Electric Motor Brake Axial Adjustment for Tolerance Compensation
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Solution Overview
Problem
Existing brake assemblies for electric motors lack sufficient functional reliability, particularly in compensating for manufacturing tolerances and achieving defined movement of brake components, which affects the consistency and effectiveness of the braking process.
Innovation Solution
A brake assembly design featuring a shaft mounted in a housing part with a torque-proof connection to a coil winding, where an armature disk is rotationally fixed but axially movable, and brake pad carriers are connected to the shaft with an axially limited disk, allowing adjustable axial movement and air gap adjustment through a screw-connected limiting means, ensuring defined movement and improved reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brake assembly uses fixed brake components without axial adjustment capability, then the structure is simpler, but manufacturing tolerances cannot be compensated and functional reliability decreases
Solution Approach 1:
The patent applies the dynamics principle by making the brake pad carriers axially movable relative to the shaft instead of fixed. The brake pad carriers can move axially within a defined range limited by limiting means, allowing the brake assembly to adapt to manufacturing tolerances and maintain reliable braking performance. This dynamic adjustment capability resolves the contradiction by enabling tolerance compensation while keeping the overall structure relatively simple.
Solution Approach 2:
The patent applies the parameter changes principle by enabling axial position adjustment of the brake pad carriers through the limiting means. The axial position parameter can be varied to compensate for manufacturing tolerances, ensuring consistent braking performance. This parameter adjustment capability improves functional reliability without requiring complete redesign of the brake assembly structure.
2Manufacturing precision
If the brake assembly allows axial movement of brake components, then manufacturing tolerances can be compensated, but the device complexity increases
Solution Approach 1:
The brake pad carriers are designed with axial movability rather than being fixed to the shaft. This dynamic capability allows the carriers to adjust their axial positions to compensate for manufacturing tolerances in the disk and armature disk. The limiting means defines the axial movement range, providing a simple yet effective tolerance compensation mechanism.
Solution Approach 2:
The brake assembly enables self-adjustment through the axial movement capability of the brake pad carriers. The components can automatically accommodate manufacturing variations within the defined axial range without requiring external adjustment mechanisms or complex calibration procedures, achieving tolerance compensation through the inherent design.
3Reliability
If the air gap between friction partners is fixed, then the structure is more stable, but braking consistency cannot be optimized
Solution Approach 1:
The air gap between the disk and armature disk is made dynamically adjustable through the axial movement capability of the brake pad carriers. The limiting means defines the axial movement range, allowing the air gap to be optimized for consistent braking performance while maintaining structural stability through the defined movement limits.
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 functional reliability by allowing adjustable axial movement and air gap adjustment, compensating for manufacturing tolerances and ensuring consistent braking performance, while also being cost-effective and adaptable to various installation positions.
Implementation Method 1
the coil winding being designed as a ring winding and being accommodated in a magnetic body that acts as a coil core
Implementation Method 2
the armature disk is made of a ferromagnetic material, in particular steel, so that when the coil winding is energized, the armature disk is attracted axially towards the magnet body
Implementation Method 3
a shaft can be braked by pressing a brake lining against a braking surface
Data Source
Figure 1
Figure 2
AI summary
Brake system comprising a shaft to be braked, which is mounted in a housing part, in particular a bearing flange, by means of a bearing, the housing part being non-rotatably connected to a coil winding (14), an armature plate (3) being non-rotatably, but axially movably connected to the housing part, a first (4) and a second (10) brake lining carrier being each non-rotatably, but axially movably connected to the shaft, a disc (6) being arranged axially between the brake lining carriers (4, 10) in a rotationally fixed but axially displaceable manner, the disc being axially delimited by means of a limiting element (8), and the limiting element (8) being connected to the housing part.