Adjustable Electromagnetic Air Gap for Precision Braking
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Solution Overview
Problem
Conventional power generating devices suffer from power wastage due to high power resistors, non-uniform torque distribution causing vibrations and damage, and high-cost precision requirements for electromagnetic braking.
Innovation Solution
An electric power generation and brake device with a rotatable wheel featuring an adjustable electromagnetic air gap, utilizing a stator unit with serrated portions and electric generating coils, and a brake unit with serrated portions and brake coils, along with a gap control jig to achieve precise resistance and braking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If high power resistor is used to consume remaining electric power, then power generator can operate continuously, but power wastage increases
Solution Approach 1:
The patent converts the harmful energy waste into useful braking force. The brake coils generate electromagnetic braking effect that utilizes the remaining electric power to create resistance, thereby converting energy loss into a functional benefit for controlling wheel speed and providing regenerative braking capability.
2Object-generated harmful factors
If magnets and serrated portions are not configured in pairs to reduce cogging torques, then electromagnetic noises are reduced, but torque distribution becomes non-uniform causing vibrations
Solution Approach 1:
The patent applies different configurations to different parts of the system. The magnets are arranged in pairs on the wheel while the serrated portions are arranged in pairs on the stator, creating localized magnetic interaction zones that produce uniform torque distribution. This local pairing configuration ensures consistent electromagnetic forces are generated at each interaction point, maintaining torque uniformity while controlling electromagnetic noises.
3Measurement precision
If electromagnetic braking uses high precision combination of components, then braking force control is accurate, but manufacturing cost increases
Solution Approach 1:
The patent employs an adjustable electromagnetic air gap between the wheel magnets and stator serrated portions. This dynamic adjustment capability allows the air gap to be optimized for precise braking force control without requiring extremely tight manufacturing tolerances on all components. The air gap can be tuned to achieve the desired braking characteristics, reducing the need for high-precision component combinations while maintaining braking accuracy.
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
The solution enhances resistance precision and reduces power wastage, maintains uniform torque distribution, and lowers costs by achieving precise electromagnetic air gap control without increasing machining precision or costs.
Implementation Method 1
a plurality of brake coils wound around the second serrated portions... capable of automatically adjusting their distance from the protruding ring structure under a magnetic force generated from the brake coils
Implementation Method 2
a plurality of electric generating coils wound around the first serrated portions, wherein the first serrated portions oppose the permanent magnets
Data Source
AI summary
A device for use in generating electric power and braking, a kit and a brake unit of the same are provided. A brake body in the brake unit includes a plurality of brake blocks. The brake unit has an electromagnetic air gap which is adjustable and controllable in high precision. Therefore, the tolerance of the electromagnetic air gap between the brake unit and the wheel is made small, even without increasing the machining precision and costs of the brake unit, thereby enhancing resistance precision.