Elastic Brake Disc for High Clamping Force
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Solution Overview
Problem
Existing braking and clamping devices for rotating shafts lack a simple, space-saving design with high clamping forces and short reaction times, while also being maintenance-free and minimizing impact on the shaft's acceleration behavior during normal operation.
Innovation Solution
The braking and clamping device features a brake disc with an outer and inner friction surface, where the friction area can be axially displaced via an elastic intermediate area, and is actuated by either dual actuators or a combination of an actuator and a spring system, ensuring direct force transmission between the device housing and the shaft, with optional pneumatic or hydraulic actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional brake disc with a dimensionally stable intermediate area is used, then the structure is simple, but the clamping force is limited and the reaction time is long
Solution Approach 1:
The intermediate area of the brake disc is designed to be elastically deformable rather than dimensionally stable, allowing it to dynamically adjust its shape during braking to amplify clamping force while maintaining structural simplicity
Solution Approach 2:
The elastic intermediate area changes its physical state from a relaxed configuration to a deformed configuration under actuation, enabling force amplification without increasing device complexity
2Force
If the friction area is fixed relative to the flange area, then the design is simple, but the clamping force distribution is suboptimal
Solution Approach 1:
The friction area is made movable relative to the flange area through the elastic intermediate area, allowing it to dynamically position itself to optimize clamping force distribution during braking operations
3Force
If heavy braking components are added to increase clamping force, then the clamping force improves, but the acceleration behavior of the shaft is adversely affected
Solution Approach 1:
The elastic intermediate area changes its stiffness characteristics during operation, providing high clamping force when needed while maintaining low mass and minimal rotational inertia during normal shaft rotation
Solution Approach 2:
The brake disc is segmented into functionally distinct areas (flange area, elastic intermediate area, friction area) that can independently optimize their properties - the flange area provides mounting strength while the elastic intermediate area provides force amplification with minimal mass
4Force
If the device housing is rigidly attached to the machine housing, then the braking force transmission is efficient, but the installation flexibility is reduced
Solution Approach 1:
The device housing is designed as a separate modular unit that can be rigidly attached to the machine housing when high force transmission is needed, or potentially repositioned for different installation scenarios, balancing force efficiency with installation flexibility
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 design achieves high clamping forces with minimal impact on the shaft's acceleration, providing a maintenance-free and space-efficient solution with short reaction times, suitable for applications in machine tool construction and robotics.
Implementation Method 1
the intermediate area, which is located between the friction area and the flange area and is at least partially elastic
Implementation Method 2
the friction area comprising at least one friction surface in the shape of a truncated cone, and with at least one brake cone arranged in the device housing, on which the friction surface comes to rest during braking or clamping
Data Source
Figure 1
Figure 2~11
Figure 3~4
AI summary
The invention relates to a braking and/or locking device of a shaft (80) which is mounted in an appliance housing or in the device housing, having a brake disk (10) which is fastened on or to the shaft in a rotationally fixed manner, wherein the brake disk has a flanging-on region (11), an intermediate region (21) and a friction region which comprises two frustoconical friction faces (32, 33). The device has at least one brake cone (45) arranged in the device housing and at least one brake cone (65) arranged on an actuating member. During braking or locking operations, the two brake cones come into contact with the friction faces of the brake disk. The present invention serves to develop a braking and/or locking device for rotating shafts which, while providing high locking forces and short reaction times, has a simple and installation-space-saving design and is additionally durably failure-free and maintenance-free.