Brake device

Abstract

To use a non-contact type brake instead of a conventional brake.SOLUTION: A brake device has at least one or more non-contact brakes (23) as a brake of a vehicle or a moving body. The non-contact brake (23) comprises at least one or more of a hysteresis brake, an eddy-current brake (26), a powder brake, and a magnetic fluid brake (25). The non-contact brake (23) is a brake device formed by a pair of structures different from each other.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a braking device, and particularly to a braking system that brakes a vehicle or a moving object by one or more non-contact brakes and efficiently controls the brakes. Furthermore, the present invention relates to a novel improvement for using a contact brake in combination when a large braking torque is required.

Background Art

[0002] Conventionally, examples of this type of braking device that has been used include the configuration of an electromechanical composite braking device for vehicles disclosed in Patent Document 1. As shown in FIG. 16, the electromechanical composite braking device for vehicles is provided with a mechanical disk braking device 15 and an eddy current braking device 5. In the mechanical disk braking device 15 supported by a frame 16 provided on a car body frame 9, a disk 8 supported by an axle 7 is arranged so as to be able to slide-contact with a brake shoe 17. That is, the mechanical disk braking device 15 includes a disk 8 that rotates integrally with the axle 7, and when a vehicle braking command is issued, the brake shoe 17 is pressed against the side surface of the disk 8, and a braking force is applied to the axle 7 by the frictional force. Also, the eddy current braking device 5 has a plurality of exciting coils 12 with magnetic pole cores 11 that are excited by a DC exciting power source when a vehicle braking command is issued, and are arranged opposite to both sides of the disk 8, and eddy currents are generated in the disk 8 by the magnetic field formed by the exciting coils 12 to apply a braking force to the axle. Furthermore, this vehicle electromechanical combined brake system is characterized by having a Hall element 18 on the magnetic pole core 11 of the eddy current brake device 5 for detecting the magnetic flux density of the gap g between the opposing surface with the disc 8, and a control device that controls the voltage of the DC excitation power supply of the eddy current brake device 5 so that the value of the magnetic flux density output from the Hall element 18 is always set to the set value when a vehicle braking command is issued, regardless of the change in the gap g between the eddy current brake device 5 and the eddy current brake device 5 caused by the wear of the disc 8 due to contact with the brake shoe 17 of the mechanical disc brake device 15. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 155701 / 1983 [Overview of the Initiative] [Problems that the invention aims to solve]

[0004] Conventional braking systems were configured as described above, and therefore had the following problems. In other words, the system uses a mechanical disc brake system 15 that combines an eddy current brake device 5, which has magnetic pole cores 11 arranged opposite each other so that an excitation current can be applied to a coil on each side of a single brake disc, with a conventional hydraulic brake shoe 17. Therefore, the piping of the hydraulic drive system for the brake shoe 17 and the application of current to the excitation coil 12 in the eddy current brake device 5 must be achieved to a high standard. For example, when adopted in an EV, a hydraulic pump, motor, hydraulic piping, etc., are required, and electrical and mechanical components are needed. As a result, the configuration involves adding an electrical eddy current brake device 5 to the conventional mechanical disc brake system 15, which is heavy and has a complex structure.

[0005] The brake system according to the present invention was made to solve the above-mentioned problems, and in particular, it efficiently controls the brakes by braking a vehicle or moving object using one or more non-contact brakes. Furthermore, it provides a brake system that uses a contact brake in combination when a larger braking torque is required. [Means for solving the problem]

[0006] The brake device according to the present invention has a configuration having at least one or more non-contact brakes as brakes for a vehicle or moving body, and the non-contact brake is configured to consist of one or more of a hysteresis brake, an eddy current brake, a powder brake, or a magnetic fluid brake, and the non-contact brake is configured to consist of a pair of different configurations, and the non-contact brake is configured to use the eddy current brake and the magnetic fluid brake, and the eddy current brake and the magnetic fluid brake are connected along the axial direction, and the non-contact brake is configured to be combined with a contact brake. [Effects of the Invention]

