Brake Disc Structure for High-Torque Electromechanical Drives
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Solution Overview
Problem
Existing electromechanical drives suffer from low braking torque and inefficient braking processes, leading to prolonged braking times and reduced safety in applications where immediate stoppage is critical.
Innovation Solution
The brake disc features an inner area, a friction surface area, and an intermediate deformation area that interacts with a stationary braking element, allowing for rapid and efficient braking by maximizing frictional engagement in the peripheral area, with the intermediate area being elastically deformable to ensure direct torque transmission and minimize contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional braking device with clutch discs is used, then the structure is simple, but the braking torque is too low and braking time is too long
Solution Approach 1:
The brake disc is segmented into three distinct functional areas: an inner area for attachment, a friction surface area for braking engagement, and an intermediate area for elastic deformation. This segmentation allows each area to perform its specific function optimally, with the friction surface area positioned in the peripheral region where highest braking torque can be generated.
Solution Approach 2:
Different regions of the brake disc are given different properties: the inner area is made rigid for secure attachment to the rotational part, the friction surface area is positioned at the periphery for maximum braking effect, and the intermediate area is made elastically deformable to transmit torque while accommodating frictional forces. This local differentiation resolves the contradiction by optimizing each region for its specific purpose.
2Force
If the friction surface area is positioned in the peripheral region, then braking torque is maximized, but the intermediate area must be deformable which complicates the structure
Solution Approach 1:
The invention merges the torque transmission function and the friction engagement function into a single integrated brake disc structure. The intermediate area serves dual purposes: it transmits torque from the inner area to the friction surface area while simultaneously accommodating the elastic deformation needed for effective braking engagement. This merging eliminates the need for separate components.
Solution Approach 2:
The material properties of the intermediate area are changed to be elastically deformable, allowing it to flex under braking loads. This parameter change enables the intermediate area to absorb and transmit forces effectively without requiring additional mechanical components, thus achieving high braking torque with relatively simple structure.
3Speed
If the braking element presses against the friction surface area, then immediate braking effect is achieved, but wear occurs on the friction surfaces
Solution Approach 1:
The invention converts the potentially harmful effect of frictional wear into a beneficial controlled process. The friction surface area is specifically designed and positioned to withstand controlled wear while maintaining effective braking. The elastic intermediate area compensates for surface irregularities and distributes contact pressure, actually reducing localized wear while maintaining immediate braking response.
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 design achieves immediate and reliable braking with enhanced braking torque, ensuring safety by promptly stopping the drive under critical conditions, thereby protecting operators and workpieces from hazards.
Implementation Method 1
a first friction surface is formed on a first side of the brake disc... a first mating surface is formed on the braking element, which mating surface faces the first friction surface and interacts with the first friction surface in the braking position
Implementation Method 2
an intermediate area extending between the friction surface area and the inner area around the rotational axis... the intermediate area is preferably designed to be deformable
Data Source
AI summary
An electromechanical drive includes a motor, a rotational part rotatable by the motor about a rotational axis, and a braking device that can be actuated between a braking position and a released position, the braking device having a brake disc that rotates with the rotational part and a braking element that can be adjusted in the axial direction and acts on the brake disc in the braking position. The brake disc has an inner area, a friction surface area extending annularly around the rotational axis with a first friction surface formed on a first side of the brake disc, and an intermediate area extending between the friction surface area and the inner area around the rotational axis. A first mating surface is formed on the braking element, which mating surface faces the first friction surface and interacts with the first friction surface in the braking position.