Electromechanical Brake Control Circuit for Power-Saving Fail-Safe Operation
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Solution Overview
Problem
Existing braking systems for electric motors face challenges in achieving high safety integrity levels (SIL) while minimizing power consumption and addressing delays in brake application, energy return issues, and the lack of effective fault detection and power saving mechanisms.
Innovation Solution
A control circuit utilizing a switching regulator with semiconductor switches, diodes, capacitors, and inductors to dynamically control the voltage applied to the brake coil, allowing for safe and rapid brake application, fault detection, and adjustable power-saving modes, with separate control signals from both the process and safety sub-systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brake coil is continuously energized to maintain safety, then safety integrity is improved, but power consumption increases
Solution Approach 1:
The patent implements periodic monitoring of the brake coil circuit through diagnostic feedback signals that periodically check the state of semiconductor switches and brake coil voltage. This allows the system to maintain safety through intermittent verification rather than continuous energization, enabling power-saving modes while maintaining SIL3 compliance.
Solution Approach 2:
The patent dynamically adjusts the brake control strategy based on operational conditions. The switching regulator and diagnostic system enable the brake to transition between fully energized, partially energized, and de-energized states while maintaining safety integrity through real-time monitoring and feedback, optimizing power consumption across different operating scenarios.
2Device complexity
If conventional brake control circuits are used, then simplicity is maintained, but brake application delay increases
Solution Approach 1:
The patent replaces conventional mechanical or simple electromagnetic brake release mechanisms with a switching regulator circuit using semiconductor switches (MOSFETs or IGBTs). This electronic switching system provides much faster brake application and release control, reducing brake application delay while maintaining manageable circuit complexity through integrated control.
Solution Approach 2:
The diagnostic feedback system continuously monitors the state of semiconductor switches and brake coil voltage before brake application is required. This preliminary monitoring ensures that the system is ready for rapid brake application when needed, reducing actual brake application delay by preparing the circuit in advance.
3Speed
If full voltage is applied to the brake coil for rapid release, then brake release speed is improved, but power loss increases
Solution Approach 1:
The patent uses a switching regulator to dynamically control the voltage parameter applied to the brake coil. The regulator can rapidly switch between different voltage levels (0V, partial voltage, full voltage) based on operational requirements. This enables rapid brake release when full voltage is needed while allowing power-saving modes with reduced voltage during normal operation, optimizing the trade-off between brake release speed and power loss.
4Ease of operation
If simple brake control is used, then ease of operation is maintained, but fault detection capability is insufficient
Solution Approach 1:
The patent implements a diagnostic feedback system that provides real-time information about the state of semiconductor switches and brake coil voltage to the control system. This feedback mechanism enables automatic fault detection without complicating the operational interface, maintaining ease of operation while significantly improving fault detection capability through intelligent monitoring and reporting.
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 ensures SIL3 compliance, rapid brake application, power savings, and fault detection, while minimizing energy return issues and board area, thus enhancing safety and efficiency in electric motor braking systems.
Implementation Method 1
a switching regulator configured to control a magnitude of voltage applied to a brake coil of the electromechanical brake; wherein said switching regulator includes at least one semiconductor switch, one diode, one capacitor and one inductor
Implementation Method 2
said switching regulator includes at least one semiconductor switch, one diode, one capacitor and one inductor
Implementation Method 3
said switching regulator includes at least one semiconductor switch, one diode, one capacitor and one inductor
Implementation Method 4
said switching regulator includes at least one semiconductor switch, one diode, one capacitor and one inductor
Data Source
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AI summary
A control circuit configured to control an electromechanical brake is provided. The control circuit includes: a switching regulator configured to control a magnitude of voltage applied to a brake coil of the electromechanical brake; wherein said switching regulator includes at least one semiconductor switch, one diode, one capacitor and one inductor; the control circuit is configured such that, in operation, at least one signal from a process sub-system specifies the magnitude of the voltage for the brake coil; and at least one brake applying control signal from a safety sub-system can cause the brake coil voltage to be reduced to a level low enough to apply the brake by opening a switch and each brake applying control signal from the safety sub-system has a corresponding diagnostic feedback signal to the safety sub-system that indicates the state of the corresponding switch. A method and a system are disclosed.