[0007] Since the brake device according to the present invention is configured as described above, the following effects can be obtained. In other words, the system efficiently controls the brakes by having at least one or more non-contact brakes as brakes for the vehicle or moving object. Furthermore, the compact and lightweight brake system, achieved through power saving, is ideal for electric vehicles (EVs). Furthermore, by comprising one or more of the following: hysteresis brakes, eddy current brakes, powder brakes, and magnetic fluid brakes, the non-contact brake can significantly contribute to reducing the weight of the EV. Furthermore, since the non-contact brakes consist of a pair of brakes with different configurations, a large braking torque can be obtained because a pair of brakes is provided on one axis. Furthermore, since the non-contact brake utilizes the eddy current brake and the magnetic fluid brake, and the brakes are compactly integrated and mounted on a single rotating shaft, a significant weight reduction of the EV's brakes can be achieved. Furthermore, by configuring the eddy current brake and the magnetic fluid brake to be joined along the axial direction, a significant reduction in the weight of the EV's brakes can be achieved by mounting a pair of brakes on a single axle. Furthermore, because the non-contact brake is combined with a contact brake, conventional contact brakes can be connected to the non-contact brake, making it easily applicable as a brake for trucks, buses, and other vehicles that are heavier than ordinary vehicles. [Brief explanation of the drawing]

[0008] [Figure 1] This perspective view shows various brake devices according to embodiments of the present invention, where A shows a disc-type contact brake, B shows a drum-type contact brake, C shows a magnetic (MR) fluid brake, and D shows an eddy current brake. [Figure 2] This is a characteristic diagram of brake torque showing the rotational speed torque (rad / s) of the MRB viscous torque, ECB magnetic torque, MRB magnetic torque, and total torque in a non-contact brake according to the present invention. [Figure 3] This is a perspective view showing the configuration of the braking device according to the present invention, which combines a magnetic fluid brake and an eddy current brake. [Figure 4] This is a schematic perspective view of the main part of the magnetic fluid brake according to the present invention. [Figure 5] Figure 4 is a front view of a magnetic fluid brake using a magnetic fluid channel. [Figure 6] Figure 5 is an enlarged cross-sectional view of the main part. [Figure 7] Figure 5 is an enlarged cross-sectional view showing another form of the main part. [Figure 8] Figure 5 is an enlarged cross-sectional view showing another form of the main part. [Figure 9]It is a winding explanatory diagram showing another form of the main part of FIG. 5. [Figure 10] It is an enlarged perspective view of the main part of FIG. 5. [Figure 11] It is a polymerization configuration diagram of the fixed disk of FIG. 10. [Figure 12] It is an enlarged perspective view of the main part A of FIG. 11. [Figure 13] It is an exploded perspective view of the main part of the rotor side disk part of FIG. 5. [Figure 14] It is an enlarged perspective view of the main part of the rotor side disk part of FIG. 5. [Figure 15] It is an enlarged perspective view of the main part of FIG. 5. [Figure 16] It is a front view of the conventional configuration. [Figure 17] It is an enlarged cross-sectional view of the main part of FIG. 16.

Embodiments for Carrying out the Invention

[0009] The braking device according to the present invention brakes a vehicle or a moving body by one or a plurality of non-contact brakes and efficiently controls the brakes. Further, when a large braking torque is required, a configuration is adopted in which a contact brake is used in combination.

Examples

[0010] Hereinafter, preferred embodiments of the braking device according to the present invention will be described with reference to the drawings. In addition, the same or equivalent parts as those in the conventional example will be described using the same reference numerals. In Figure 1, the symbol 1 indicates a hybrid brake consisting of a contact brake 20 and a non-contact brake 23. Each of these is a brake for a vehicle or moving object. Category A includes the conventionally used disc brake 21, Category B includes the drum brake 22, Category C includes the magnetic (MR) fluid brake 25, and Category D includes the eddy current brake 26. In the case of multiple non-contact brakes 23, one or more of the well-known hysteresis brakes, eddy current brakes 26, powder brakes, and magnetic fluid brakes 25 are connected in parallel along the axial direction P.

[0011] Of the aforementioned brakes, the magnetic fluid brake 25 uses a magnetic fluid brake with an undisclosed structure that the inventor has recently developed and filed a patent application for, and an eddy current brake 26 is disclosed as Category D. As shown on the right side of Figure 1 and in Figure 3, the magnetic fluid brake 25 is provided at the front and an eddy current brake 26 is provided at the rear. By combining the magnetic fluid brake 25 and the eddy current brake 26, a hybrid non-contact brake 23 can be constructed, which is a combination of the magnetic fluid brake 25 and the eddy current brake 26.

