (2.97-2.98mm), X2 (2.98-2.99mm), and X3 (2.99-3.00mm). Brake discs are divided into two groups: Z1 (2.88-2.89mm) and Z2 (2.89-2.90mm). Bushings are divided into six groups: C1 (5.97-5.975mm), C2 (5.975-5.98mm), C3 (5.98-5.985mm), C4 (5.985-5.99mm), C5 (5.99-5.995mm), and C6 (5.995-6.00mm).

[0048] 3. Calculation of theoretical working clearance: Simulation calculations show a total of 18 combinations that meet the fitting requirements, as shown in the table below:

[0049]

[0050] 4. Determine whether each combination is qualified. The results are shown in the table above.

[0051] 5. The selection system prioritizes the combination that makes the working gap value close to the median value of 0.105mm and within the specified range of 0.085mm~0.125mm from all qualified combinations, such as (X2, Z2, C2) in the table above; the planning system sends instructions to the warehouse management system (WMS) or assembly line to require the parts in the qualified combination to be shipped out in pairs.

[0052] After the staff assembles the products using this method, random checks verify that the working gaps fully meet the design requirements, requiring no rework.

[0053] The above embodiments are merely preferred embodiments of the present invention and are not intended to limit the technical solutions of the present invention. Any technical solution that can be implemented based on the above embodiments without creative effort should be considered to fall within the scope of protection of the patent of the present invention.

Claims

1. A method for controlling the working clearance of a high-precision electromagnetic brake, the high-precision electromagnetic brake comprising a slotted disc, an armature, a brake disc, and a cover plate, wherein the armature is located between the slotted disc and the brake disc, the brake disc is located between the armature and the cover plate, the slotted disc and the cover plate are connected by connecting screws, and a bushing is installed outside the connecting screws and located between the slotted disc and the cover plate, and outside the outer peripheral edges of the brake disc and the armature, characterized in that: The method for controlling the working clearance of the high-precision electromagnetic brake includes the following steps: Step 1: Before assembling the armature, the brake disc, and the bushing, measure the thickness Ha of the multiple armatures, the thickness Hb of the multiple brake discs, and the length L of the multiple bushings, respectively. Step 2: Enter the measured part size data into the database. According to the preset grouping interval value, divide the multiple armatures into m groups according to the thickness range, namely X1, X2, ..., Xm; divide the multiple brake discs into n groups according to the thickness range, namely Z1, Z2, ..., Zn; and divide the multiple bushings into p groups according to the length range, namely C1, C2, ..., Cp. Step 3: Exhaustively combine one group from X1, X2, ..., Xm, one group from Z1, Z2, ..., Zn, and one group from C1, C2, ..., Cp. For each combination of three sets of dimensional data, calculate the theoretical minimum working clearance G' using the following formula. min The maximum theoretical working gap G' max : G’ min =L min -(Ha max +Hb max ), G’ max =L max -(Ha min +Hb min ), Among them, L min L is the minimum length of the bushing in the corresponding combination. max Ha is the maximum length of the bushing in the corresponding combination. max It is the maximum thickness of the armature in the corresponding combination, Ha min It is the minimum thickness of the armature in the corresponding assembly, Hb max It is the maximum thickness of the brake disc in the corresponding combination, Hb min It is the minimum thickness of the brake disc in the corresponding combination; Step 4: Calculate the minimum theoretical working clearance G' in the corresponding combination. min The maximum theoretical working gap G' max The minimum standard working clearance G within the preset standard working clearance range. min and the maximum standard working clearance G max Compare, if G' min Not less than G min And G' max Not greater than G max If the given condition is met, the corresponding combination is considered a qualified combination; otherwise, it is considered an unqualified combination. Step 5: Mark all armatures, brake discs and bushings in the qualified assembly as qualified parts for assembling the high-precision electromagnetic brake.

2. The method for controlling the working gap of a high-precision electromagnetic brake according to claim 1, characterized in that: In step 4, if the number of unqualified combinations exceeds the set number, the grouping interval value is reduced, and then steps 2 to 4 are repeated.

3. The method for controlling the working gap of a high-precision electromagnetic brake according to claim 1 or 2, characterized in that: In step 5, among the qualified combinations, G' is compared. min +G' max The results and G min +G max The smaller the result, the earlier the combination is ranked. Based on this principle, the combinations are sorted, and then all the armatures, brake discs and bushings in the highest-ranked combinations are selected as the relevant parts for assembling the high-precision electromagnetic brake.

4. The method for controlling the working gap of a high-precision electromagnetic brake according to claim 1 or 2, characterized in that: In step 1, in a clean environment, a high-precision measuring device is used to measure the thickness Ha of multiple armatures, the thickness Hb of multiple brake discs, and the length L of multiple bushings. Then, an automated device is used to complete the warehousing of the relevant parts. In steps 2 to 4, a computer is used to complete data entry, grouping, calculation, and combination. In step 5, an automated device is used to complete the warehousing of the relevant parts.

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