Cyclic-Force Brake Caster Assembly for ULD Skid Prevention
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Solution Overview
Problem
Existing cargo handling systems face challenges in safely decelerating or stopping unit load devices (ULDs) on aircraft cargo decks, as the braking mechanisms often apply too much force, leading to skidding and wear of the friction material when the load is insufficient, particularly under light loads.
Innovation Solution
A brake caster mechanism with a slider plate and guide plate configuration that cycles between maximum and minimum brake forces, utilizing a slider disk subassembly with a shaft, guide plate, and flange to adjust brake force dynamically based on axial movement, allowing for effective braking without excessive wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a preset braking load is selected for maximum weight of loaded ULD at maximum angle, then the braking mechanism can effectively stop heavy ULDs, but the braking load becomes too powerful to allow the rotating element to roll under light loads, causing skidding and wear of friction material
Solution Approach 1:
The brake mechanism transitions from a static preset braking load to a dynamic cyclic braking force that varies between maximum and minimum values. The rotating element periodically contacts the friction material at specific angular positions, creating a time-varying braking effect that adapts to different load conditions and prevents continuous friction wear.
Solution Approach 2:
The brake mechanism applies braking force periodically rather than continuously. The cyclic engagement of the rotating element with the friction material at specific angular positions creates intermittent braking action, allowing the element to roll freely between engagement points and reducing cumulative wear on the friction material.
2Force
If a rotating element with friction material is used to decelerate or stop ULDs, then the braking mechanism can effectively control ULD movement, but under light loads the braking force is too strong, causing the ULD to skid and wear away the friction material
Solution Approach 1:
The brake mechanism applies partial braking force only at specific angular positions rather than full continuous braking. By limiting the braking action to discrete engagement points during rotation, the system provides sufficient braking effect when needed while allowing free rotation during the majority of the rotational cycle, especially under light load conditions.
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 cyclic-brake force mechanism ensures safe deceleration of ULDs by adjusting brake force according to load conditions, reducing wear and damage to the braking components, and preventing skidding under varying load conditions.
Implementation Method 1
The rotating element of the braking caster is configured to decelerate or stop a ULD... The rotating element often includes a friction material that surrounds the outer surface of a cylindrical roller... the slider plate configured to slide on the shaft in response to the roller interacting with the slider plate trough and the slider plate peak
Data Source
AI summary
A brake mechanism for a brake caster is disclosed. In various embodiments, the brake mechanism includes a shaft; a guide plate having a roller; and a slider plate having a first axial facing surface with a slider plate trough and a slider plate peak, the slider plate configured to slide on the shaft in response to the roller interacting with the slider plate trough and the slider plate peak.