Brake Roller Assembly With Electrorheological Load-Adaptive Braking

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Solution Overview

Problem

Existing braking systems for cargo rollers are too powerful for light loads, leading to skidding and wear on the rollers, as they are preset for maximum braking load.

Innovation Solution

A variable braking system using a brake roller assembly with an electro-rheological fluid and a braking arrangement comprising electrodes and rotor disks, which adjusts braking force based on cargo weight by varying the electric field and fluid viscosity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the braking mechanism is preset at maximum braking load, then the braking force is sufficient for heavy cargo, but the braking force is too strong for light loads causing skidding and roller wear

Engineering Contradiction:

Improvebraking effectivenessVSAvoidroller wear and skidding

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The braking system transitions from a static, fixed braking force to a dynamic, variable braking force that automatically adjusts according to the load weight. The electro-rheological fluid changes its viscosity in real-time based on the electric field strength, enabling the brake roller to adapt its braking characteristics to match the actual cargo weight, thereby preventing both insufficient braking and excessive braking that causes skidding and wear.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the physical parameter of the braking medium (electro-rheological fluid viscosity) in response to varying load conditions. By applying different voltages to the electro-rheological fluid, the viscosity can be precisely controlled to provide the appropriate braking force for each load weight, resolving the contradiction between needing strong brakes for heavy loads and weak brakes for light loads.

Inventive Principle:

Principle #35Parameter changes

2Power

If a friction material is used around the outer surface of the roller, then braking is achieved, but flat spots are created on the roller under light loads

Engineering Contradiction:

Improvebraking powerVSAvoidroller surface integrity

Core Design Contradiction:

PowerVSManufacturing precision

Solution Approach 1:

The patent replaces the traditional mechanical friction-based braking system with an electro-rheological fluid-based braking system. Instead of relying on friction material contact that causes surface wear and flat spots, the system uses controllable fluid viscosity to generate braking force, eliminating direct frictional contact damage to the roller surface while maintaining effective braking power.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Force

If strong brakes are used on rollers, then maximum braking load is controlled, but the roller cannot roll under light loads

Engineering Contradiction:

Improvebraking forceVSAvoidroller mobility

Core Design Contradiction:

ForceVSEase of operation

Solution Approach 1:

The braking system becomes dynamically adjustable, allowing the brake roller to transition between different operational states: free-rolling mode for light loads and braking mode for heavy loads. The electro-rheological fluid's viscosity can be rapidly changed by adjusting the electric field, enabling the roller to easily start and move under light loads while providing strong braking when needed.

Inventive Principle:

Principle #15Dynamics

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 system provides a variable braking force that adapts to the weight of the cargo, reducing wear on the rollers and ensuring efficient braking, even under varying load conditions.

Implementation Method 1

Methodology Applied

Scientific EffectElectro-rheological effect: Electrorheological Effect

Implementation Method 2

The brake roller assembly may further comprise a stator disk having a piezoelectric material, wherein the piezoelectric material is configured to act as a power source for the plurality of electrodes.

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 3

The anode and the cathode may be configured to create an electric field therebetween. The fluid may be an electro-rheological fluid.

Methodology Applied

Scientific EffectElectric field effect on fluid viscosity: Electrorheological Effect

Data Source

PatentUS20250033909A1Variable braking systems and devices

Publication Date: 2025.01.30 GOODRICH CORP

AI summary

A brake roller assembly may comprise: a shaft; a first roller bearing coupled to the shaft and disposed at a first axial end of the shaft a second roller bearing coupled to the shaft and disposed at a second axial end of the shaft; a roller cylinder disposed radially outward of the first roller bearing and the second roller bearing; and a braking arrangement, including a plurality of electrodes, and a plurality of rotor disks coupled to the roller cylinder, each rotor disk in the plurality of rotor disks disposed between an anode in the plurality of electrodes and a cathode in the plurality of electrodes.