Integral Damper Structure in Electromagnetic Brakes for Noise Reduction
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Solution Overview
Problem
Existing electromagnetically switchable brakes face challenges in effectively damping switching noises across a wide temperature range and require complex adjustments, leading to increased noise and operational costs.
Innovation Solution
An integral damper structure featuring elastic tabs with elevations, or 'feet,' integrated into the armature disk or coil carrier, which are pre-tensioned to counteract movement and reduce noise by providing a consistent damping force across varying temperatures without the need for additional adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If elastomers are used for damping switching noise, then noise reduction is achieved in a limited temperature range, but the damping effect deteriorates outside this temperature range due to stiffness changes
Solution Approach 1:
The patent uses spring steel instead of elastomers, changing the material parameter from polymer-based damping to metal-based elastic damping. Spring steel maintains consistent elastic properties across a wide temperature range, eliminating the temperature sensitivity of elastomers while providing reliable damping of switching noise in both cold and hot environments.
2Object-affected harmful factors
If adjusting screws are used to optimize damping elements, then damping performance is improved, but device complexity and adjustment time increase
Solution Approach 1:
The spring steel damper plate is designed to function automatically based on the physical properties of spring steel and the geometry of the air gap. The damping force self-adjusts according to the armature disk position and air gap variations, eliminating the need for manual adjustment screws or complex adjustment mechanisms while maintaining optimal damping performance.
3Object-affected harmful factors
If a large format damping plate is used, then damping coverage is improved, but manufacturing precision requirements increase due to air gap tolerance chain
Solution Approach 1:
The patent replaces the need for high-precision mechanical positioning with a magnetic field-based solution. The spring steel damper plate leverages the magnetic attraction force between the armature disk and coil carrier to maintain optimal damping contact, substituting mechanical precision requirements with magnetic field control that is inherently more tolerant of manufacturing variations.
4Object-affected harmful factors
If damping elements with high force hysteresis are used, then damping effect is improved, but energy loss increases
Solution Approach 1:
The patent changes the material parameter from high-hysteresis elastomers to low-hysteresis spring steel. Spring steel exhibits minimal force hysteresis during elastic deformation, providing effective damping of switching noise while minimizing energy loss, thereby improving operational efficiency compared to polymer-based dampers.
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 integral damper structure significantly reduces switching noise by ensuring consistent performance across a wide temperature range, simplifies installation, and minimizes force hysteresis, thereby improving operational quietness and reducing assembly costs.
Implementation Method 1
at least one elastic tab (12), which is fitted with a foot (13), is incorporated into the coil carrier (3) or the armature disk (1) as part of the manufacture or processing of the coil carrier or armature disk
Implementation Method 2
The tasks of the brakes include holding static loads and retarding uncontrolled drive movements in emergency situations
Data Source
AI summary
An electromagnetically switchable brake, preferably spring-loaded brake, comprising at least one coil carrier (3) and at least one armature plate (1), wherein the axial distance of the coil carrier and armature plate relative to out another is variable, comprising at least one rotor (7) or at least one hub of a shaft to be braked, and comprising damping members arranged between the armature plate (1) and coil carrier (3), between the end faces of the coil carrier (3) and armature plate (1) which face one another. It is considered to be novel and inventive that the solid body of coil carrier (3) and/or armature plate (1) has an integral damper structure (D), which is composed of an least one elastic tab (12) and a foot (13), the elastic tab (12) being an integral part of the solid body of the armature plate (1) or of the coil carrier (3) (FIG. 1.1).