Conveyor Brake Gap Sensing to Prevent Vibration and Smoking
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Solution Overview
Problem
The manual adjustment of the gap between brake linings and brake drums in automatic conveyor devices is uncertain, leading to potential vibration and accidental contact, which can cause smoking and emergency shutdowns due to excessive wear.
Innovation Solution
A braking device with an electromagnetic actuator and sensor system that monitors specific positions during the lifting of the brake arm, ensuring a safe gap is maintained by outputting signals to prevent excessive adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment of the gap between brake lining and brake drum is performed, then the brake arm position can be adjusted, but the adjustment is uncertain leading to vibration and accidental contact
Solution Approach 1:
The patent replaces the manual mechanical adjustment system with an automated sensor-based control system. Sensors detect the gap between brake lining and brake drum, and a control system automatically adjusts the brake arm position, eliminating uncertain manual adjustment while maintaining operational ease.
Solution Approach 2:
The patent implements a feedback mechanism where sensors continuously monitor the gap between brake lining and brake drum, and this information is fed back to the control system which adjusts the brake arm position accordingly. This closed-loop control ensures reliable gap maintenance without manual intervention.
2Productivity
If the gap between brake lining and brake drum is reduced, then braking efficiency is improved, but vibration and accidental contact occur causing smoking and shutdowns
Solution Approach 1:
The patent uses sensors to provide real-time feedback on the gap between brake lining and brake drum, allowing the control system to maintain the optimal gap that maximizes braking efficiency while preventing vibration and accidental contact. The feedback loop continuously adjusts the position to avoid harmful effects.
Solution Approach 2:
The patent implements a self-adjusting system where the brake arm position is automatically controlled based on sensor feedback, eliminating the need for manual intervention. The system self-regulates the gap to prevent vibration and smoking while maintaining high braking efficiency.
3Ease of repair
If workers regularly adjust the gap using calipers, then the brake lining wear is managed, but the uncertainty of manual adjustment creates safety risks
Solution Approach 1:
The patent replaces manual measurement and adjustment operations with an automated sensor-based system. Sensors continuously monitor the gap and control the brake arm position, eliminating the need for workers to use calipers and perform regular manual adjustments, thereby ensuring operational safety.
Solution Approach 2:
The patent implements a self-monitoring and self-adjusting system that automatically manages brake lining wear without human intervention. The system continuously measures the gap and adjusts the brake arm position as needed, providing ease of maintenance while ensuring operational safety.
4Ease of operation
If the electromagnetic rod lifts the brake arm too much, then the brake lining separates from the brake drum, but excessive lifting causes vibration and accidental contact
Solution Approach 1:
The patent uses sensors to provide feedback on the brake arm position and gap between brake lining and brake drum. The control system uses this feedback to precisely control the electromagnetic rod lifting action, ensuring the brake lining separates adequately without excessive lifting that would cause vibration and accidental contact.
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 system ensures a stable gap is maintained, preventing smoking and accidental shutdowns by accurately monitoring and adjusting the brake lining position, enhancing safety and reliability.
Implementation Method 1
an electromagnetic actuator, comprising an electromagnetic rod, where when the electromagnetic actuator is energized, the electromagnetic rod lifts the brake arm to separate the brake lining of the brake arm from the brake drum
Implementation Method 2
a spring member that acts on the brake arm, urging the brake lining on the brake arm to make contact with the brake drum
Data Source
AI summary
An automatic conveyor device system and a braking device therefor. A braking device includes: a brake drum; a brake arm, with a brake lining provided thereon; a spring member that acts on the brake arm, urging the brake lining on the brake arm to make contact with the brake drum; an electromagnetic actuator, including an electromagnetic rod, where when the electromagnetic actuator is energized, the electromagnetic rod lifts the brake arm to separate the brake lining of the brake arm from the brake drum; and a sensor, configured to monitor a first position and a second position with a given spacing a during the extending process of the electromagnetic rod, and to respectively output a first signal and a second signal when the electromagnetic rod passes through the first position and the second position.