Stator conductive disc water-cooled excitation eddy current brake and brake control method

Abstract

The application relates to the technical field of electromagnetic braking, and discloses a stator conductive disc water-cooled excitation eddy current brake and a brake control method, which comprise a water cooling system, a stator conductive structure adopting a conductive disc fixed to a stator end, and a reserved adhering interface on the back of the conductive disc, wherein the water cooling system is arranged on the adhering interface and is used for maintaining stable geometric shape and mechanical performance when high-power eddy current heat is absorbed, and through optimization of thickness, diameter and geometric shape, sufficient eddy current energy absorption volume can be formed, and heat can be rapidly guided to a water cooling area, so that high-power density application is supported; and an excitation magnetic pole rotor structure is arranged in a cavity enclosed by the stator conductive structure and is arranged at a rotor end, is used for enabling a magnetic field to form a highly concentrated and directionally stable magnetic flux density distribution in a gap area, and ensuring that the magnetic field uniformly passes through the fixed conductive disc of the stator end under high-speed rotation conditions, so that the eddy current formation efficiency is maximally improved.

Description

Technical Field

[0001] This invention relates to the field of electromagnetic braking technology, and in particular, to a stator conductive disk water-cooled excitation eddy current brake and braking control method. Background Technology

[0002] Eddy current braking, as a non-contact braking technology, is widely used in rail transit, lifting and transportation, industrial test platforms, and energy absorption devices due to its characteristics of no mechanical friction, fast response speed, high reliability, and convenient maintenance. Traditional eddy current brakes typically employ two main structures: one is a combination structure of stator excitation poles and rotor conductive disks, where the excitation source (permanent magnet or electromagnet) is located on the stator side, while the conductive disk, as the main heat source, rotates at high speed with the rotor; the other is a combination structure of rotor magnetic poles and conductive disks, which, although placing the conductive disk on the stator side, still faces the challenge of heat dissipation due to high-speed rotation because the conductive disk is still required to be fixed to the rotor, and the magnetic field is provided by the permanent magnet on the rotor, resulting in an unadjustable magnetic field strength.

[0003] The aforementioned traditional structure has significant technical bottlenecks in high-power-density, high-frequency braking applications, mainly in the following aspects:

[0004] 1. Limited heat dissipation capacity hinders power density improvement. In traditional designs, placing the conductive disk on the high-speed rotating rotor side is constrained by factors such as rotational dynamic balance, sealing reliability, and structural strength, making it difficult to directly integrate efficient, complex, and durable liquid cooling channels onto the conductive disk. Therefore, such structures are typically forced to use cooling methods with low heat transfer coefficients, such as natural air convection or forced air cooling. When the braking system needs to absorb a large amount of kinetic energy in a short time, the enormous eddy current heat generated within the conductive disk cannot be dissipated in time, causing the disk temperature to rise sharply. This easily leads to failure problems such as annealing softening of the conductive material and thermal stress cracking, severely limiting the device's continuous operating capability and power density ceiling.

[0005] 2. Braking torque is difficult to adjust continuously and precisely. For traditional eddy current brakes using permanent magnet excitation, the magnetic field strength is fixed, and the braking force mainly depends on the rotational speed, making it impossible to dynamically match the braking torque according to the kinetic energy differences of the object being braked (such as different masses or different speeds). In applications requiring precise control of braking distance or energy absorption, this unadjustable characteristic results in poor system adaptability and makes it difficult to meet the needs of complex operating conditions.

[0006] 3. Structural reliability challenges of high-speed rotating components. When the conductive disk rotates at high speed as a rotor component, it is not only affected by thermal stress, but also has to withstand huge centrifugal forces. Centrifugal forces may cause plastic deformation of the disk or accelerate fatigue damage. At the same time, the complex stress environment also limits the optimization space of the conductive disk in terms of thickness, geometry and material selection, which is not conducive to achieving the optimal balance between eddy current energy absorption volume and heat dissipation performance.

[0007] In summary, existing eddy current brakes generally suffer from power density bottlenecks due to insufficient heat dissipation, lack of braking force control precision due to unadjustable magnetic fields, and reliability issues caused by structural limitations of high-speed rotating components. Therefore, there is an urgent need for an eddy current brake that can fundamentally solve the problems of heat dissipation, control, and structural reliability to meet the demands for high power density, high frequency, and precise controllable eddy current braking. Summary of the Invention

[0008] This invention provides a stator conductive disk water-cooled excitation eddy current brake and braking control method. By fixing the conductive disk to the stator end and integrating a high-efficiency water-cooling structure, the heat dissipation capacity is greatly improved. At the same time, controllable excitation magnetic poles are arranged at the rotor end to generate an adjustable rotating magnetic field, thereby efficiently generating eddy currents in the fixed conductive disk to achieve braking. This solves the technical problems of traditional eddy current brakes, such as heat dissipation difficulties, limited power density, unadjustable braking force, and poor structural reliability of high-speed rotating components caused by the high-speed rotation of the conductive disk.

[0009] According to one aspect of the present invention, a stator conductive disk water-cooled excitation eddy current brake is provided, comprising: a water-cooling system for rapidly removing heat in a short time to ensure that the temperature remains within a safe operating range under continuous braking conditions; a stator conductive structure employing a conductive disk fixed to the stator end, with a bonding interface reserved on the back of the conductive disk, the water-cooling system being disposed at the bonding interface to maintain stable geometry and mechanical properties when absorbing high-power eddy current heat, and by optimizing the thickness, diameter, and geometry, both sufficient eddy current energy absorption volume can be formed, and heat can be rapidly directed to the water-cooled area, thereby supporting high power density applications; and an excitation magnetic pole rotor structure disposed within the cavity formed by the stator conductive structure and disposed at the rotor end, for forming a highly concentrated and directionally stable magnetic flux density distribution in the air gap region, and ensuring that the magnetic field uniformly passes through the fixed conductive disk at the stator end under high-speed rotation conditions, thereby maximizing eddy current formation efficiency.

[0010] Furthermore, the thickness of the conductive pad is optimized, including: the thickness design of the fixed conductive pad needs to take into account both the eddy current effect and heat dissipation; the lower limit of the conductive pad thickness is set to be greater than the effective penetration depth of the eddy current to avoid insufficient energy absorption caused by the eddy current penetrating to the bottom; and the upper limit of the conductive pad thickness is set to enable the heat inside the pad to be conducted to the water-cooled surface on the back of the conductive pad.

[0011] Furthermore, the thickness of the conductive disk was set to 5mm-20mm, and the optimal thickness was determined through thermal simulation.

[0012] Furthermore, the optimization of the conductive disk thickness also includes: setting the conductive disk thickness to a uniform thickness distribution; or setting the conductive disk thickness to a non-uniform thickness distribution, in order to optimize the eddy current effect and thermal management performance in different regions, thereby achieving a balance between eddy current distribution, structural weight and heat dissipation efficiency.

[0013] Furthermore, the conductive pad adopts an integral copper alloy structure; the bonding interface of the conductive pad includes a heat diffusion layer, and / or the bonding interface of the conductive pad is provided with reinforcing ribs.

[0014] Furthermore, the design of the conductive disk diameter and geometry includes: matching the diameter of the conductive disk with the structure of the excitation pole rotor to ensure that the magnetic field covers the effective eddy current generation area and avoids wasting power due to edge effects; and / or using a corrugated disk surface, a ribbed disk surface, or a grooved disk surface to increase the contact area with the cooling medium of the water cooling system; and / or dividing the disk surface of the conductive disk into a strong magnetic field area and an edge area, with the water cooling system densely distributed in the strong magnetic field area.

[0015] Furthermore, the excitation pole rotor structure includes multiple electromagnet poles arranged at the rotor end, with the multiple electromagnet poles being equally spaced along the circumference of the rotor end; a composite power supply system of brushes and slip rings is used to supply excitation current to the rotating electromagnet poles, so that the magnetic field can rotate synchronously with the rotor, thereby achieving strong magnetic field, high response and wide adjustment range braking torque control.

[0016] Furthermore, the composite power supply system of brushes and slip rings adopts a wide-face contact design and a silver-graphite composite brush material design to maintain stable contact impedance under high current density and long-term repeated use conditions.

