Concentric Brake Assembly With Pretensioned Friction Release
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Solution Overview
Problem
Existing brake devices for direct drive motors in industrial applications are large, energy-inefficient, and require high energy consumption due to the need for a solenoid or electric actuator to overcome clamping force, generating heat and being unsuitable for compact designs, especially when a shaft is not available.
Innovation Solution
A compact brake device with a concentric design featuring a shaft, a brake element with frictional surfaces, and a pre-tensioned forcing member, decoupled from the actuator, allowing for efficient braking through frictional engagement between concentric components, using a power-off actuator for energy efficiency and simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a traditional brake device is scaled up to generate high braking torque for direct drive motors, then the braking capability is improved, but the device size and energy consumption increase significantly
Solution Approach 1:
A forcing member acts as an intermediary between the brake element and the second device, pre-tensioned to force the brake surfaces together. This mediator creates the normal force needed for friction braking without requiring the actuator to directly apply clamping force, thereby reducing actuator size and energy consumption while maintaining high braking torque capability
Solution Approach 2:
The brake device is segmented into distinct functional components: a brake element with engageable structure, a forcing member for pre-tensioning, and an actuator with engaging structure. This segmentation allows each component to be optimized independently, enabling compact design while achieving high braking torque through the coordinated action of friction surfaces
2Ease of operation
If a solenoid or electric actuator is used to overcome clamping force and release the brake, then the brake can be released, but energy consumption increases and heat is generated
Solution Approach 1:
The forcing member serves as a mechanical intermediary that maintains pre-tension between the brake surfaces. The actuator only needs to apply a small releasing force to overcome this pre-tension rather than the full clamping force, significantly reducing energy consumption and heat generation during brake release operation
Solution Approach 2:
The forcing member is pre-tensioned to establish the normal force between brake surfaces before braking engagement. This preliminary action means the actuator does not need to create the full clamping force during operation, reducing the energy required for both engagement and release cycles
3Power
If a pin brake is used to decouple the normal force from the actuator, then braking effectiveness is improved, but the device requires a shaft for mounting which may not be available
Solution Approach 1:
The brake device is designed with multi-functionality to adapt to different mounting scenarios. The concentric arrangement of the brake element and second device around a central axis allows the brake to function effectively whether mounted on a shaft or integrated directly into a motor housing, eliminating the strict requirement for an external shaft while maintaining braking effectiveness
4Power
If the brake element is forced against the brake surface with pre-tension, then friction braking is enabled, but the actuator size increases to provide the clamping force
Solution Approach 1:
The forcing member acts as a mechanical advantage intermediary, amplifying the small force from the compact actuator into the large clamping force needed for effective friction braking. This allows a small actuator to generate high braking torque through the pre-tensioned forcing member that forces the brake surfaces together
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 brake device provides effective braking with reduced energy consumption, compact size, and simplified design, suitable for traction wheels in drive units with electric motors, and can be integrated into industrial devices like AGVs and robots.
Implementation Method 1
a forcing member pre-tensioned to force the second frictional brake surface against the first frictional brake surface
Data Source
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AI summary
A brake device (18a, 18b) comprising a first device (20) having a shaft (34); a brake element (22) having a first frictional brake surface (78a, 78b) and an engageable structure (38); a second device (24) rotatable relative to the first device (20) about a rotation axis (28), the second device (24) comprising a second member (40) having an opening (60), a second frictional brake surface (80a, 80b), and a forcing member (44) pre-tensioned to force the second frictional brake surface (80a, 80b) against the first frictional brake surface (78a, 78b); and an actuator (26) connected to the first device (20), the actuator (26) comprising an engaging structure (52) movable between a disengaged position (82), and an engaged position (54) to brake relative rotation between the first device (20) and the second device (24) about the rotation axis (28); wherein the shaft (34) is concentric with the rotation axis (28) and passes through the opening (60).