[0012] As the aforementioned disc brakes 21 and drum brakes 22 are commonly used in vehicles and are well known, and as is the eddy current brake 26, which is also well known in integrators and the like, the configuration of the magnetic fluid brake 25 proposed by the applicant as described above will now be explained based on the principle diagram. As shown in Figure 1, an eddy current brake 26 is concentrically positioned behind the rotating shaft 25A of the aforementioned magnetic fluid brake 25, and the magnetic fluid brake 25 and the eddy current brake 26 are integrally provided on the same central axis P. Figure 2 also shows the relationship between the viscous torque of the magnetic fluid brake 25, the magnetic torque of the eddy current brake 26, the magnetic torque of the magnetic fluid brake 25, and the total torque. Figure 4 shows a schematic configuration of the magnetic fluid brake 25 according to this embodiment. In Figure 4, the cylindrical stator body 60 of the magnetic fluid brake 25 is provided with ring-shaped disc-shaped fixing discs 70 at predetermined intervals.

[0013] A ring-shaped fixed excitation winding 51, as shown in Figure 10, is installed inside the fixed disk 70. The rotor 63, which is mounted coaxially with the stator 60, is waterproof and rotatable to the stator 60 via a seal 60A made of an O-ring or the like and a bearing 60B, as shown in Figure 5. Multiple rotating disks 64 are provided on the peripheral wall 63A of the rotor 63 at predetermined intervals.

[0014] As an example, the fixed disk 70 is composed of a pair of stator pieces 70A and 70B, as shown in Figure 6, and the fixed excitation winding 51 is provided within a holding space 110 which is formed by combining the recesses 130 formed on the inner surfaces of each of the stator pieces 70A and 70B. A magnetic fluid channel 111 is formed between the outer surface of each stator piece 70A, 70B and each rotating disk 64 adjacent to each stator piece 70A, 70B for the flow of magnetic fluid 80. Therefore, the magnetic fluid 80 in each magnetic fluid channel 111 is configured to be in direct contact with each rotating disk 64 and each stationary disk 70. Accordingly, in the configurations of Figures 4 and 5, since the stationary excitation windings 51 are installed inside each stationary disk 70, by turning on the excitation of each stationary excitation winding 51 and applying a predetermined current, the magnetic flux 400 flows in a ring shape along the loop in Figure 1, forming a magnetic circuit 401.

[0015] On both sides of the rotating disk group 100, which is formed by providing multiple rotating disks 64 along the axial direction P of the rotor body 63, a pair of rotor-side disk portions 120 and 120A, as shown in Figure 13, are provided, and a pair of lock plates 3 are provided on the outside of each rotor-side disk portion 120 and 120A. On the right side of the stator body 60, as seen in the figure, is a pump 121 connected in series to all of the magnetic fluid channels 111. This pump 121 circulates the magnetic fluid 80 through the magnetic fluid channels 111 via a control unit (not shown), ensuring that there are no variations in the concentration of magnetic particles.

[0016] Furthermore, in the configuration shown in Figure 4, no magnetic flux 400 flows through the stator body 60, and no magnetic circuit 401 is formed. Therefore, a magnetic circuit 401 is formed only around the rotating disk 64 and stationary disk 70 surrounding the fixed excitation winding 51, allowing the magnetic circuit 400 to be maximized to a larger value than in conventional designs. Figure 6 describes a configuration in which the fixed excitation winding 51 is housed and held within a holding space 110 formed by a pair of stator pieces 70A and 70B. However, the configuration is not limited to that shown in Figure 6, and it is also possible to provide the fixed excitation winding 51 on one side of the fixed disk 70, as in the other embodiment shown in Figure 7. In other words, in Figure 7, a fixed excitation winding 51 is provided in a recess 130 of either one of the stator pieces 70A or 70B. In another embodiment shown in Figure 8, the fixed disk 70 between the rotating disks 64 has a connecting portion 70E formed at its center, and first and second recesses 70C and 70D are formed on both sides of this connecting portion 70E. Each fixed excitation winding 51 provided in the respective recesses 70C and 70D is configured to be flush with the surface 70M of the fixed disk 70.