[0017] Furthermore, the excitation pole rotor structure optimizes the coil inductance, number of winding turns, and electromagnet pole pitch to enable the electromagnet poles to not only generate a strong magnetic field but also respond to excitation current changes within milliseconds, thereby supporting real-time closed-loop control of braking torque. The combined power supply system of brushes and slip rings dynamically adjusts the excitation current based on the rotor's rotational speed, temperature, and target energy absorption curve. The electromagnet poles on the rotor then instantaneously generate corresponding magnetic flux changes, causing the magnetic field strength in the air gap to change in a controllable manner, directly affecting the vortex generated by the conductive disk. The magnitude of the current allows for continuous, stepless, and rapid adjustment of the braking torque; and / or centrifugal air ducts and embedded heat-conducting blocks are installed around the magnetic pole core of the electromagnet to create a self-cooling effect when the coil rotates at high speed, so as to more effectively prevent the coil from overheating and improve the working stability; and / or by comprehensively optimizing the shape of the electromagnet poles, the length of the pole shoes, the magnetic flux distribution of the electromagnet poles, and the rotor mass, the power density and efficiency of eddy current braking are enhanced, and electromagnetic force pulsation and noise are reduced, so as to perform more reliable and stable in high-speed, high-energy absorption applications.

[0018] Furthermore, the water cooling system includes annular or serpentine water cooling channels. The interface between the water cooling channels and the back of the conductive disk forms a thermally conductive contact interface, so that the heat generated by eddy current heating can be conducted to the cooling medium through the shortest path. Different water cooling channel cross-sections and flow ranges are designed according to braking requirements, and multiple channels are designed in parallel. The optimal flow rate and pressure drop range are determined by CFD thermal analysis to ensure that the temperature of the conductive disk remains within the safe operating range under continuous braking conditions.

[0019] Furthermore, the water cooling system also includes temperature sensors, flow sensors, and pressure monitoring structures to monitor the water cooling status of the system in real time, thereby avoiding thermal runaway problems caused by blockage of water cooling channels, air resistance, or pump failure.

[0020] According to another aspect of the present invention, a stator conductive disk water-cooled excitation eddy current braking control method is also provided. Employing the aforementioned stator conductive disk water-cooled excitation eddy current brake, the method includes the following steps: A braking torque adjustment method based on excitation current is adopted. By real-time monitoring of rotor speed, conductive disk temperature, water-cooling system status, and the kinetic energy to be absorbed, a suitable excitation current command value is calculated, and the drive power supply outputs a stable current, thereby achieving precise adjustment of the braking torque. In the initial braking stage, when the rotor speed is high, a large excitation current is applied according to the target absorbed energy and the rate of change of speed, causing the braking torque to rise rapidly in order to quickly absorb most of the kinetic energy. As the rotor speed decreases, the inherent torque decay characteristic of eddy current braking will naturally reduce the braking torque. At this time, the excitation current is gradually reduced to ensure a stable torque output at low speeds. Simultaneously, to prevent excessive temperature, the excitation current is dynamically limited to ensure that the conductive disk temperature does not exceed a set threshold, achieving coupled control of thermal protection and braking torque, making the entire braking process both safe and efficient.

[0021] The present invention has the following beneficial effects: 1. In terms of heat dissipation and thermal management, since the conductive disk is fixed to the stator end, it is no longer limited by dynamic balance, sealing and structural strength caused by high-speed rotation, making it possible to directly integrate a complex and efficient water cooling system on the back of the conductive disk. The water cooling system is in close contact with the conductive disk through a high thermal conductivity bonding interface, which can quickly dissipate the high-power heat generated during eddy current braking in a short time. Compared with the traditional air cooling or indirect cooling of the rotating disk, this direct water cooling method significantly improves the heat exchange efficiency, thereby effectively suppressing the temperature rise of the conductive disk, avoiding material annealing and softening and thermal stress cracking caused by overheating, and ensuring that the conductive disk can still maintain a stable geometric shape and mechanical properties under continuous braking conditions. This solves the power density bottleneck and high-frequency braking failure problem caused by insufficient heat dissipation capacity of traditional eddy current brakes.

[0022] 2. In terms of braking force control, by arranging the excitation poles at the rotor end and adopting a controllable excitation method, the excitation current can be dynamically adjusted according to the kinetic energy requirements of the object being braked, thereby changing the magnetic field strength passing through the stator conductive disk. This adjustable rotating magnetic field makes the braking force no longer solely dependent on the rotational speed, realizing continuous and precise adjustment of the braking torque, effectively solving the technical problems of the traditional permanent magnet excitation method, which suffers from the inability to adjust the braking force and poor system adaptability due to the fixed magnetic field.

[0023] 3. In terms of structural reliability, the conductive disk fixed to the stator end is completely free from the influence of high-speed rotation centrifugal force, and there is no need to consider the problems of disk deformation and fatigue damage caused by centrifugal force. This static structure provides ample design space for optimizing the thickness, diameter and geometry of the conductive disk, so that it can form a sufficient eddy current energy absorption volume and quickly guide heat to the water-cooling area, achieving the optimal balance between eddy current effect and heat dissipation performance, thereby significantly improving the structural reliability and service life of the brake.

[0024] 4. Regarding eddy current formation efficiency, the excitation magnetic poles rotate at high speed with the rotor, forming a highly concentrated and directionally stable magnetic flux density distribution in the air gap region, ensuring that the magnetic field can pass through the fixed conductive disk at the stator end uniformly and efficiently; this structural configuration maximizes the eddy current formation efficiency, thereby improving braking performance.

[0025] In addition to the objectives, features, and advantages described above, the present invention has other objectives, features, and advantages. The invention will now be described in further detail with reference to the figures. Attached Figure Description

[0026] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is one of the structural schematic diagrams of a water-cooled excitation eddy current brake for a stator conductive disk according to a preferred embodiment of the present invention; Figure 2 This is the second schematic diagram of the structure of the stator conductive disk water-cooled excitation eddy current brake of the preferred embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of a composite power supply system of brushes and slip rings according to a preferred embodiment of the present invention.

[0027] Legend: 100. Water cooling system; 200. Stator conductive structure; 201. Conductive disk; 300. Excitation pole rotor structure; 301. Electromagnet pole; 302. Coil; 400. Rotor; 500. Composite power supply system of brush and slip ring; 501. Graphite disk; 502. Metal brush; 503. Wire. Detailed Implementation

[0028] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings. However, the present invention can be implemented in many different ways as defined and covered below.

[0029] like Figure 1 and Figure 2As shown, the stator conductive disk water-cooled excitation eddy current brake of this embodiment includes: a water-cooling system 100, used to quickly remove heat in a short time to ensure that the temperature remains within a safe operating range under continuous braking conditions; a stator conductive structure 200, which adopts a conductive disk 201 fixed to the stator end, with a bonding interface reserved on the back of the conductive disk 201, and the water-cooling system 100 is arranged at the bonding interface to maintain stable geometry and mechanical properties when absorbing high-power eddy current heat, and by optimizing the thickness, diameter and geometry, it can form a sufficient eddy current energy absorption volume and quickly guide heat to the water-cooled area, thereby supporting high power density applications; and an excitation magnetic pole rotor structure 300, arranged in the cavity formed by the stator conductive structure 200 and arranged at the rotor end, used to form a highly concentrated and directionally stable magnetic flux density distribution in the air gap region, and to ensure that the magnetic field uniformly passes through the fixed conductive disk 201 at the stator end under high-speed rotation conditions, thereby maximizing the eddy current formation efficiency. This invention relates to a stator conductive disc water-cooled excitation eddy current brake. By fixing the conductive disc 201 to the stator end and integrating a high-efficiency water-cooling system 100, while arranging controllable excitation poles at the rotor end, the conductive disc 201, fixed to the stator end, is no longer subject to the limitations of dynamic balance, sealing, and structural strength caused by high-speed rotation. This makes it possible to directly integrate the complex and efficient water-cooling system 100 on the back of the conductive disc 201. The water-cooling system 100 is in close contact with the conductive disc 201 through a high thermal conductivity bonding interface, which can quickly dissipate the high-power heat generated during eddy current braking in a short time. Compared with the traditional air cooling or indirect cooling of the rotating disc, this direct water cooling method significantly improves the heat exchange efficiency, thereby effectively suppressing the temperature rise of the conductive disc 201 and avoiding material annealing and softening and thermal stress cracking caused by overheating. This ensures that the conductive disc 201 can maintain a stable geometric shape and mechanical properties under continuous braking conditions, solving the power density bottleneck and high-frequency braking failure problem caused by insufficient heat dissipation capacity in traditional eddy current brakes. By arranging the excitation poles (electromagnet poles 301) at the rotor end and employing a controllable excitation method, the excitation current can be dynamically adjusted according to the kinetic energy requirements of the braked object, thereby changing the magnetic field strength passing through the stator conductive disk 201. This adjustable rotating magnetic field makes the braking force no longer solely dependent on the rotational speed, achieving continuous and precise adjustment of the braking torque. This effectively solves the technical problems of the traditional permanent magnet excitation method, which suffers from unadjustable braking force and poor system adaptability due to a fixed magnetic field. The conductive disk 201, fixed at the stator end, completely eliminates the influence of high-speed rotating centrifugal force, eliminating the need to consider issues such as disk deformation and fatigue damage caused by centrifugal force. This static structure provides ample design space for optimizing the thickness, diameter, and geometry of the conductive disk 201, enabling it to form sufficient eddy current energy absorption volume while rapidly directing heat to the water-cooling area. This achieves an optimal balance between eddy current effect and heat dissipation performance, significantly improving the structural reliability and service life of the brake.The excitation poles rotate at high speed with the rotor 400, forming a highly concentrated and directionally stable magnetic flux density distribution in the air gap region. This ensures that the magnetic field can pass through the fixed conductive disk 201 at the stator end uniformly and efficiently. This structural configuration maximizes the formation efficiency of eddy currents, thereby improving braking performance. The stator conductive disk water-cooled excitation eddy current brake of this invention, through the synergistic effect of the combination of the fixed conductive disk 201 and direct water cooling, and the combination of the rotating excitation poles (electromagnet poles 301) and the controllable magnetic field, produces synergistic gains in terms of improving heat dissipation capacity, achieving adjustable braking force, enhancing structural reliability, and optimizing eddy current efficiency. It overcomes the key technical defects of traditional eddy current brakes and provides an effective solution for high power density, high frequency, and precisely controllable eddy current braking applications.

