Chain Disk Locking Mechanism for Clutch-Free Door Machine Operation
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Solution Overview
Problem
Conventional electric door machines with clutch mechanisms are complex, expensive, and prone to failure, requiring a clutch switch for mode changes, which complicates operation and reduces lifespan, especially during frequent opening and closing in warehouse or garage settings.
Innovation Solution
An electric door machine with a chain disk locking mechanism that eliminates the need for a clutch, featuring a simplified structure, adjustable brake force, and an electromagnetic brake module for flexible operation between electric and manual modes, including a chain disk, engaging rotary block, stationary shaft, moving pins, and an electromagnetic brake system for enhanced reliability and maintenance convenience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a clutch mechanism is used to switch between motor driven rolling and manual chain disk rolling, then mode switching capability is achieved, but device complexity increases and cost increases
Solution Approach 1:
The patent removes the clutch mechanism entirely from the system. Instead of using a clutch to switch between motor-driven and manual modes, the design directly couples the motor to the chain disk through a brake mechanism, eliminating the need for mode switching hardware while maintaining operational flexibility.
Solution Approach 2:
The brake mechanism serves multiple functions: it acts as a holding brake to prevent the door from falling when closed, and it can be released to allow manual operation. This multi-functional design replaces the need for a dedicated clutch mechanism, simplifying the overall system while maintaining adaptability.
2Adaptability or versatility
If a clutch mechanism is used to switch between operating modes, then mode switching is enabled, but manufacturing cost increases
Solution Approach 1:
By extracting and removing the clutch mechanism from the design, the patent significantly reduces manufacturing costs. The simplified structure uses fewer precision components, reducing both material costs and assembly complexity while maintaining the essential functionality of supporting both motor-driven and manual operation.
3Adaptability or versatility
If a clutch mechanism is used for mode switching, then operational flexibility is achieved, but reliability decreases due to high failure chances
Solution Approach 1:
Removing the clutch mechanism eliminates the primary source of mechanical failure in mode switching systems. The direct coupling design with electromagnetic brake has fewer moving parts and potential failure points, significantly improving reliability while maintaining operational flexibility through the brake release mechanism.
Solution Approach 2:
The patent replaces the mechanical clutch switching system with an electromagnetic brake system. This substitution reduces mechanical wear and friction-related failures, improving reliability while maintaining the ability to switch between motor-driven and manual operation modes.
4Force
If the number of brake disks and brake wheels is increased, then brake force increases, but device complexity increases
Solution Approach 1:
The patent pre-positions multiple brake disks and brake wheels in a compact arrangement that provides sufficient brake force without requiring complex control mechanisms. The brake components are strategically positioned to maximize friction contact area and leverage, achieving high braking capability through intelligent design rather than sheer quantity.
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 provides a cost-effective, easy-to-maintain, and long-lasting electric door machine that can operate at high speeds without a clutch, ensuring reliable operation with flexible brake adjustment and extended service life, capable of switching modes without a clutch mechanism, achieving over 300,000 cycles.
Implementation Method 1
an electromagnetic brake module for switching between the electric motor driven rolling and the manual chain disk rolling
Implementation Method 2
the moving pins is engaged between the first end face of the engaging rotary block and the inner walls of the central circular bore, so the stationary shaft is prohibited from rotating
Data Source
AI summary
A door machine having an electric motor and a chain disk locking mechanism. The chain disk locking mechanism includes a chain disk, an engaging rotary block, a stationary shaft and a plurality of moving pins. When the chain disk is pulled to rotate, the fixed pins of the chain disk press the moving pins so as to push the engaging rotary block to rotate with the stationary shaft together. When the stationary shaft is pulled to rotate, the engaging rotary block prohibits the moving pins from rotation. When the chain disk is pulled manually, the rolling door can be rolled upward or downward; when cease pulling the chain disk, braking is immediately effected so as to prevent the rolling door from moving upward or downward. Hence, the clutch mechanism can be omitted for cost saving and the structure of the mechanism can be simplified.