Friction Brake Lock Collar Torque Stability
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Solution Overview
Problem
Friction brakes face issues due to overload, size, complexity, and torque variations over time, leading to increased costs and operational challenges, particularly in maintaining performance across varying conditions.
Innovation Solution
A friction brake design incorporating a shaft with a lock collar and tolerance rings providing an interference fit, along with a locking component that engages the lock collar to prevent rotation, utilizing a tolerance ring with annular bands and projections to adjust torque and compensate for manufacturing variations, and featuring a locking mechanism actuated by magnetic, electric, or electromagnetic means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a friction brake uses a traditional design without a tolerance ring, then the structure is simpler, but the torque varies over time due to wear and manufacturing variations
Solution Approach 1:
A tolerance ring is introduced as an intermediary component between the brake rotor and the locking component. This tolerance ring absorbs manufacturing variations and wear, maintaining consistent torque transmission without requiring higher precision in other components. The tolerance ring acts as a buffer that compensates for dimensional changes over time.
Solution Approach 2:
The tolerance ring is designed with specific material properties and dimensional parameters that allow it to deform elastically under load. By carefully selecting the ring's thickness, material modulus, and initial dimensions, the system maintains constant torque despite wear and manufacturing tolerances in other components.
2Strength
If the friction brake uses a larger size to handle overload situations, then the strength increases, but the device complexity and cost increase
Solution Approach 1:
The tolerance ring provides dynamic overload protection by deforming elastically when excessive force is applied. Instead of requiring an oversized rigid structure, the system uses the ring's elastic deformation to absorb overload energy, then returns to its original shape. This dynamic response allows smaller overall dimensions while maintaining strength.
Solution Approach 2:
The tolerance ring is pre-installed in a state that allows it to absorb sudden overload forces. The ring's elastic properties are selected to provide cushioning before damage occurs, protecting the brake components from shock loads without requiring oversized protective structures.
3Ease of operation
If the locking mechanism uses magnetic, electric, or electromagnetic engagement, then the actuation force is reduced, but the dependency on solenoid strength increases
Solution Approach 1:
The traditional mechanical spring-based locking mechanism is replaced with magnetic, electric, or electromagnetic actuation. This substitution reduces the actuation force required while maintaining reliable locking engagement. The magnetic field provides the necessary holding force without requiring strong mechanical springs.
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 enhances torque stability and reduces dependence on solenoid strength, allowing for effective braking with minimal actuation force, even under larger loads, while maintaining performance across varying conditions and reducing component wear.
Implementation Method 1
at least one tolerance ring disposed between the lock collar and the shaft providing an interference fit therebetween
Implementation Method 2
a locking component adapted to engage the lock collar to prevent rotation of the lock collar
Data Source
AI summary
A friction brake including a shaft having an input end and an output end, at least one lock collar, at least one tolerance ring disposed between the lock collar and the shaft providing an interference fit therebetween, and a locking component adapted to engage the lock collar to prevent rotation of the lock collar.