[0030] In this embodiment, the thickness optimization of the conductive disk 201 includes: the thickness design of the fixed conductive disk 201 needs to balance eddy current effect and heat dissipation; the lower limit of the thickness of the conductive disk 201 is set to be greater than the effective penetration depth of the eddy current to avoid insufficient energy absorption due to eddy current penetration to the bottom; the upper limit of the thickness of the conductive disk 201 is set to allow the heat inside the disk to be conducted to the water-cooled surface on the back of the conductive disk 201. By setting the lower limit of the thickness to be greater than the effective penetration depth of the eddy current, it is ensured that the magnetic field can fully penetrate inside the conductive disk 201, avoiding the eddy current penetration effect due to the disk being too thin. This ensures that the conductive disk 201 can form a sufficient eddy current energy absorption volume, maximizing the use of the material to generate braking force and effectively improving the eddy current braking efficiency. By setting the maximum thickness to allow for efficient heat transfer from the internal surface of the disk to the water-cooled back surface, the thermal resistance inside the conductive disk 201 is effectively controlled. This design prevents excessive heat buildup and the formation of a high-temperature core area due to excessive disk thickness. It ensures that the heat generated by eddy currents can be efficiently transferred from the disk itself to the tightly fitted water-cooling system 100 on the back, thus achieving rapid heat dissipation. This solves the problem of localized overheating caused by excessively long heat dissipation paths in traditional designs, ensuring the temperature uniformity and structural stability of the conductive disk 201 under continuous high-power braking conditions. The thickness optimization scheme, by balancing the eddy current effect and heat dissipation path, effectively improves heat dissipation performance while ensuring eddy current energy absorption efficiency. This enables the conductive disk 201 to support high power density applications, avoiding performance degradation and structural failure due to insufficient energy absorption or poor heat dissipation. It provides structural assurance for the reliable operation of the stator conductive disk water-cooled excitation eddy current brake.

[0031] In this embodiment, the thickness of the conductive disk 201 is set to 5mm-20mm, and the optimal thickness is determined through thermal simulation. Setting a thickness range of 5mm to 20mm provides a reasonable design space for the conductive disk 201 to balance eddy current effect and heat dissipation performance. The lower limit of the range is 5mm, which ensures that the conductive disk 201 has sufficient thickness to exceed the effective penetration depth of the eddy current, thereby avoiding the eddy current penetration effect due to the disk being too thin. This ensures that the magnetic field fully penetrates within the conductive disk 201 to form an effective eddy current energy absorption volume, maintaining the necessary braking performance. The upper limit of the range is 20mm, which limits the maximum thickness of the conductive disk 201, preventing the internal heat conduction path from being too long and the thermal resistance from being too high due to the disk being too thick. This ensures that the heat generated by the eddy current can be conducted to the back water cooling system 100 in a timely manner, avoiding the accumulation of internal heat to form a high-temperature area and ensuring heat dissipation efficiency. By employing thermal simulation to determine the optimal thickness, the thickness of the conductive disk 201 can be precisely optimized for specific application conditions, magnetic field distribution, and the performance of the water-cooling system 100. Thermal simulation technology can simulate the eddy current distribution, heat generation, and heat conduction processes inside the conductive disk 201 at different thicknesses, thereby determining the specific thickness value that achieves the best balance between eddy current energy absorption efficiency and heat dissipation performance under specific conditions. This simulation-based optimization method avoids the blindness of relying solely on experience-based design, making the design of the conductive disk 201 thickness more scientific and targeted, ensuring the performance and reliability of the brake in high-power-density applications. The technical solution combining thickness range limitation and thermal simulation optimization not only ensures the balance between eddy current energy absorption and heat dissipation performance of the conductive disk 201, but also achieves precise thickness optimization through scientific design methods, providing structural and performance guarantees for the stable operation of the stator conductive disk 201 water-cooled excitation eddy current brake under high-power-density conditions.

[0032] In this embodiment, the thickness optimization of the conductive disk 201 further includes: setting the thickness of the conductive disk 201 to a uniform thickness distribution; or setting the thickness of the conductive disk 201 to a non-uniform thickness distribution, in order to optimize the eddy current effect and thermal management performance in different regions, thereby achieving a balance between eddy current distribution, structural weight, and heat dissipation efficiency. The uniform thickness distribution scheme provides the technical effects of simple structure, easy manufacturing, and predictable performance; by setting the entire conductive disk 201 to the same thickness, it is beneficial to ensure that the penetration depth of the magnetic field is consistent throughout the disk surface, thereby forming a relatively uniform eddy current distribution; this uniformity simplifies the complexity of thermal management design, making the heat conduction path inside the disk relatively consistent, which helps to achieve stable heat dissipation performance and is suitable for application scenarios where the magnetic field distribution is relatively uniform or where there are strict limitations on structural complexity. The non-uniform thickness distribution scheme achieves a more optimized technical effect by designing the thickness differently according to the functional requirements of different areas. In areas with strong magnetic fields or poor heat dissipation, the thickness can be appropriately increased to enhance the eddy current energy absorption volume and improve heat capacity; while in areas with weak magnetic fields or excellent heat dissipation, the thickness can be appropriately reduced to reduce structural weight and shorten the heat conduction path. This non-uniform design allows the conductive disk 201 to dynamically balance the relationship between eddy current generation efficiency, structural lightweight, and heat dissipation efficiency according to the magnetic field distribution and heat dissipation requirements under actual working conditions. For example, increasing the thickness in the edge magnetic field concentration area can enhance the eddy current effect, while reducing the thickness in the central heat dissipation favorable area can optimize weight and heat dissipation, thereby achieving an overall optimal balance between eddy current distribution, structural weight, and heat dissipation efficiency. The thickness distribution scheme provides two design paths, uniform and non-uniform, enabling the conductive disk 201 to flexibly optimize the configuration of eddy current effect, thermal management performance and structural characteristics according to the specific needs of different application scenarios. The uniform thickness distribution ensures the stability of performance and the convenience of manufacturing, while the non-uniform thickness distribution further explores the potential for performance optimization, realizing a more refined design and higher overall performance, and providing structural support for the adaptability, reliability and performance of the stator conductive disk water-cooled excitation eddy current brake.

