Electric Motor Braking Device with Overrunning Clutch
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Solution Overview
Problem
Conventional braking devices for drive trains in industrial settings, such as chain and belt conveyors, require expensive and complex hydraulic or pneumatic systems for fail-safe operation, leading to high maintenance efforts and energy consumption.
Innovation Solution
A device with an electric motor-driven actuating element, utilizing an overrunning clutch and hydraulic fluid circulation, which eliminates the need for hydraulic or pneumatic supplies and features a low-maintenance mechanical design, ensuring fail-safe behavior and efficient energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic or pneumatic release devices are used for braking devices, then fail-safe behavior is achieved, but the device complexity and maintenance effort increase due to expensive hydraulic or pneumatic power supply and control components
Solution Approach 1:
The patent replaces the hydraulic or pneumatic release device with a purely mechanical spring-loaded brake mechanism. The spring accumulator stores mechanical energy that automatically engages the brake when hydraulic pressure is lost, eliminating the need for complex hydraulic control components while maintaining fail-safe behavior.
Solution Approach 2:
The spring-loaded brake mechanism is designed to automatically engage and hold the braking position without requiring external hydraulic or pneumatic power for maintaining the brake application. The stored mechanical energy in the spring accumulator provides self-sustaining braking action, reducing dependency on complex external power systems.
2Reliability
If hydraulic or pneumatic release devices are used for braking devices, then fail-safe behavior is achieved, but the maintenance effort increases due to media preparation, media filtering and condensate separation
Solution Approach 1:
The patent eliminates hydraulic or pneumatic fluid systems entirely by using a mechanically-loaded spring accumulator. This substitution removes all maintenance requirements associated with fluid media including filtering, condensate separation, and media preparation, while preserving the automatic fail-safe braking function.
3Ease of operation
If a threaded spindle (linear spindle) is used for adjusting the brake head position, then the brake can be adjusted between braking and release positions, but the device complexity increases and fail-safe behavior is compromised due to self-locking tendency
Solution Approach 1:
The patent replaces the threaded spindle mechanism with a direct mechanical linkage system consisting of a lever arm and pivot point. This substitution eliminates the self-locking tendency of threaded spindles while providing reliable position control through geometric constraints and mechanical advantage, ensuring fail-safe operation.
4Extent of automation
If a linear drive unit with stepping motor and linear spindle is used for brake release, then automated control is achieved, but the device complexity and component count increase
Solution Approach 1:
The patent replaces the electric linear drive unit with a simple mechanical spring accumulator system. The automation function is achieved through the inherent mechanical properties of the spring-loaded mechanism that automatically responds to hydraulic pressure changes, eliminating motors, spindles, and associated control components.
Solution Approach 2:
The spring accumulator provides automatic brake release functionality through its mechanical design. When hydraulic pressure is applied, it automatically overcomes the spring force and releases the brake without requiring external electrical power or complex control systems, reducing component count while maintaining automation.
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 solution provides reliable, low-maintenance, and energy-efficient automatic braking with minimal energy consumption, suitable for universal use in industrial settings, and allows for compact design and adjustable braking force.
Implementation Method 1
the clutch is designed as an overrunning clutch
Implementation Method 2
the actuating element being designed as a piston rod of an auxiliary cylinder containing hydraulic fluid, in which pistons are arranged
Implementation Method 3
an electric motor for moving the actuating element from the braking position to the release position
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
The device has a clamping unit (3) that is clamped in the release position during movement of a movable actuation element (1) from the braking position to release position. An electric motor (4) moves the braking element from the braking position to release position, and is coupled with the actuation element through a coupling (5). The actuating element is provided with a rack that is driven by the electric motor. The electric motor transmits torque through the coupling on a drive pinion.