Eddy Current Brake for Crusher Roller Wear-Free Restraint
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Friction-based braking systems in crushers wear quickly and require actuator control, leading to frequent replacements and wear-related component failure due to sudden material-induced braking.
Innovation Solution
An eddy current brake system using a conductive braking disc and magnetic yokes to generate a magnetic braking force without friction, controlled by relative movement between the disc and yokes, eliminating the need for actuators and reducing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If friction-based braking systems are used to restrict rotation of the crushing roller, then the rotational speed can be controlled, but the braking components wear quickly and require frequent replacement
Solution Approach 1:
The patent replaces the friction-based mechanical braking system with an eddy current braking system that uses electromagnetic fields. The eddy current brake includes a magnetic brake disc mounted on the crushing roller and magnetic brake yokes that generate eddy currents in the conductive disc to create a non-contact braking force, eliminating mechanical friction and wear while maintaining rotational speed control.
Solution Approach 2:
The patent introduces a conductive brake disc as an intermediary between the crushing roller and the magnetic brake yokes. This disc serves as the medium through which the magnetic field generates eddy currents, transferring the braking force without direct mechanical contact between the yokes and the roller, thereby preventing wear.
2Force
If friction-based braking systems are used to restrict rotation, then braking force can be applied, but actuators and control systems are required which increase device complexity
Solution Approach 1:
The eddy current braking system is designed to operate automatically based on the rotational speed of the crushing roller. The relative motion between the magnetic brake yokes and the conductive brake disc naturally generates the required eddy currents and braking force without needing external actuators or complex control systems. The system self-regulates based on operational conditions.
Solution Approach 2:
The patent replaces the actuator-based mechanical control system with an electromagnetic field-based system. The magnetic brake yokes generate eddy currents in the conductive disc through their relative motion, creating a self-regulating braking force that eliminates the need for additional actuators, sensors, and control electronics.
3Duration of action of stationary object
If the crushing roller rotates freely during idle operation, then bearing wear is reduced, but impulse forces occur when material is fed which reduce component lifespan
Solution Approach 1:
The eddy current braking system applies a preliminary braking action during idle operation to prevent the crushing roller from rotating at full speed. When material is fed into the crusher, the roller is already partially restrained, preventing sudden impulse forces. The braking force is automatically applied based on the roller's rotational state without requiring detection of material presence.
Solution Approach 2:
The braking system automatically activates based on the rotational motion of the crushing roller itself. During idle operation, the roller's rotation generates eddy currents in the conductive disc, creating a self-regulating braking force that prevents excessive speed buildup without needing external sensors or control systems.
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 eddy current brake effectively restricts the rotation of the crushing roller, reducing wear and eliminating the need for frequent replacements, while maintaining operational efficiency and minimizing energy dissipation.
Implementation Method 1
an eddy current brake that is used to restrict the rotation of the moving crushing member of a crusher
Implementation Method 2
an inductive current braking system that is operable to create a braking force that restrict the rotational movement
Data Source
AI summary
A braking system for use with a crusher having a moving crushing member and a stationary crushing member. The braking system is positioned and is operable to restrict rotational movement of the moving crushing member. The braking system includes a braking disc or plate and one or more braking yokes that each include a magnetic member, such as a permanent magnet or an electric magnet. The braking disc is formed from an electrically conductive material and is perpendicular to the magnets of the braking yoke. Relative movement between the braking disc and the braking yoke induces an eddy current in the braking disc. The induced eddy current creates a magnetic force that opposes rotational movement of the moving crushing member. The braking system can be used with a compact eccentric crusher to restrict the rotation of a crushing roller during an idle mode.