[0033] In this embodiment, the conductive disk 201 adopts an integral copper alloy structure; the bonding interface of the conductive disk 201 includes a heat diffusion layer, and / or the bonding interface of the conductive disk 201 is provided with reinforcing ribs. The integral copper alloy structure of the conductive disk 201 fully utilizes the dual advantages of high electrical conductivity and high thermal conductivity of copper alloy; the high electrical conductivity ensures that eddy currents of sufficient strength can be generated under the action of a magnetic field, thereby ensuring braking performance; the high thermal conductivity is conducive to the rapid conduction of heat generated by eddy currents to the back of the disk, laying the foundation for efficient heat dissipation through the subsequent water cooling system 100; the integral structure avoids the interface thermal resistance, weak points in mechanical strength and potential failure risks that may be introduced by splicing or assembly, and improves the mechanical strength, thermal uniformity and long-term working reliability of the conductive disk 201. A heat diffusion layer at the bonding interface effectively improves the heat conduction performance between the conductive disk 201 and the water cooling system 100. This heat diffusion layer can rapidly and evenly spread the heat generated within the conductive disk 201 to the entire bonding interface, reducing local heat flux and preventing localized high temperatures caused by heat concentration at the bonding interface. This reduces interface thermal resistance, improves the efficiency of heat transfer to the water cooling system 100, and further enhances heat dissipation capacity. Reinforcing ribs at the bonding interface primarily enhance the mechanical structural strength and deformation resistance of the conductive disk 201. The reinforcing ribs effectively resist warping or deformation of the disk body caused by thermal stress, ensuring a tight and stable contact between the bonding interface and the water cooling system 100, maintaining a low thermal resistance state at the interface. The reinforcing ribs also improve the structural stability of the conductive disk 201 under high-speed airflow or vibration environments, preventing structural deformation from affecting the magnetic field gap or causing mechanical failure.

[0034] In this embodiment, the diameter and geometry design of the conductive disk 201 include: matching the diameter of the conductive disk 201 with the excitation pole rotor structure 300 to ensure that the magnetic field covers the effective eddy current generation area and avoids wasted power due to edge effects; and / or the conductive disk 201 adopts a corrugated disk surface, a ribbed disk surface, or a grooved disk surface to increase the contact area with the cooling medium of the water cooling system 100; and / or the disk surface of the conductive disk 201 is divided into a strong magnetic field area and an edge area, with the water cooling system 100 densely distributed in the strong magnetic field area. Matching the diameter of the conductive disk 201 with the excitation pole rotor structure 300 ensures that the magnetic field can cover the effective eddy current generation area of ​​the conductive disk 201, avoiding power waste caused by a weak magnetic field and low eddy current effect in the edge area due to an excessively large disk diameter, and also preventing reduced braking efficiency due to insufficient utilization of part of the magnetic field caused by an excessively small disk diameter; this size matching design optimizes the utilization efficiency of the magnetic field and improves the overall efficiency of eddy current braking. By employing non-planar disk structures such as wave-shaped, ribbed, or grooved designs, the contact area between the conductive disk 201 and the cooling medium of the water-cooling system 100 is increased. This increased contact area design improves the efficiency of heat transfer from the conductive disk 201 to the cooling medium, enhances convective heat transfer, and thus can more quickly remove the heat generated by eddy currents, effectively suppressing disk temperature rise and improving heat dissipation performance, making it particularly suitable for high power density braking conditions. The conductive disk 201 is divided into a strong magnetic field area and an edge area, with the water-cooling system 100 densely distributed in the strong magnetic field area, achieving precise matching between heat dissipation resources and heat generation sources. Since the strong magnetic field area is the main region for eddy current generation and also the area where heat generation is most concentrated, the dense arrangement of the water-cooling system 100 in this area can specifically enhance heat dissipation, ensuring that heat from high heat flux areas is dissipated in a timely and efficient manner, avoiding local overheating and achieving optimal heat dissipation efficiency. The design of the diameter and geometry of the conductive disk 201, through size matching, surface morphology optimization, and partitioned layout of the cooling structure, produces a synergistic gain effect in terms of improving the eddy current effect, enhancing heat dissipation capacity, and optimizing system efficiency. This enables the stator conductive disk water-cooled excitation eddy current brake to achieve high power density, high efficiency, and high reliability braking performance.

[0035] like Figure 1 and Figure 2As shown, in this embodiment, the excitation pole rotor structure 300 includes multiple electromagnet poles 301 arranged at the rotor end, with the multiple electromagnet poles 301 spaced at equal intervals along the circumference of the rotor end. A composite power supply system 500 using brushes and slip rings supplies excitation current to the rotating electromagnet poles 301, so that the magnetic field can rotate synchronously with the rotor 400, achieving strong magnetic field, high response, and wide adjustment range braking torque control. The multiple electromagnet poles 301 arranged at equal intervals along the circumference of the rotor 400 ensure that the magnetic field distribution on the stator conductive disk 201 is periodic, uniform, and stable during the rotation of the rotor 400. This uniform magnetic field distribution is conducive to the formation of stable and efficient eddy currents within the conductive disk 201, avoiding braking force fluctuations or local overheating caused by uneven magnetic field distribution, thereby improving the smoothness of the braking process and the overall efficiency of eddy current formation. A composite power supply system 500 using brushes and slip rings supplies excitation current to the rotating electromagnet poles 301, solving the problem of power and signal transmission between rotating and stationary components. This system enables a stable and reliable supply of controllable excitation current to the electromagnet poles 301 even when the rotor 400 is rotating at high speed. This allows the magnetic field to rotate synchronously with the rotor 400, creating a rotating magnetic field with relative motion between the stator conductive disk 201 and the rotor 400, thus facilitating efficient eddy current braking. By controlling the magnitude of the excitation current, continuous and precise adjustment of the magnetic field strength can be achieved. This allows for wide-range dynamic control of the braking torque based on actual needs (such as the kinetic energy of the object being braked, the target braking distance, etc.). This achieves braking torque control with a strong magnetic field, high response, and wide adjustment range, overcoming the limitation of the unadjustable magnetic field in traditional permanent magnet excitation methods and significantly improving the adaptability and control accuracy of the braking system.

[0036] like Figure 3As shown, in this embodiment, the composite power supply system 500 of brush and slip ring adopts a wide-area contact design and a silver-graphite composite brush material design to maintain stable contact impedance under high current density and long-term repeated use conditions. The wide-area contact design reduces the current density per unit area by increasing the effective contact area between the brush and slip ring. Under the condition of transmitting high excitation current, this design can effectively disperse the current and avoid local overheating, arc erosion and contact point burning caused by current concentration, thereby maintaining the physical stability of the contact interface. The larger contact area also helps to maintain a uniform distribution of contact pressure during long-term use, reducing the risk of poor contact due to vibration or wear, and providing a stable physical basis for high current transmission. The silver-graphite composite brush design combines the high electrical and thermal conductivity of silver with the self-lubricating and arc-resistant properties of graphite. The silver component ensures extremely low resistance at the contact points, which helps reduce contact voltage drop and heat generation, improving power transmission efficiency. The graphite component provides excellent lubrication, reducing friction and wear between the brush and slip ring, enhancing the system's lifespan. Its arc-resistant properties suppress sparks or arcs that may occur during high-current switching, protecting the contact surface. This composite material allows the brush to maintain stable contact impedance under high current density and long-term repeated use conditions, preventing increased power loss or control signal distortion due to increased contact resistance. The synergistic application of the wide-area contact design and the silver-graphite composite brush effectively solves the contact stability and durability issues under high current density transmission by optimizing the contact area and contact material properties. This ensures that the excitation current can be stably and efficiently transmitted to the rotating excitation poles (electromagnet pole 301), providing a power transmission guarantee for long-term reliable and highly responsive adjustable magnetic field control of the stator conductive disk water-cooled excitation eddy current brake. Optionally, such as Figure 3 As shown, the composite power supply system 500 of brushes and slip rings includes a graphite disk 501, metal brushes 502, and wires 503. The graphite disk 501 is part of the stator, and the metal brushes 502 are part of the rotor 400 and rotate with the rotor 400 and the electromagnet poles 301. Since the graphite disk 501 is conductive, after the graphite disk 501 is connected to an external power source, power is supplied to the electromagnet poles 301 through the metal brushes 502 and the wires 503. Because the graphite disk 501 has self-lubricating properties, the metal brushes 502 and the graphite disk 501 are powered by frictional contact (the principle is similar to that of a brushed motor, a tram, etc.). Optionally, the electromagnet poles 301 and the wires 503 are arranged in a one-to-one correspondence. Optionally, a set of metal brushes 502 is provided with 3-5 wires 503; one set of metal brushes 502 can be provided, or multiple sets can be provided.

