Dual Piston Hydraulic Brake Release Mechanism
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Solution Overview
Problem
Hydraulic machines face challenges in brake release control due to increasing braking torque requirements, necessitating high pressures that are not acceptable in all applications, particularly due to associated constraints and risks.
Innovation Solution
The hydraulic machine employs a dual-brake release piston system with a primary and secondary brake release piston, hydraulically connected in a specific arrangement to reduce the pressure needed for brake release, utilizing a chamber separator to isolate pressures and a pressure supply of less than or equal to 30 bar, allowing for efficient brake disengagement with reduced size constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If high pressure is used to achieve brake release control, then the braking torque constraint is satisfied, but the system accepts constraints and risks associated with high pressure
Solution Approach 1:
The brake release piston is divided into two separate pistons (first and second brake release pistons) with各自的 chambers. Each piston independently applies force to the spring washer, allowing the system to achieve the required brake release force through combined action of two lower-pressure pistons rather than one high-pressure piston, thereby reducing the harmful effects of high pressure while maintaining braking torque control
2Force
If high pressure is applied to disengage the static brake, then the braking torque constraint is met, but the size constraints become more stringent
Solution Approach 1:
The single high-pressure chamber is segmented into two separate chambers (primary and secondary brake release chambers), each operating at lower pressure. This segmentation allows the brake release mechanism to maintain the required force output while reducing the volume constraints, as lower pressure operations require larger surface areas that can be distributed across two pistons rather than concentrated in one compact high-pressure chamber
3Device complexity
If a single brake release piston is used, then the system is simpler, but it requires high pressure (100-130 bar) to achieve brake release
Solution Approach 1:
The single brake release piston is segmented into two separate pistons with independent chambers. Although this increases device complexity by adding an additional piston and chamber, it successfully reduces the operating pressure from 100-130 bar to lower levels, achieving the trade-off where moderate complexity increase yields significant pressure reduction and associated safety benefits
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 solution achieves a greater brake release force with lower required pressure, typically between 12 and 30 bar, while maintaining constant size or reducing the size of the braking system, thereby enhancing safety and operational efficiency.
Implementation Method 1
a spring washer mounted bearing on the casing, and tending to urge the first and second braking elements in a braking direction
Implementation Method 2
a brake release piston, configured to urge the spring washer in a direction opposite to the braking direction
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Hydraulic machine (1) comprising first and second braking elements (92, 93), a spring washer (65) tending to actuate the first and second braking elements (92, 93) in a braking direction, a release piston (61) configured to actuate the spring washer (65) in a direction opposite to the braking direction, characterized in that the release piston (61) comprises a primary release piston (61a) associated with a primary release chamber (62a) and a secondary release piston (61b) associated with a secondary release chamber (62b), said primary (62a) and secondary (62b) chambers extending radially around the shaft (2), such that the projections of the primary release chamber (62a) and the secondary release chamber (62b) lie in a plane perpendicular to a longitudinal axis (XX) defined by the axis of rotation of the hydraulic machine (1) overlap at least partially.