[0017] In Figure 9, the fixed excitation winding 51 is formed using a well-known rectangular wire 140 in a rectangular wire II winding (α winding is also acceptable) so as to create upper and lower winding layers with respect to the center line P' of the stator body 60. Furthermore, Figures 11 and 12 show the energizing portion 70F provided on the inner diameter portion 70a of the fixed disk 70. Furthermore, the inner diameter portion 70a of the fixed disc 70 shown in Figure 11 is formed in an uneven shape to match the uneven shape of the stator body 60 into which the fixed disc 70 is fitted.

[0018] Figures 13 and 14 show the first rotor side disk section 120 located to the left of the rotating disk group 100 in Figure 5. As shown in Figure 14, a rotor side plate 160 made of a non-magnetic material is provided with a rotor side disk 162 made of a magnetic material having fins 161 with different outer diameters from the inside to the outside. In Figure 13, a non-magnetic lock plate 163 is provided adjacent to the rotor side plate 160, and the rotor side disk 162, made of a magnetic material having a large number of fins 162a, is superimposed on the open side 160a of the rotor side plate 160. By overlapping the lock plate 163, rotor side plate 160, and rotor side disc 162 shown in Figure 13, the rotor side disc portions 120 and 120A are overlapped with each other.

[0019] As shown in Figure 15, the stator body 60 is provided with a plurality of energizing rails 180 that electromechanically contact the energizing sections 70F shown in Figures 11 and 12, which are connected to the fixed excitation windings 51 provided on each of the fixed disks 70. Lead wires 181 connected to the energizing rails 180 from the back surface are connected to a control unit (not shown) via the central hole 120Aa, and are configured to switch the excitation of the fixed excitation windings 51 on and off.

[0020] In the above-described configuration, for example, when connecting the rotating shaft of a motor or device (not shown) to the rotor body 63 of the magnetic fluid brake 25 and stopping the rotating shaft, applying power to the fixed excitation winding 51 to turn on the excitation of the fixed excitation winding 51 causes the magnetic flux generated to cause each magnetic particle of the magnetic fluid 80 to couple along the magnetic field and semi-solidify, as is well known, thereby generating a high torque for braking, and stopping the rotation of the rotor body 63 can stop the rotational operation of the motor or actuator. Also, by turning off the excitation, the generation of magnetic flux is turned off, and the rotating disk 64 rotates again. Therefore, the magnetic fluid brake according to this embodiment can be made lighter than conventional ones because the proportion of magnetic circuits other than the rotor is small. In other words, in conventional magnetic circuits, the proportion of magnetic circuits in the fixed part is large, but according to the actual embodiment shown in Figure 5, the configuration does not include the stator body 60, and the magnetic circuits other than the torque generating part can be made smaller, making it possible to realize a high-torque, lightweight magnetic fluid brake.

[0021] Furthermore, the fixed disc 70 can be manufactured by press (prototypes can be made by milling or wire cutting). For sealing the fixed disc 70, welding (EBW, laser, TIG, seam welding, etc.) is preferable, but casting, mold molding, FRP, and CFRP are also possible. For connecting the coil wires, direct wire connection, electrode-rail connection, and connectors are also possible. To secure the flow path for the magnetic fluid, a magnetic fluid flow path can be added to the fixed disc, a magnetic fluid flow path can be added to the rotating disc, or, for example, holes can be drilled in them. Furthermore, to improve the heat resistance of the magnetic fluid 80, Permendur can be used as the magnetic powder. Also, to improve the heat resistance of the magnetic fluid 80, silicone oil can be used as the base oil. Also, to improve the heat conductivity of the magnetic fluid 80, water can be used as the base oil. Also, to improve the heat dissipation of the magnetic fluid 80, heat exchange of the base oil can be performed. Also, to improve heat dissipation, a space for circulating air, moisture, etc. can be provided inside the rotating disk 64. Also, to increase brake torque, concentric side fins (magnetic poles) can be provided on the rotating disk and the stationary disk. Also, oil-impregnated bearings may be used for the bearings. Also, a magnetic fluid seal may be used for the sealing 60A. Furthermore, the stationary excitation winding 51 needs to be efficiently wound into a narrow space inside or outside the stationary disk 70. To improve the heat resistance of the winding, coils with high heat resistance, such as polyimide wire or ceramic wire, can be used. To improve the coil occupancy rate of the winding, flat rectangular wire can be used with α winding or II winding. To improve the thermal conductivity of the windings, the use of varnishes and molding agents with good thermal conductivity is preferable. For insulating the windings, polyimide film insulating coating is preferable. [Industrial applicability]