[0037] like Figure 3As shown, in this embodiment, the excitation pole rotor structure 300 optimizes the coil inductance, winding turns, and electromagnet pole pitch 301 so that the electromagnet pole 301 can not only generate a strong magnetic field but also respond to excitation current changes within milliseconds, thereby supporting real-time closed-loop control of braking torque; and / or the composite power supply system 500 of brushes and slip rings dynamically adjusts the excitation current according to the rotational speed, temperature, and target energy absorption curve of the excitation pole rotor structure 300. The electromagnet pole 301 on the rotor 400 then instantaneously generates a corresponding change in magnetic flux, causing the magnetic field strength in the air gap to change in a controllable manner, and directly affecting the conductive disk 201. The magnitude of the generated eddy currents enables continuous, stepless, and rapid adjustment of the braking torque; and / or centrifugal air ducts and embedded heat-conducting blocks are arranged around the magnetic core of the electromagnet pole 301, so that the coil 302 forms a self-cooling effect when rotating at high speed, so as to more effectively prevent the coil 302 from overheating and improve the working stability; and / or by comprehensively optimizing the shape of the electromagnet pole 301, the length of the pole shoe of the electromagnet pole 301, the magnetic flux distribution of the electromagnet pole 301, and the mass of the rotor 400, the power density and efficiency of eddy current braking are enhanced, and electromagnetic force pulsation and noise are reduced, so as to perform more reliable and stable performance in high-speed and high-energy absorption applications. By optimizing the inductance, number of winding turns, and pole pitch of coil 302, the response speed of the excitation system is improved, enabling the excitation poles (electromagnet poles 301) to respond to changes in excitation current within milliseconds, thus supporting real-time closed-loop control of braking torque. This rapid response capability ensures that the braking system can accurately and promptly adjust the braking force according to the real-time operating conditions of the braked object (such as speed and kinetic energy), meeting the requirements of high-frequency, high-precision braking control. The brush and slip ring composite power supply system dynamically adjusts the excitation current based on the rotational speed, temperature, and target energy absorption curve, achieving continuous, stepless, and rapid adjustment of braking torque. By providing real-time feedback of parameters such as rotational speed and temperature, combined with the preset target energy absorption curve, the excitation current can be precisely controlled, causing the electromagnet poles 301 to instantly generate corresponding magnetic flux changes, thereby controlling the air gap magnetic field strength and directly affecting the magnitude of eddy currents generated by the conductive disk 201. This dynamic adjustment mechanism overcomes the defect of the non-adjustable braking force of traditional eddy current brakes, achieving precise and flexible control of braking torque and improving the adaptability and intelligence level of the braking system. Centrifugal air ducts and embedded heat-conducting blocks are set around the magnetic pole core. The centrifugal force generated by the high-speed rotation of the rotor 400 forms forced air cooling. At the same time, the heat conduction blocks enhance the heat dissipation of the coil 302, forming a self-cooling effect. This effectively prevents the insulation aging or performance degradation of the excitation coil (coil 302) due to overheating, and improves the working stability and reliability of the excitation system under high-speed and high-power conditions.By comprehensively optimizing the magnetic pole shape, pole shoe length, magnetic flux distribution, and rotor 400 mass, the power density and efficiency of eddy current braking are further enhanced. The optimized magnetic pole shape and magnetic flux distribution facilitate the formation of a more concentrated and uniform air gap magnetic field, improving eddy current generation efficiency. The optimized pole shoe length and rotor 400 mass help reduce electromagnetic force pulsation and noise, and reduce vibration and mechanical stress, thus resulting in more stable, reliable, and reliable performance in high-speed, high-energy absorption applications. By improving the excitation response speed, achieving real-time dynamic adjustment of braking force, enhancing the heat dissipation capacity of the excitation system, and optimizing the magnetic pole structure and rotor 400 performance, synergistic gains are achieved in braking force control accuracy, response speed, system stability, and overall efficiency. This provides magnetic field generation, regulation, and stability guarantees for achieving high power density, high reliability, and intelligent braking control in stator conductive disc water-cooled excitation eddy current brakes. Optionally, the inductance of coil 302, the number of turns of the winding, and the pole pitch of electromagnet 301 can be optimized. Specifically, the inductance of the excitation coil can be precisely controlled by adjusting the number of turns of the coil winding, the cross-sectional area of ​​the wire 503, and the winding method. At the same time, the pole pitch is optimized (usually a smaller pole pitch is used to reduce the magnetic circuit resistance and shorten the magnetic flux establishment time). This allows the excitation system to have a low electromagnetic time constant while taking into account the ability to generate a strong magnetic field. This ensures that when the excitation current command changes, the magnetic flux can be established or decayed at a speed of milliseconds, thereby realizing real-time closed-loop control of the braking torque. Optionally, the shape of the electromagnet pole 301, the length of the pole shoe of the electromagnet pole 301, the magnetic flux distribution of the electromagnet pole 301, and the mass of the rotor 400 are comprehensively optimized. Specifically, by using finite element electromagnetic-structural coupling simulation, the shape of the pole (such as using an arc surface or a conical surface to optimize the air gap magnetic field distribution), the length of the pole shoe (adjusted to balance the magnetic flux concentration and leakage magnetic loss), the magnetic flux distribution (by optimizing the magnetic circuit design to make the magnetic field uniformly cover the effective area of ​​the stator conductive disk), and the mass of the rotor 400 (under the premise of ensuring structural strength, lightweight design is carried out to reduce the moment of inertia) are optimized in a multi-objective collaborative manner. In this way, while ensuring the output of a strong magnetic field, the electromagnetic force pulsation and vibration noise caused by magnetic field harmonics are reduced, and a high power density, high efficiency, and stable and reliable eddy current braking effect is achieved. This invention constructs an active braking control closed loop based on a millisecond-level fast-response excitation system. Specifically, by optimizing the parameters of the excitation coil (coil 302) and the magnetic pole structure, the excitation current is precisely controllable, thereby driving the rotor 400 to generate a rotating magnetic field with controllable intensity and distribution. When this magnetic field passes through the conductive disk 201 fixed at the stator end, it excites eddy currents of corresponding magnitude, thereby converting the electronic control signal into a braking force that can be adjusted in real time. At the same time, in conjunction with the thermal management of air cooling on the rotor side and water cooling on the stator side, the problem of non-adjustable braking force and thermal runaway under high power conditions of traditional eddy current brakes is effectively solved.Millisecond-level excitation response is achieved by optimizing the coil inductance, number of winding turns, and pole pitch of the excitation pole rotor structure 300. Combined with the brush and slip ring composite power supply system, the excitation current is dynamically adjusted according to the speed, temperature, and target energy absorption curve, thereby generating a controllable rotating magnetic field in the air gap. This magnetic field directly acts on the conductive disk 201 fixed at the stator end to generate eddy currents of controllable magnitude, thereby achieving continuous, stepless, and rapid adjustment of braking torque. At the same time, the rotor 400 centrifugal air duct heat dissipation, magnetic pole structure optimization, and water cooling system 100 work together to ensure thermal safety and braking performance under high power density. Active braking is manifested in intelligent closed-loop control capability. The system actively and dynamically adjusts the excitation current through the excitation system with millisecond-level response based on the preset target energy absorption curve and real-time collected operating condition signals such as speed and temperature. This precisely controls the intensity and distribution of the rotating magnetic field, thereby actively inducing eddy currents of the expected size on the conductive disk 201. Ultimately, it achieves continuous, stepless and real-time adjustment of braking torque. This active control capability, from command input and parameter adjustment to the generation of physical effects, breaks through the limitation of the non-adjustable braking force of traditional eddy current brakes.

