Brake Leaf Spring Integrating Elastic Element and Friction Plate
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Solution Overview
Problem
Existing power tools with mechanical brakes have complex assemblies, occupy large space, and have short use life and long brake times due to the need for complex arrangement of brake plates and elastic elements.
Innovation Solution
A power tool design featuring a brake leaf spring with fixed and moving portions, where the moving portion is mounted with a friction plate that engages or disengages with a brake disc under the spring's biasing force, allowing for efficient braking without the need for complex assembly or large space occupation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical brake with brake plate and elastic element is used, then the braking function is reliable, but the assembly becomes complex and occupies large space
Solution Approach 1:
The brake leaf spring integrates multiple functions: it serves as both the elastic element and the brake plate mounting structure. The moving portion of the leaf spring directly carries the friction plate, eliminating the need for separate brake plate components and their mounting mechanisms, thus simplifying the assembly while maintaining reliable braking function
Solution Approach 2:
The brake leaf spring performs multiple roles simultaneously: it provides elastic biasing force, supports the friction plate, and enables the braking action through its moving portion. This multi-functional design reduces the number of components needed while ensuring reliable brake engagement
2Reliability
If a mechanical brake with brake plate and elastic element is used, then the braking function is reliable, but the brake occupies large space
Solution Approach 1:
By merging the elastic element and brake plate into a single brake leaf spring structure, the overall volume required for the brake mechanism is significantly reduced. The integrated design eliminates gaps and spacing requirements between separate components, allowing compact arrangement within the power tool housing
Solution Approach 2:
The brake leaf spring is designed to fit within the housing structure, with its fixed portion anchored to the housing and its moving portion extending only as far as needed to engage the brake disc. This nested arrangement minimizes the space occupied by the brake mechanism while ensuring reliable engagement
3Reliability
If a conventional mechanical brake is used, then the braking function is direct, but the use life is short and brake time is long
Solution Approach 1:
The brake leaf spring is designed with optimized curvature and thickness distribution to provide dynamic elastic response. The moving portion can quickly engage and disengage from the brake disc, reducing brake time while the elastic properties of the leaf spring distribute stress more evenly, extending the use life of the braking components
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 design provides a reliable and efficient braking mechanism that reduces assembly complexity, occupies less space, and extends the use life of the brake system while ensuring quick brake engagement.
Implementation Method 1
a brake leaf spring for contacting with the brake disc so as to brake the main shaft. The brake leaf spring includes fixed portions fixedly connected with the housing, a moving portion being capable of moving relative to the housing
Implementation Method 2
a friction plate thereon. When the moving portion is in a first position, the friction plate is disengaged with the brake disc, when the moving portion is in a second position, the friction plate is contacted with the brake disc
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A power tool includes a housing, a main shaft being capable of rotating about a first axis, which is formed with or fixedly connected with a brake disc, and a brake leaf spring for contacting with the brake disc so as to brake the main shaft. The brake leaf spring includes fixed portions fixedly connected with the housing, a moving portion being capable of moving relative to the housing, which is mounted with a friction plate thereon. When the moving portion is in a first position, the friction plate is disengaged with the brake disc, when the moving portion is in a second position, the friction plate is contacted with the brake disc. The moving portion can be moved from the first position to the second position under the action of a biasing force of the brake leaf spring.