Brake Conveyor Roller Eddy-Current Layout With Ferrite Magnets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing brake conveyor rollers using eddy current brakes require high-value materials like rare earth metals and copper to achieve sufficient magnetic braking strength, limiting cost-effectiveness and space efficiency.
Innovation Solution
The innovative arrangement of magnetic yoke elements and eddy current receivers, utilizing ferrite magnets and aluminum instead of rare earth metals and copper, reduces magnetic losses and allows for a more cost-effective and space-efficient brake conveyor roller design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If high-value magnetic materials like rare earth metals and copper are used, then sufficient magnetic braking strength is achieved, but cost increases and space requirements increase
Solution Approach 1:
The patent changes the magnetic material from rare earth metals to ferrite magnets, and the eddy current receiver from copper to aluminum. This material substitution maintains the magnetic braking effect while significantly reducing cost and material value, directly resolving the contradiction between achieving sufficient braking strength and manufacturing cost
Solution Approach 2:
The patent replaces expensive magnetic materials (rare earth metals) with cheaper alternatives (ferrite magnets) and expensive conductive materials (copper) with cheaper alternatives (aluminum). This substitution achieves the same functional effect using less valuable materials, directly addressing the cost issue while maintaining braking performance
2Force
If high-value magnetic materials like rare earth metals and copper are used, then sufficient magnetic braking strength is achieved, but device complexity and material quantity increase
Solution Approach 1:
The patent substitutes ferrite magnets for rare earth magnets and aluminum for copper, achieving the same magnetic braking effect with different material properties. This parameter change in material selection reduces the quantity and value of magnetic relevant materials required while maintaining sufficient braking strength
Solution Approach 2:
By using cheaper materials (ferrite and aluminum) instead of expensive materials (rare earth metals and copper), the patent reduces both the cost and quantity of magnetic relevant materials needed to achieve the same braking effect, resolving the contradiction between force generation and material quantity
3Force
If conventional magnetic arrangement is used, then magnetic braking effect is achieved, but magnetic losses increase
Solution Approach 1:
The patent modifies the magnetic arrangement parameters by positioning the magnetic yoke elements radially outward from the magnetic array, with the eddy current receiver positioned between the magnetic array and yoke elements. This geometric parameter change optimizes magnetic flux distribution and reduces magnetic losses while maintaining the braking effect
Solution Approach 2:
The magnetic yoke elements act as intermediaries that guide and concentrate the magnetic flux from the magnetic array to the eddy current receiver. This intermediary structure improves magnetic coupling efficiency and reduces magnetic losses by providing a defined flux path
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 improved design achieves the same braking effect with reduced material usage, lowering costs and maintaining performance, while allowing for the use of cheaper materials like ferrite magnets and aluminum.
Implementation Method 1
When the roller tube rotates, an eddy currents is induced in the insert by the magnetic field, which counteracts the rotary motion of the roller shell with a braking torque
Implementation Method 2
A magnet is stationarily connected with the bearing. When the roller tube rotates, an eddy currents is induced in the insert by the magnetic field
Data Source
Figure 1~2
Figure 3~4
AI summary
Brake conveyor roller (4) for a roller conveyor (1), comprising at least one axle element (41); a roller tube (42) adapted to be rotatable about at least on axle element (41); a brake (5) adapted to provide a brake force against the rotation of the roller tube (42) relative to the axle element (41), wherein the brake comprises a first brake component (51) and a second brake component (52), wherein one of said a first and second brake components (51, 52) is rotatably connected to the axle element and the other one of said a second and first brake components (52, 51) is rotatably connected to the roller tube (42), wherein the first brake component (51) comprises an magnetic array (512) of magnetized sections (S, N), wherein the second brake component (52) comprises an eddy current receiver (523) adapted to generate an eddy current brake effect in case that the first brake second brake component is rotated relative to the first brake component; wherein the second brake component (52) comprises a second yoke element (524) adapted to provide a magnetic yoke effect (Y) attached to the eddy current receiver (523).