[0038] In this embodiment, the water-cooling system 100 includes annular or serpentine water-cooling channels. The interface between the water-cooling channels and the back of the conductive disk 201 forms a thermally conductive contact interface, allowing the heat generated by eddy current heating to be conducted to the cooling medium via the shortest path. Different water-cooling channel cross-sections and flow ranges are designed according to braking requirements, and a multi-channel parallel structure is also designed. The optimal flow rate and pressure drop range are determined through CFD thermal analysis to ensure that the temperature of the conductive disk 201 remains within a safe operating range under continuous braking conditions. The annular or serpentine water-cooling channels are in close contact with the back interface of the conductive disk 201, forming a highly efficient, low-thermal-resistance heat conduction path. This allows the heat generated by the eddy currents within the conductive disk 201 to be rapidly transferred to the cooling medium with the shortest conduction distance, preventing heat accumulation inside the conductive disk 201 and significantly improving heat dissipation efficiency. This provides a thermal management foundation for high-power-density braking. Different water-cooling channel cross-sections and flow ranges are designed according to braking requirements, and a multi-channel parallel structure is adopted to achieve fine adjustment and optimization of heat dissipation capacity. The multi-channel parallel structure can increase the contact area between the cooling medium and the heat conduction interface, improve the overall heat exchange efficiency, and ensure uniform flow of the cooling medium in the channel by rationally designing the channel cross-section and flow rate, avoiding uneven heat dissipation caused by dead water zones or local low flow rates. This allows the water-cooling system 100 to adapt to the operating conditions of different braking intensities and frequencies. The optimal flow rate and pressure drop range are determined by CFD thermal analysis, ensuring the scientific and accurate design of the water-cooling system 100. CFD thermal analysis can simulate the fluid flow, heat conduction, and convective heat transfer processes in the water-cooling channel, thereby determining the flow rate and pressure drop parameters required to achieve the best heat dissipation effect under specific operating conditions. This simulation-based optimization design avoids the blindness of experience-based design and ensures that the temperature of the conductive disc 201 can be effectively controlled within the safe operating range under continuous braking conditions, guaranteeing the long-term reliable operation of the braking system. The water-cooling system 100 design, through optimization of channel structure, heat conduction interface and fluid parameters, has produced synergistic gains in enhancing heat dissipation capacity, achieving fine-tuning of heat dissipation, and ensuring heat dissipation reliability. It provides thermal management assurance for the stator conductive disk water-cooled excitation eddy current brake to achieve high power density and high-frequency continuous braking.

[0039] In this embodiment, the water cooling system 100 also includes a temperature sensor, a flow sensor, and a pressure monitoring structure. By monitoring the water cooling status of the water cooling system 100 in real time, thermal runaway problems caused by blockage of water cooling channels, air resistance, or pump failure can be avoided. Real-time monitoring of the temperature of key components of the water cooling system 100 (such as inlets and outlets, and near the interface of the conductive plate 201) by the temperature sensor allows for timely understanding of the actual operating status of the heat dissipation system. When an abnormal temperature increase is detected, it can quickly determine whether there is insufficient heat dissipation capacity or local overheating risk, providing timely and accurate basis for taking corresponding control measures (such as adjusting the excitation current, increasing the cooling flow rate, or triggering a protection shutdown), thereby effectively preventing damage to the conductive plate 201 due to heat dissipation failure. Real-time monitoring of the flow rate of the cooling medium by the flow sensor allows for timely detection of flow abnormalities caused by blockage of water cooling channels, pump failure, or pipeline leakage. Flow abnormalities are one of the direct causes of reduced heat dissipation capacity. Real-time flow monitoring enables the system to issue timely warnings or trigger protection when the flow rate is below a safe threshold, avoiding thermal runaway problems caused by insufficient cooling medium flow. By monitoring the pressure of the water-cooling system 100 in real time through a pressure monitoring structure, pressure anomalies caused by air resistance, blockage, or pump performance degradation can be effectively identified. Pressure anomalies are often accompanied by flow anomalies or localized overheating. The combination of real-time pressure monitoring with flow and temperature monitoring constitutes a comprehensive monitoring of the operating status of the water-cooling system 100, further improving the accuracy and reliability of fault detection. The multi-sensor real-time monitoring scheme, through the coordinated monitoring of key parameters such as temperature, flow, and pressure, constructs a real-time status perception and fault early warning mechanism for the water-cooling system 100. It can promptly detect and warn of abnormal operating conditions such as blockage of water-cooling channels, air resistance, or pump failure, effectively avoiding thermal runaway problems caused by heat dissipation system failure. This provides a safety guarantee for the safe and reliable operation of the stator conductive disc water-cooled excitation eddy current brake under continuous high-power braking conditions.

[0040] The stator conductive disk water-cooled excitation eddy current braking control method of this embodiment adopts the above-mentioned stator conductive disk water-cooled excitation eddy current brake and includes the following steps: A braking torque adjustment method based on excitation current is adopted. By real-time monitoring of the rotor 400 speed, conductive disk 201 temperature, water-cooling system 100 status, and the kinetic energy to be absorbed, a suitable excitation current command value is calculated, and the drive power supply outputs a stable current, thereby achieving precise adjustment of the braking torque. In the initial braking stage, when the rotor 400 speed is high, a large excitation current is applied according to the target absorbed energy and the rate of change of speed, causing the braking torque to rise rapidly in order to quickly absorb most of the kinetic energy. As the rotor 400 speed decreases, the inherent torque decay characteristic of eddy current braking will naturally reduce the braking torque. At this time, the excitation current is gradually reduced to ensure a stable torque output in the low-speed range. Simultaneously, to prevent excessive temperature, the excitation current is dynamically limited to ensure that the conductive disk 201 temperature does not exceed a set threshold, achieving coupled control of thermal protection and braking torque, making the entire braking process both safe and efficient. This invention discloses a stator conductive disk water-cooled excitation eddy current braking control method. It employs a closed-loop regulation strategy centered on excitation current, combined with real-time monitoring and coordinated control of multiple parameters including rotational speed, temperature, water cooling status, and target energy absorption. By real-time monitoring of rotor speed 400 rpm, conductive disk temperature 201, water cooling system status 100, and target energy absorption, a multi-parameter feedback closed-loop control system is constructed. Based on this real-time data, a suitable excitation current command value is calculated, and the drive power supply outputs a stable current, achieving precise adjustment of the braking torque. This closed-loop control method overcomes the limitation of traditional eddy current brakes where braking force depends solely on rotational speed, significantly improving the accuracy and adaptability of braking force control and meeting the needs of different braking conditions. Applying a large excitation current during the initial high-speed braking phase leverages the strong eddy current effect at high speeds to rapidly establish a large braking torque and efficiently absorb most of the kinetic energy. As the speed decreases, the natural decay of the eddy current braking torque becomes apparent. At this point, gradually reducing the excitation current compensates for the torque decay in the low-speed phase, ensuring relatively stable braking torque throughout the braking process. This avoids shocks or instability caused by sudden torque changes during braking, improving the comfort and safety of the braking process. Dynamically limiting the excitation current achieves coupled control of thermal protection and braking torque, ensuring both safety and efficiency in the braking process. When the temperature of the conductive disc 201 approaches a set threshold, the system can limit the braking torque by reducing the excitation current, preventing overheating of the conductive disc 201 that could lead to material degradation or structural damage, while also maintaining braking performance. This thermal protection mechanism allows the braking system to maximize braking efficiency while ensuring safety, achieving a balance between safety and efficiency.The control method of this invention, through multi-parameter closed-loop control, braking process torque optimization, and thermal protection coupling control, produces synergistic gain effects in improving braking force control accuracy, optimizing braking process stability, and ensuring system operation safety. It provides a control strategy guarantee for achieving efficient, safe, and controllable braking performance of the stator conductive disk water-cooled excitation eddy current brake.

[0041] In practice, this invention provides a stator conductive disk water-cooled excitation eddy current brake and braking method, which can completely solve key engineering problems of traditional eddy current brakes, such as insufficient heat dissipation, unadjustable braking force, and inability to adapt to high-energy scenarios. By fixing the conductive disk 201 to the stator housing, and using high thermal conductivity materials and direct water-cooling channels, high-efficiency thermal management is achieved. Simultaneously, the excitation poles are arranged at the rotor end, and a rotating magnetic field is established through a controllable excitation current, achieving continuous and controllable adjustment of the braking torque. Through this structure, the invention can ensure that under extreme conditions of high-speed, high-inertia energy absorption (such as UAV braking), the brake can quickly absorb a large amount of kinetic energy while maintaining low temperature rise and good repetitive braking capability. Furthermore, the invention enhances the thermal stress resistance of the conductive disk 201 through mechanical structural optimization, avoiding the structural fatigue problems caused by centrifugal force in traditional high-speed rotor conductive disks, resulting in a longer brake life, higher reliability, and greater suitability for high-frequency deployment scenarios.

[0042] The stator conductor plate water-cooled excitation eddy current brake and braking method are as follows: 1. Stator conductive structure 200: This invention employs a structure in which the conductive disk 201 is fixedly mounted on the stator end. Unlike traditional high-speed rotating disks, the conductive disk 201 does not move with the rotor 400. This allows for the use of a thicker, stronger, and more thermally efficient copper alloy integral structure, with a large-area bonding interface reserved on the back of the disk to connect to the water-cooling channel inside the stator. Because the conductive disk 201 is fixed, the design allows for complex water-cooling channels, reinforcing ribs, and heat diffusion layers, significantly enhancing its thermal management capabilities and preventing material degradation or disk deformation due to excessive temperature. Simultaneously, the fixed structure eliminates the centrifugal force effect of the high-speed rotating disk, enabling the conductive disk 201 to maintain stable geometry and mechanical properties when absorbing high-power eddy current heat, thus improving the long-term reliability of the system. By optimizing the thickness, diameter, and geometry of the conductive disk 201, it can form sufficient eddy current energy absorption volume while rapidly directing heat to the water-cooling area, thereby supporting high-power-density applications.

