Backlash Gear Train Drive for Fast Electric Braking Force
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Solution Overview
Problem
Existing braking, clamping, or gripping devices face challenges in achieving high dynamic response with low energy consumption, requiring a small installation space, and ensuring a long service life without a compressed air drive.
Innovation Solution
The gear train is accelerated by a non-switchable shaft coupling with backlash, utilizing a disc coupling or thrust coupling with longitudinal backlash, allowing gear parts to jerk stationary parts into motion, and incorporating a highly dynamic brushless DC motor with a series of gears to achieve high braking, clamping, or gripping forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a compressed air drive is used to achieve high braking force, then the braking force is sufficient, but the installation space increases and the system complexity increases
Solution Approach 1:
The patent replaces the compressed air drive system with an electric motor drive system. The electric motor (221) directly drives the gear train (230, 260) to generate braking force, eliminating the need for compressors, air tanks, and pneumatic hoses, thereby significantly reducing installation space while maintaining sufficient braking capability
Solution Approach 2:
The patent extracts and removes the compressed air drive components from the braking system, replacing them with a compact electric motor system. This extraction eliminates unnecessary mechanical complexity and reduces the overall system footprint while preserving the essential braking function
2Force
If a compressed air drive is used to achieve high braking force, then the braking force is sufficient, but the device complexity increases
Solution Approach 1:
The patent substitutes the complex compressed air drive system with a simpler electric motor system. The electric motor (221) with its direct coupling to the gear train eliminates multiple pneumatic components, valves, and control mechanisms, thereby reducing device complexity while maintaining high braking force capability
Solution Approach 2:
The electric motor system serves multiple functions: it provides braking force, controls the braking timing, and can be integrated with the control unit (299) for automated operation. This multi-functionality reduces the need for separate pneumatic control systems, thereby simplifying the overall device complexity
3Speed
If the gear train is accelerated quickly to improve dynamic response, then the response time decreases, but the energy consumption increases
Solution Approach 1:
The patent applies preliminary action by pre-accelerating the gear parts near the motor before engagement. The electric motor accelerates the gear train incrementally, storing kinetic energy in the rotating masses, which is then utilized during braking operations to reduce peak energy consumption while maintaining fast dynamic response
Solution Approach 2:
The patent employs periodic action through the backlash mechanism in the shaft coupling. The coupling elements engage and disengage periodically, allowing the gear train to be accelerated in controlled increments rather than continuously, thereby reducing overall energy consumption while maintaining rapid response capability
4Speed
If a shaft coupling with backlash is used to transfer momentum, then the dynamic response improves, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies dynamics by designing the shaft coupling with intentional backlash that allows for dynamic momentum transfer. The coupling elements (62, 63) are designed with flat flanks that engage at specific coupling angles (at least 10 degrees), creating a controlled dynamic interaction that improves response time while accommodating manufacturing tolerances through the designed play in the coupling
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 solution provides a high dynamic response with low energy consumption, small installation space, and long service life, enabling automatic release of jammed devices by detecting faults with position and speed sensors, and utilizing clutch backlash for momentum transfer.
Implementation Method 1
The backlash or longitudinal backlash is fully available during each engagement and release process in order to jerk the stationary gear parts into motion using the already accelerated gear parts
Implementation Method 2
a non-switchable shaft coupling based on a disc coupling and subject to backlash, consisting of a drive pulley and an output pulley, or a thrust coupling with longitudinal backlash
Implementation Method 3
The electric motor has an output member that acts on a lifting carriage via the gears
Implementation Method 4
a highly dynamic brushless DC motor with a series of gears
Data Source
Figure 1~2
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Figure 6~15
AI summary
The invention relates to a method and a drive for a device for accelerating a gear train of a braking, clamping, or gripping device that is moving on a block. The device implementing the method has a drive that houses at least one electric motor and at least two gearboxes in a housing, wherein the electric motor has an output element that acts on a lifting slide via the gearboxes. The part of the gear train closest to the motor can be accelerated before the part furthest from the motor. For this purpose, a non-switchable, backlash-prone shaft coupling or a longitudinally backlash-prone sliding coupling is integrated into the gear train.The present invention develops a method and a device for accelerating a gear train traveling on a block of a braking, clamping or gripping device, which exhibits high dynamics with low energy consumption while providing high braking, clamping or gripping force, low installation space requirements and a long service life.