Electromagnetic Brake Wear Monitoring via Nested Sensor
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Solution Overview
Problem
Brake devices face challenges in maintaining safety due to wear and require compact integration of monitoring solutions without enlarging the brake structure.
Innovation Solution
An electromagnetically actuable brake device incorporating a coil shell, armature disk, sensor housing, spring part, and screwed cable gland, where the sensor is integrated within the brake to monitor wear and function, utilizing a stepped design and eddy-current sensor for distance sensing, allowing compact placement without modifying the coil or enlarging the brake.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor is integrated into the brake device for wear monitoring, then safety and reliability are improved, but the device complexity increases
Solution Approach 1:
The sensor is integrated into the existing brake structure by utilizing the coil shell and cable gland assembly, merging the monitoring function with the electromagnetic actuator components. This allows wear detection capability to be added without creating a separate monitoring system, thereby improving reliability while limiting the increase in overall device complexity.
Solution Approach 2:
The coil shell and cable gland assembly serve multiple functions: they provide structural support for the electromagnetic actuator, seal the internal components, and now also house the wear monitoring sensor. This multi-functionality approach allows the same structural elements to serve both actuation and monitoring purposes, adding safety without proportionally increasing complexity.
2Volume of moving object
If the sensor is placed inside the brake housing, then the brake structure remains compact, but the sensor installation space is limited
Solution Approach 1:
The sensor is nested within the existing cable gland assembly and coil shell structure. The cable gland, which already exists to seal the cable entry point, is configured to also hold and position the sensor. This nesting approach allows the sensor to be placed inside the brake housing without requiring additional external space or enlarging the brake structure.
Solution Approach 2:
Instead of adding the sensor in the radial or axial directions that would increase brake volume, the sensor is positioned in the circumferential direction within the plane of the coil shell. The sensor measures wear in the axial direction while being mounted in the radial plane, effectively utilizing unused dimensional space within the existing structure.
3Ease of manufacture
If the spring part is used to press the sensor against the bore step, then the sensor mounting is simplified, but the cable routing distance increases
Solution Approach 1:
The spring part acts as an intermediary element between the sensor and the cable gland. It provides the necessary contact force to press the sensor against the bore step for stable mounting and electrical contact, while the cable gland serves as the intermediary that routes the cable from the sensor to the external connection point. This intermediary approach simplifies sensor mounting while managing the cable routing distance.
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 solution enhances safety by enabling wear monitoring and compact integration of the sensor within the brake, ensuring reliable operation and maintaining a compact design without hampering rotational motion, while achieving high resolution in sensing the armature disk position.
Implementation Method 1
The spring part is braced on a step of the sensor housing on one side and braced on the screwed cable gland on the other. The sensor housing is pressed against a step of the bore, in particular by the spring part.
Implementation Method 2
The sensor may be arranged as an eddy-current sensor. The spring part presses the sensor against a step of the bore, the spring being braced on a screwed cable gland through which the sensor cable is routed to the outside.
Implementation Method 3
the coil, inserted into the coil shell, attracting the armature disk to the coil shell when energized
Data Source
AI summary
An electromagnetically actuable brake device includes: a coil shell, in particular of the solenoid, an armature disk, which is connected to the coil shell in a torque-proof yet displaceable manner, a sensor having a sensor housing, a spring part, and a screwed cable gland. The coil shell has a stepped through bore, the sensor housing of the sensor has a stepped configuration, the screwed cable gland is situated at an end of the bore, in particular is screwed into a threaded section of the bore, the spring part is situated in the bore between the screwed cable gland and the sensor housing, the spring part is braced on a step of the sensor housing on one side and on the screwed cable gland on the other, and the sensor housing is pressed against a step of the bore, in particular by the spring part.