[0043] 2. Excitation pole rotor structure 300: The excitation pole rotor structure 300 of this invention innovatively extends the traditional armature power supply principle of electric motors, forming a controllable excitation structure specifically designed for high-energy eddy current braking scenarios. This structure arranges multiple electromagnet poles 301 at the rotor end and employs a highly reliable brush-slip ring composite power supply system to deliver excitation current to the rotating poles, enabling the magnetic field to rotate synchronously with the rotor 400. This achieves strong magnetic field, high response, and wide-range braking torque control. Unlike traditional motors, this invention specifically optimizes the magnetic flux path, heat dissipation mechanism, and electromagnetic polarization direction of the excitation coil (coil 302) on the rotor 400. This allows the magnetic field to form a highly concentrated and directionally stable magnetic flux density distribution in the air gap region, ensuring that the magnetic field uniformly passes through the fixed conductive disk 201 at the stator end under high-speed rotation conditions, maximizing eddy current formation efficiency. Furthermore, the slip ring and brush system of the present invention adopts a wide-face contact design and silver-graphite composite brush material, which can maintain stable contact impedance under high current density and long-term repeated use conditions. At the same time, the double-redundant structure avoids the problem of excitation current interruption due to wear of contact components, which significantly improves the reliability of the entire brake.

[0044] Compared to conventional motor structures, this invention further optimizes the coil inductance, winding turns, and pole pitch to address the transient characteristics of eddy current braking. This allows the excitation poles to not only generate a strong magnetic field but also respond to changes in excitation current within milliseconds, thus supporting real-time closed-loop control of the braking torque. During actual braking, the control system dynamically adjusts the excitation current based on speed, temperature, and the target energy absorption curve. The magnetic poles on rotor 400 then instantaneously generate corresponding magnetic flux changes, causing the magnetic field strength in the air gap to change in a controllable manner. This directly affects the magnitude of the eddy currents generated by the conductive disk 201, achieving continuous, stepless, and rapid adjustment of the braking torque. Furthermore, this invention incorporates centrifugal air ducts and embedded heat-conducting blocks around the magnetic pole core, enabling the coil 302 to achieve a self-cooling effect during high-speed rotation. Compared to traditional stator excitation systems, this more effectively prevents overheating of the coil 302, improving the operational stability of the excitation system. By comprehensively optimizing the magnetic pole shape, pole shoe length, magnetic flux distribution, and rotor mass, the rotor excitation magnetic pole structure of this invention not only enhances the power density and efficiency of eddy current braking, but also significantly reduces electromagnetic force pulsation and noise, making it more reliable and stable in high-speed, high-energy absorption applications.

[0045] 3. High-efficiency water cooling system 100: This invention arranges annular or serpentine water-cooling channels inside the stator housing, forming a thermally conductive contact interface with the back of the conductive disk 201. This allows the heat generated by eddy current heating to be conducted to the cooling water via the shortest path. Compared to traditional air cooling, water cooling has higher heat exchange efficiency, capable of removing a large amount of heat in a short time, making it particularly suitable for high-energy instantaneous absorption conditions such as UAV braking. This invention can also design different water-cooling channel cross-sections, flow ranges, and multi-channel parallel structures according to braking requirements. Optimal flow rates and pressure drop ranges are determined through CFD thermal analysis to ensure that the temperature of the conductive disk 201 remains within a safe operating range during repeated braking operations. To improve reliability, this invention also incorporates temperature sensors, flow sensors, and pressure monitoring structures. The control system monitors the water-cooling status in real time, preventing thermal runaway problems caused by blockages, air resistance, or pump failure.

[0046] 4. Braking control method: The control system of this invention employs a braking torque adjustment method centered on excitation current. By real-time monitoring of rotational speed, the temperature of the conductive disk 201, the status of the water-cooling system 100, and the kinetic energy to be absorbed, it calculates a suitable excitation current command value and controls the drive power supply to output a stable current, thereby achieving precise adjustment of the braking torque. In the initial braking phase, when the rotational speed is high, the system applies a large excitation current based on the target energy absorption and the rate of change of rotational speed, causing the braking torque to rise rapidly to quickly absorb most of the kinetic energy. As the speed decreases, the inherent torque decay characteristic of eddy current braking naturally reduces the braking torque. At this point, the control system gradually reduces the excitation current to ensure a stable torque output at low speeds. Simultaneously, to prevent overheating, the control system dynamically limits the excitation current, ensuring that the temperature of the conductive disk 201 does not exceed a set threshold, achieving coupled control of thermal protection and braking torque, making the entire braking process both safe and efficient.

[0047] More specifically, regarding the excitation method, this invention differs fundamentally from existing self-excited or passively excited eddy current brakes in principle. Existing self-excited or passively excited eddy current brakes derive their excitation current from the induction effect generated during the rotation of a conductor or magnetic circuit. There is a high degree of coupling between the excitation intensity and the rotational speed: changes in rotational speed directly lead to changes in the amplitude of the excitation current and the strength of the magnetic field, resulting in a significant speed-dependent braking force. While this self-excited structure is relatively simple in engineering, its inherent drawback lies in the inability to independently control the excitation current. Especially under low-speed or rapidly changing speed conditions, the braking force response is lag-dependent and difficult to precisely adjust, significantly limiting the control strategy. The stator conductive disc water-cooled excitation eddy current brake of this invention actively establishes a magnetic field through a controllable excitation current powered by an external power supply. The magnitude, rate of change, and modulation method of the excitation current are independent of the rotational speed and can be independently set by the control system. It achieves decoupling of the magnetic field change frequency and mechanical rotational speed from the electromagnetic principle level. It not only innovates in structure, but also forms an essential distinction from the self-excited eddy current brake in terms of control freedom and system dynamic response capability. It represents a substantial change to the excitation mechanism of existing technology.

[0048] More specifically, from the perspective of magnetic pole structure and magnetic field interaction, this invention does not simply follow the common single form of circumferential magnetic pole arrangement (magnetic pole direction perpendicular to the axial direction) or disk-shaped magnetic pole arrangement (magnetic pole direction parallel to the axial direction) in existing technologies. Instead, it achieves active design and optimization of the spatial distribution of the magnetic field through a combined magnetic pole structure. Traditional magnetic pole arrangement methods usually serve the working mode of "mechanical rotation cutting the magnetic field," and their magnetic field spatial shape is relatively fixed, making it difficult to balance magnetic field utilization and eddy current distribution uniformity. The stator conductive disk water-cooled excitation eddy current brake of this invention, through the combined magnetic pole arrangement and the coordinated design of magnetic pole direction, pole pair relationship, and their spatial position with the conductive disk, forms a more uniform and adjustable rotating magnetic field distribution within the fixed conductive disk area of ​​the stator. Thus, without relying on the mechanical rotation of the conductive disk, it can still obtain a high effective magnetic field change rate and eddy current density. This magnetic pole design concept based on "magnetic field spatial configuration" provides a completely new technical approach compared to existing circumferential or disk-shaped magnetic pole arrangement methods.

[0049] More specifically, from the perspective of braking control methods, the stator conductive disc water-cooled excitation eddy current brake of this invention differs from existing self-excited or weakly controlled eddy current brakes. Existing braking control technologies typically only allow for coarse adjustment of braking force through structural parameters or limited excitation adjustment methods, and the controlled object is essentially still the rotational speed itself. However, the stator conductive disc water-cooled excitation eddy current brake of this invention uses the excitation current as the core control variable in its control method. By controlling the amplitude and rate of change of the excitation current, as well as its coupling control with state parameters such as rotational speed and temperature, it achieves continuous adjustability of braking torque and dynamic response optimization. Because the excitation current is completely controllable, the stator conductive disc water-cooled excitation eddy current brake of this invention can actively set the braking force target under different operating conditions, rather than passively responding to changes in rotational speed, thus possessing significant advantages in low-speed braking, constant torque braking, and complex operating condition switching. This braking control method, "with excitation current as the main control variable," provides a completely new technical approach.

