Electric Actuator Release Brake Mechanism for Fail-Safe Return Control

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Solution Overview

Problem

Existing electric actuators in safety-critical systems face challenges in achieving reliable fail-safe functions with high Safety Integrity Level (SIL) approval, particularly in oil and gas applications, due to the need for complex redundancy systems and the risk of excess energy during return movements, which can damage components like wire line intervention wires.

Innovation Solution

The electric actuator incorporates a speed reducer/gear assembly housing that co-rotates with the rotation to linear transformer, allowing controlled braking mechanisms to manage return speed and force, utilizing non-motor driven forces like springs and fluid pressure to absorb excess energy, and integrates mechanical overrides for safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If complex redundancy systems are used to achieve reliable fail-safe functions, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvefail-safe function reliabilityVSAvoidredundancy system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the fail-safe return mechanism with the speed reducer/gear assembly housing, allowing the housing to co-rotate with the nut of the rotation to linear transformer. This integration eliminates the need for separate redundancy systems while maintaining reliable fail-safe functionality through the inherent mechanical design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The speed reducer/gear assembly housing automatically co-rotates with the nut during fail-safe return, utilizing the existing mechanical components to provide the fail-safe function without requiring additional active control systems or redundant mechanisms.

Inventive Principle:

Principle #25Self-service

2Force

If high force is provided to cut intervention wires, then cutting capability is improved, but risk of damaging the actuator increases

Engineering Contradiction:

Improvewire cutting forceVSAvoidactuator damage risk

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The patent incorporates braking mechanisms that activate during the return movement to control and dissipate excess energy before it can reach harmful levels. This cushioning effect prevents damage to the actuator while maintaining the necessary force capability for cutting intervention wires.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent converts the potentially harmful excess energy during return movement into a useful braking action. The braking mechanisms utilize the kinetic energy to activate the braking function, which then dissipates the energy safely, transforming what would be a harmful effect into a beneficial control mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Use of energy by moving object

If hydraulic fluids are used for energy absorption, then energy control is improved, but environmental risks increase

Engineering Contradiction:

Improveenergy absorption capabilityVSAvoidenvironmental risk

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent replaces hydraulic fluid-based energy absorption with a mechanical braking system. The braking mechanisms use friction and mechanical force to absorb and dissipate energy, eliminating the need for hydraulic fluids and their associated environmental risks while maintaining effective energy control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design ensures reliable fail-safe operations with minimized redundancy, achieving high SIL approval while providing the necessary force to cut intervention wires without damaging the actuator, and avoids hydraulic fluids to prevent environmental risks.

Implementation Method 1

a braking mechanism with a friction activating force

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

utilizing non-motor driven forces like springs

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12441284B2Release and brake mechanism for electric actuator

Publication Date: 2025.10.14 TECHNI HLDG

AI summary

An electric fail-safe actuator includes a speed reducer/gear assembly housing arranged between one or more electric motors, and a rotation to linear transformer including a roller or ball nut and a screw, or a nut and a roller or ball screw. The speed reducer/gear assembly housing is connected to an actuator housing via a counter hold release mechanism, allowing the speed reducer/gear assembly housing to co-rotate with a rotational side of the rotation to linear transformer when the counter hold release mechanism is released.