Redundant Disk Brake Control Circuits for Hoisting Safety
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Solution Overview
Problem
Existing disk brake systems for hoisting machines and winches lack redundancy in control circuits, leading to variable deceleration upon control failure, which can result in rope slippage and safety issues, especially during safety braking.
Innovation Solution
A disk brake system with at least two brake circuits, each equipped with two redundant active control circuits, a compact control unit, and redundant pumps, ensuring constant deceleration even if one control circuit fails, with pressure reservoirs supporting normal operation and maintaining braking force through redundant pumps and pressure limiting valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate active brake aggregates are used to brake one brake circuit, then braking redundancy is improved, but device complexity increases and constant deceleration cannot be guaranteed upon control failure
Solution Approach 1:
The brake system is divided into two independent brake circuits, each capable of independently stopping the machine. Each brake circuit can be controlled by one or two control circuits, creating a segmented redundant structure that improves reliability without requiring complete duplication of the entire braking system.
Solution Approach 2:
Pressure reservoirs are pre-charged with hydraulic fluid to provide a predetermined deceleration profile. Upon control failure, these pre-charged reservoirs automatically engage to ensure constant deceleration regardless of the operational status, cushioning against the harmful effect of variable deceleration before it can cause rope slippage.
2Reliability
If control circuits are made redundant with two active circuits per brake circuit, then safety braking reliability is improved, but system complexity and cost increase
Solution Approach 1:
Multiple control circuits are merged into a single compact control unit that houses pressure reservoirs, monitoring systems, and control electronics. This consolidation reduces spatial complexity and interconnection requirements while maintaining the functional redundancy of multiple control circuits within each brake circuit.
Solution Approach 2:
The control units are designed with multi-functionality, serving both normal operation and safety braking functions. The same control unit structure and components (pressure reservoirs, pumps, electronics) are used across different brake circuits, reducing overall system complexity through standardization and universal design.
3Stability of the object's composition
If pressure reservoirs are used to maintain constant deceleration, then deceleration stability is improved, but system complexity increases
Solution Approach 1:
Pressure reservoirs are pre-charged with hydraulic fluid at predetermined pressures during normal operation. This preliminary action ensures that when control failure occurs, the reservoirs can immediately provide the required deceleration force without requiring complex real-time pressure regulation systems, simplifying the overall hydraulic control architecture.
Solution Approach 2:
The pressure reservoirs are designed to automatically maintain constant deceleration upon control failure without requiring external intervention or complex control algorithms. The system uses its own pre-stored hydraulic pressure to self-regulate the deceleration profile, reducing the need for additional monitoring and control components.
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 safe and constant deceleration of hoisting machines and winches during safety braking, enhancing safety by allowing each brake circuit to operate independently, reducing the risk of accidents and simplifying maintenance and operation.
Implementation Method 1
The braking force is generated by pre-tensioned springs and lifted hydraulically
Implementation Method 2
The braking force is generated by pre-tensioned springs
Implementation Method 3
brake elements (2, 4, 6, 8) which can be pressed onto a brake disk
Data Source
AI summary
The invention relates to a disk brake system for hoisting machines and winches, equipped with at least two brake circuits, wherein to each brake circuit at least one brake caliper with associated brake pads is allocated, and wherein two redundant, active control circuits (10, 12, 14, 16) are provided per brake circuit.