[0022] The braking device according to the present invention brakes a vehicle or moving object using one or more non-contact brakes, and furthermore, when a large braking torque is required, a contact brake can be used in combination, thereby achieving a compact and lightweight configuration. [Explanation of Symbols]

[0023] 1. Hybrid Brake 3 Lock Plate 20 Contact brake 21 Disc brakes 22 Drum brakes 23 Non-contact brakes 25A Rotating shaft 25 Magnetic fluid brake 26 Eddy current brake 51 Fixed Excitation Winding 60 Stator body (general stator mounting shaft) 60A Ceiling 60B bearing 63 Rotor Body 63A Peripheral wall 64 RPM disc 70 Fixed disks 70A, 70B stator piece 70C, 70D: First and second recesses 70E Connection 70F Current carrying part 70M surface 70a Inner diameter 80 Magnetic fluid 100 RPM Disc Group 110 Holding space 111 Flow path for magnetic fluid 120 First rotor side disc section 120A Second rotor side disc section 120Aa center hole 121 Pump 130 recess 140 Flat-angled line 160 Rotor Side Plate 160a Open side 161 Fins 162 Rotor side disc 162a Fin 163 Lock Plate 180 Powered rail section 181 Lead wire 400 magnetic flux 401 Magnetic Circuit P Axial direction / center axis P´ center line

Claims

1. A braking device having at least one or more non-contact brakes (23) as brakes for a vehicle or moving object.

2. 2. The brake device according to claim 1, wherein the non-contact brake (23) is one or more of a hysteresis brake, an eddy current brake (26), a powder brake, and a magnetic fluid brake (25).

3. 3. The brake device according to claim 1, wherein the non-contact brake (23) comprises a pair of brakes having mutually different configurations.

4. 3. The brake device according to claim 2, wherein the non-contact brake (23) uses the eddy current brake (26) and the magnetic fluid brake (25).

5. 5. The brake device according to claim 4, characterized in that the eddy current brake (26) and the magnetic fluid brake (25) are joined together along the axial direction (P).

6. 2. The braking device according to claim 1, wherein the non-contact brake (23) is combined with a contact brake (20).

7. The magnetic fluid brake (25) comprises a rotor body (63) rotatably mounted on a stator body (60) via bearings (60B), a plurality of rotating disks (64) provided at predetermined intervals on a peripheral wall (63A) of the rotor body (63), a plurality of fixed disks (70) provided on the stator body (60) and each consisting of a pair or one stator piece (70A, 70B), a fixed excitation winding (51) provided on the fixed disk (70), and a magnetic fluid flow path (111) for supplying a magnetic fluid (80) to each of the rotating disks (64) and the fixed disk (70), 6. The brake device according to claim 5, characterized in that the generation of magnetic flux is turned on / off by turning on / off excitation to the fixed excitation winding (51), and the rotation / stop of the rotor body (63) is controlled via the magnetic fluid (80).

8. 8. The brake device according to claim 7, wherein the magnetic fluid flow passage (111) is formed on both sides in the axial direction (P) of the rotary disk group (100) formed by the rotary disk (64).

9. 8. The brake device according to claim 7, characterized in that, when the stator pieces (70A, 70B) are a pair, the fixed excitation winding (51) is provided within a retaining space (110) formed by recesses (130) formed in each of the stator pieces (70A, 70B).

10. 8. The brake device according to claim 7, characterized in that, when there is one stator piece (70A, 70B), the fixed excitation winding (51) is provided within a recess (130) formed on only one surface of the stator piece (70A or 70B).

11. 8. The brake device according to claim 7, wherein the fixed excitation winding (51) is formed by winding a rectangular wire (140) in a ring shape.

Images