[0050] More specifically, regarding the excitation power supply structure, this invention employs a slip ring to supply power to the excitation coil and provides a specific structural implementation method, thereby solving the stability problem. This invention draws upon and improves upon the mature power supply structure design of brushed motors. Through a brush-slip ring combination structure optimized for brake operating conditions, it achieves stable power supply from the external power source to the rotor excitation system, ensuring the continuity and reliability of the excitation current under high speed and long-term braking conditions. The power supply structure of this invention is not a simple adoption of existing slip ring schemes, but rather a structural improvement made to meet the requirements of excitation controllability and system stability, playing a crucial supporting role in the engineering implementation of the controllable excitation braking mechanism of this invention.

[0051] In summary, the stator conductive disk water-cooled excitation eddy current brake of the present invention has achieved synergistic overall technological progress in terms of excitation mechanism, magnetic pole structure design, braking control method and excitation power supply structure.

[0052] Matters not covered in this invention are common knowledge.

[0053] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0054] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

[0055] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A stator conductor disk water-cooled excitation eddy current brake, characterized in that, include: A water cooling system (100) is used to remove heat quickly in a short time to ensure that the temperature remains within the safe operating range during multiple consecutive braking conditions; The stator conductive structure (200) adopts a conductive disk (201) fixed to the stator end. The back of the conductive disk (201) has a bonding interface. The water cooling system (100) is arranged on the bonding interface to maintain stable geometry and mechanical properties when absorbing high-power eddy current heat. By optimizing the thickness, diameter and geometry, it can form a sufficient eddy current energy absorption volume and quickly guide heat to the water cooling area, thereby supporting high power density applications. The excitation pole rotor structure (300) is arranged in the cavity formed by the stator conductive structure (200) and at the rotor end. It is used to make the magnetic field form a highly concentrated and directionally stable magnetic flux density distribution in the air gap region, and to ensure that the magnetic field passes through the fixed conductive disk (201) at the stator end uniformly under high-speed rotation conditions, thereby maximizing the eddy current formation efficiency.

2. The stator conductor disk water-cooled excitation eddy current brake according to claim 1, characterized in that, Thickness optimization of conductive pad (201) includes: The thickness design of the fixed conductive disk (201) needs to take into account both the eddy current effect and heat dissipation. The lower limit of the thickness of the conductive disk (201) is set to be greater than the effective penetration depth of the eddy current to avoid insufficient energy absorption caused by the eddy current penetrating to the bottom. The upper limit of the thickness of the conductive disk (201) is set to enable the heat inside the disk to be conducted to the water-cooled surface on the back of the conductive disk (201).

3. The stator conductor disk water-cooled excitation eddy current brake according to claim 2, characterized in that, The thickness of the conductive disk (201) was set to 5mm-20mm, and the optimal thickness was determined by thermal simulation.

4. The stator conductor disk water-cooled excitation eddy current brake according to claim 3, characterized in that, The thickness optimization of the conductive disk (201) also includes: The thickness of the conductive disk (201) is set to a uniform thickness distribution; or The thickness of the conductive disk (201) is set to a non-uniform thickness distribution to optimize the eddy current effect and thermal management performance in different regions, thereby achieving a balance between eddy current distribution, structural weight and heat dissipation efficiency.

5. The stator conductor disk water-cooled excitation eddy current brake according to claim 4, characterized in that, The conductive disk (201) adopts an integral copper alloy structure; The bonding interface of the conductive disk (201) includes a heat diffusion layer, and / or the bonding interface of the conductive disk (201) is provided with reinforcing ribs.

6. The stator conductor disk water-cooled excitation eddy current brake according to any one of claims 2 to 5, characterized in that, The diameter and geometry design of the conductive disk (201) includes: The diameter of the conductive disk (201) is matched with the excitation pole rotor structure (300) to ensure that the magnetic field covers the effective eddy current generation area and avoids wasted power due to edge effects; and / or The conductive disk (201) adopts a corrugated disk surface, a ribbed disk surface, or a grooved disk surface to increase the contact area with the cooling medium of the water cooling system (100); and / or The surface of the conductive disk (201) is divided into a strong magnetic field area and an edge area, and the water cooling system (100) is densely distributed in the strong magnetic field area.

7. The stator conductor disk water-cooled excitation eddy current brake according to claim 1, characterized in that, The excitation pole rotor structure (300) includes multiple electromagnet poles (301) arranged at the rotor end, and the multiple electromagnet poles (301) are arranged at equal intervals along the circumferential direction of the rotor end; A composite power supply system (500) using brushes and slip rings is used to supply excitation current to the rotating electromagnet poles (301) so that the magnetic field can rotate synchronously with the rotor (400), thereby achieving strong magnetic field, high response and wide adjustment range braking torque control.

8. The stator conductor disk water-cooled excitation eddy current brake according to claim 7, characterized in that, The combined power supply system of brush and slip ring (500) adopts a wide-face contact design and a silver-graphite composite brush material design to maintain stable contact impedance under high current density and long-term repeated use conditions.

9. The stator conductor disk water-cooled excitation eddy current brake according to claim 7, characterized in that, The excitation pole rotor structure (300) optimizes the coil inductance, number of winding turns, and pole pitch of the electromagnet poles (301) so that the electromagnet poles (301) can not only generate a strong magnetic field, but also respond to changes in excitation current within milliseconds, thereby supporting real-time closed-loop control of braking torque; and / or The composite power supply system (500) of brush and slip ring dynamically adjusts the excitation current based on the rotational speed, temperature, and target energy absorption curve of the excitation pole rotor structure (300). The electromagnet poles (301) on the rotor (400) then instantaneously generate corresponding magnetic flux changes, causing the magnetic field strength in the air gap to change in a controllable manner. This directly affects the magnitude of the eddy currents generated by the conductive disk (201), achieving continuous, stepless, and rapid adjustment of the braking torque; and / or Centrifugal air ducts and embedded heat-conducting blocks are arranged around the magnetic pole core of the electromagnet pole (301) to create a self-cooling effect when the coil (302) rotates at high speed, so as to more effectively prevent the coil (302) from overheating and improve the working stability; and / or By comprehensively optimizing the shape of the electromagnet pole (301), the length of the pole shoe of the electromagnet pole (301), the magnetic flux distribution of the electromagnet pole (301), and the mass of the rotor (400), the power density and efficiency of eddy current braking are enhanced, and the electromagnetic force pulsation and noise are reduced, thereby making it more reliable and stable in high-speed and high-energy absorption applications.

10. The stator conductor disk water-cooled excitation eddy current brake according to claim 1, characterized in that, The water cooling system (100) includes an annular or serpentine water cooling channel. The water cooling channel and the interface on the back of the conductive disk (201) form a thermally conductive contact interface so that the heat generated by the eddy current heating can be conducted to the cooling medium through the shortest path. Different water-cooling channel cross sections and flow ranges are designed according to braking requirements, and a multi-channel parallel structure is designed. The optimal flow rate and pressure drop range are determined by CFD thermal analysis to ensure that the temperature of the conductive disk (201) remains within the safe operating range under continuous braking conditions.

11. The stator conductor disk water-cooled excitation eddy current brake according to claim 10, characterized in that, The water cooling system (100) also includes a temperature sensor, a flow sensor and a pressure monitoring structure, which monitors the water cooling status of the water cooling system (100) in real time to avoid thermal runaway caused by blockage of water cooling channels, air resistance or pump failure.

12. A stator conductor disk water-cooled excitation eddy current braking control method, characterized in that, The stator conductor disk water-cooled excitation eddy current brake according to any one of claims 1 to 11 includes the following steps: The braking torque is adjusted by using excitation current as the core. By real-time monitoring of rotor (400) speed, conductive disk (201) temperature, water cooling system (100) status and the kinetic energy to be absorbed, the appropriate excitation current command value is calculated and the drive power supply outputs a stable current, thereby achieving precise adjustment of braking torque. In the initial braking stage, when the rotor (400) speed is at a high speed, the excitation current is applied according to the target energy absorption and the speed change rate, so that the braking torque rises rapidly in order to quickly absorb most of the kinetic energy. As the rotor (400) speed decreases, the inherent torque decay characteristic of eddy current braking will naturally reduce the braking torque. At this time, the excitation current is gradually reduced to ensure that the torque output remains stable in the low-speed range. Meanwhile, to prevent excessive temperature, the temperature of the conductive disk (201) is kept below the set threshold by dynamically limiting the excitation current, thereby achieving coupled control of thermal protection and braking torque, making the entire braking process both safe and efficient.

Images