Integrated Brake-Transmission Assembly for Compact Torque Amplification
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Solution Overview
Problem
Conventional brake systems are not compact enough and lack efficient torque transmission, requiring additional components like electric motors and separate wheel axles, which increases size and complexity.
Innovation Solution
A compact brake assembly that integrates a brake, an adapter, and a transmission, where the adapter connects the brake directly to the transmission, amplifying braking torque through the transmission's gear ratio, and includes a magnetically actuated brake mechanism with a centering bearing for high torsional stiffness and safety features like spring-loaded armature disks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a brake is connected directly to a transmission via an adapter, then the device complexity is reduced and size is minimized, but the braking torque transmission efficiency must be sufficiently high
Solution Approach 1:
The brake assembly is merged with the transmission unit through the adapter, combining functions that were previously separate. The adapter housing integrates the brake mounting interface with the transmission input shaft bearing support, creating a compact unified assembly that reduces overall device complexity while maintaining functional integrity
Solution Approach 2:
The adapter serves multiple functions simultaneously: it provides the mechanical interface for brake mounting, supports the input shaft bearing, and transmits the amplified braking torque from the brake to the transmission. This multi-functionality eliminates the need for separate components, reducing complexity while ensuring efficient torque transmission
2Volume of moving object
If the brake is made compact by eliminating intermediate components, then the volume is reduced, but the reliability of braking must be maintained or improved
Solution Approach 1:
The spring element is pre-loaded to provide a biasing force that ensures the brake pads are positioned correctly and maintain proper contact pressure. This pre-cushioning mechanism ensures reliable braking engagement from the start, maintaining safety while enabling a compact design without intermediate components
Solution Approach 2:
The magnetic coil and armature assembly create a self-contained actuation system where the magnetic field directly engages the brake mechanism through the armature disk. This self-service magnetic actuation eliminates the need for external linkages or intermediate mechanical components, reducing volume while maintaining reliable braking through direct magnetic force application
3Ease of manufacture
If the brake assembly is compacted by integrating components, then the manufacturing cost is reduced, but the ease of manufacture must be maintained
Solution Approach 1:
The brake assembly is segmented into distinct functional modules: the adapter housing as a separate component, the brake mechanism with its own mounting interface, and the magnetic actuation system. This segmentation allows each module to be manufactured independently using standard processes, reducing overall manufacturing cost while managing assembly complexity through modular design
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 achieves a compact design with enhanced braking torque, increased safety through magnetic engagement, and eliminates the need for separate wheel axles by directly connecting the output shaft to the guide wheel, allowing for efficient and safe braking in storage and retrieval devices.
Implementation Method 1
the magnetic force generated by the coil with the magnetic body overcomes the spring force generated by the spring elements in terms of magnitude, and the armature disk is pulled towards the magnetic body so that the brake is released
Implementation Method 2
spring elements supported on the magnet body press onto the armature disk
Implementation Method 3
a braking surface is formed on the flange part, e.g., formed in a finely machined manner. Thus, the frictional heat of the brake is transferred to a housing part
Data Source
AI summary
A brake assembly includes a brake, an adapter, and a transmission. The adapter has an adapter housing, which is connected to a housing part of the transmission, and a flange part of the brake is connected to the adapter housing on the side of the adapter housing facing away from the transmission. A cover part of the brake is connected to the flange part, and at least one bearing for rotatably mounting the input shaft of the transmission is accommodated in the adapter housing.