Compact Electromagnetic Brake Layout for Reduced Axial Thickness
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Solution Overview
Problem
Traditional electromagnetic brakes have a large thickness, which is not suitable for applications with limited installation space, and reducing their thickness using existing methods leads to issues like reduced magnetic field, material weakness, noise amplification, and thermal stress.
Innovation Solution
The brake design incorporates a magnetic yoke iron core with internal mounting spaces for the friction disk and movable plate, allowing the armature and coil to be positioned without increasing overall thickness, using a magnetic field to attract the armature and an elastic part to control the movable plate's movement for braking, thus maintaining structural integrity and reducing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the traditional stacking assembly method is used, then the brake can be manufactured with simple structure, but the axial thickness becomes large
Solution Approach 1:
The friction disk is nested within the magnetic yoke's internal cavity space, and the armature is positioned within the magnetic circuit structure. This nesting arrangement allows multiple components to occupy the same axial space rather than stacking sequentially, dramatically reducing the overall axial thickness while maintaining manufacturability through conventional machining of the magnetic yoke cavity.
Solution Approach 2:
The design transitions from a one-dimensional stacking arrangement (components arranged along the axial direction) to a three-dimensional integrated structure where components are distributed in radial and axial dimensions. The magnetic yoke's internal cavity accommodates the friction disk radially, while the armature is positioned within the magnetic circuit, creating a compact spatial arrangement that reduces axial thickness.
2Length of moving object
If the thickness of magnetic yoke, armature, friction disk and tail plate is reduced, then the overall thickness decreases, but the magnetic field strength reduces and heating power increases
Solution Approach 1:
The coil is nested within the magnetic yoke's internal cavity, maximizing the use of available space. This allows for adequate coil volume and turns to generate sufficient magnetic field strength without increasing the external dimensions of the brake, thereby maintaining magnetic performance while achieving reduced overall thickness.
Solution Approach 2:
The magnetic yoke is designed with optimized local magnetic path geometry, including concentrated flux paths and strategic positioning of the armature within the magnetic field. This local optimization ensures high magnetic field density in the critical braking region, maintaining effective magnetic force despite reduced overall component thicknesses.
3Length of moving object
If the thickness of friction pair parts is reduced, then the overall thickness decreases, but rigidity is weakened and parts are prone to creep or stress deformation
Solution Approach 1:
The friction disk and armature are designed with optimized local thickness distributions and reinforcement features in critical stress zones. The friction disk maintains adequate thickness at the friction surfaces for rigidity, while the overall brake thickness is reduced through the nested arrangement. Strengthening ribs or optimized cross-sectional geometry are incorporated where stress concentration occurs, preventing creep and deformation.
Solution Approach 2:
High-strength, low-alloy materials or composite materials with enhanced mechanical properties are selected for the friction disk and armature. These materials provide superior strength-to-thickness ratios, enabling the components to maintain adequate rigidity and resistance to stress deformation even with reduced thickness, while contributing to the overall compactness of the brake.
4Length of moving object
If the thickness of friction pair parts is reduced, then the overall thickness decreases, but heat capacity decreases and temperature rises rapidly
Solution Approach 1:
The friction disk is designed with optimized local thickness and geometry to maximize thermal mass in the friction zones while minimizing overall brake thickness through the nested arrangement. Heat dissipation features such as venting channels or thermal pathways are incorporated into the magnetic yoke and friction disk structure, enabling efficient heat transfer away from the friction surfaces, thereby controlling temperature rise despite reduced material volume.
Solution Approach 2:
Friction materials with high specific heat capacity and good thermal conductivity are selected for the friction disk. These materials can absorb and dissipate heat more effectively per unit mass, compensating for the reduced overall thickness. The use of thermally conductive materials helps rapidly transfer heat from the friction surfaces to the magnetic yoke and surrounding structure, preventing rapid temperature rise and thermal stress.
5Length of moving object
If the thickness of friction pair parts is reduced, then the overall thickness decreases, but noise is amplified
Solution Approach 1:
The friction surfaces are designed with optimized local geometry, including surface finish control and micro-structure features that reduce vibration and noise generation during braking. The nested arrangement provides natural acoustic isolation, as the magnetic yoke structure encloses the friction disk, dampening noise propagation. Vibration-damping features or constrained layer damping are incorporated at critical interfaces to suppress noise-amplifying resonances.
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
This design effectively reduces the brake's thickness without compromising its structural integrity or increasing noise, ensuring reliable operation and improved braking performance, especially in applications requiring compactness.
Implementation Method 1
When the coil 92 is energized, a magnetic force is generated. Under the attraction of the magnetic force, the armature 94 overcomes the elastic force of the spring 93
Implementation Method 2
When the coil 92 is not energized, the spring 93 pushes the armature 94 close to the tail plate 95
Implementation Method 3
When the friction disk 96 is clamped by the armature 94 and the tail plate 95, the friction disk 96 rubs against the armature 94 and the tail plate 95 to generate a braking force
Data Source
AI summary
The disclosure provides a brake including a magnetic yoke iron core, a movable plate, a friction disk, a coil, an armature and an elastic part; a first mounting space penetrates through a center position of the magnetic yoke iron core in the axial direction; an opening of a second mounting space faces a second shaft end; the movable plate is located in the first mounting space and close to a first shaft end; the friction disk is arranged in the first mounting space and located at a side of the movable plate close to the second shaft end; the coil is arranged in the second mounting groove; the armature is located at the second shaft end, and the armature is connected with the movable plate through a connector; and the elastic part has pre-tightening force that enables the armature to be far away from the magnetic yoke iron core.