Brake Lever Segmentation Reduces Manual Force
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Solution Overview
Problem
Existing brake assemblies for electric motors lack improved safety features, particularly in terms of manual ventilation and maintenance, with high operational forces and susceptibility to wear, which compromises safety and efficiency.
Innovation Solution
A brake assembly design featuring a brake lever with two lever sections, a pivot bearing, and a roller mechanism that reduces operational force and enhances durability, allowing for compact and low-wear operation, along with redundant braking units for increased safety and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single lever design is used for manual brake release, then the structure is simple, but high operational force is required and wear susceptibility increases
Solution Approach 1:
The brake lever is divided into two separate lever sections (first lever section and second lever section) connected by a pivot bearing. The first lever section has a longer lever arm that applies force to the second lever section, which then actuates the brake release mechanism. This segmentation allows the operational force to be applied at a more favorable mechanical advantage point while keeping each individual lever section relatively compact.
2Reliability
If a pivot bearing is introduced between lever sections, then wear is reduced and durability enhanced, but device complexity increases
Solution Approach 1:
A pivot bearing is introduced as an intermediary element between the first and second lever sections. This pivot bearing acts as a low-wear connection that allows relative rotation between the two lever sections while transmitting the actuating force. The pivot bearing specifically addresses the wear issue at the connection point between lever sections, providing a durable, maintenance-free connection that simplifies the overall structure compared to alternative high-wear connections.
3Volume of moving object
If lever arm length is reduced for compact design, then installation space is minimized, but operational force requirements increase
Solution Approach 1:
The brake lever system utilizes a two-dimensional arrangement of the two lever sections connected by a pivot bearing, allowing the force application point and the brake release actuation point to be positioned at different locations in space. This dimensional arrangement enables a compact overall footprint while maintaining an effective lever arm length for force multiplication, as the lever sections can be arranged at angles to each other rather than requiring a single long linear lever.
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 simplifies manual ventilation and maintenance, reduces operational force, enhances durability, and improves safety through reduced wear and redundant braking, ensuring reliable operation and safety even in case of component failure.
Implementation Method 1
a roller, in particular a free-rotating roller, is rotatably mounted on the second lever section
Implementation Method 2
a pivot bearing, in particular comprising a pin, is arranged between the first lever section and the second lever section
Implementation Method 3
the brake lever having a first and a second lever section
Data Source
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AI summary
The invention relates to an electromagnetically actuatable brake arrangement, particularly for an electric motor with a rotor shaft, and to an electric motor, wherein the brake arrangement has an anchor plate, characterised in that the brake arrangement has a brake lever, particularly for manually supplying air to a brake, wherein the brake lever has a first lever section and a second lever section, and is particularly composed of a first lever section and a section lever section.