Electromagnetic Brake Assembly for Stable Forklift Parking Force
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Solution Overview
Problem
Electric forklifts face safety risks due to insufficient braking force for parking, as conventional brake systems rely on controlling motor current, which may not provide adequate braking stability.
Innovation Solution
An electromagnetic brake system featuring a brake disc integrated with a drive shaft, an armature disc movable by an elastic member and an inductor, allowing for controlled engagement and disengagement with the brake disc via electrical signals to manage braking force effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If motor current control is used for braking, then the brake system structure is simple, but the braking force is insufficient for parking
Solution Approach 1:
The patent combines motor current control braking with an electromagnetic brake mechanism into a unified system. The electromagnetic brake includes an inductor that generates magnetic force to press the brake disc against the drive shaft, working together with motor current control to provide both service braking and reliable parking braking functionality.
2Reliability
If separate brake components are used, then the braking function is reliable, but the assembly and mountability are complex
Solution Approach 1:
The brake disc is integrally formed with the drive shaft as a single component, eliminating the need for separate mounting operations. The electromagnetic brake components (inductor, armature, springs) are assembled as a integrated unit that mounts to the drive motor, simplifying overall assembly while maintaining reliable braking function.
Solution Approach 2:
The brake disc serves multiple functions: it provides friction surfaces for braking, acts as a structural connection between the drive shaft and brake mechanism, and integrates with the drive motor housing. This multi-functionality reduces the number of separate components needed.
3Device complexity
If the brake disc is integrated with the drive shaft, then the assembly is simplified, but the component abrasion increases
Solution Approach 1:
The brake disc is divided into distinct friction surfaces that contact the brake pads, separating the wear-prone friction zones from the structural integration with the drive shaft. This allows the friction surfaces to be optimized for low wear while maintaining the integrated structure for simplified assembly.
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 provides stable and reliable braking and release mechanisms, enhancing safety and operational efficiency by integrating a simplified structure that reduces component abrasion and noise, improving assembly, productivity, and durability.
Implementation Method 1
an elastic member configured to elastically press the armature disc to one side of the brake disc
Implementation Method 2
an inductor configured to separate the armature disc from the brake disc by an electrical signal
Data Source
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AI summary
The invention relates to an electromagnetic brake system (100). The electromagnetic brake system includes a brake disc (110) configured to be rotated together with a drive shaft (10) of a drive motor (1) configured to operate a vehicle wheel, an armature disc (120) configured to be movable so as to be in close contact with or so as to be separated from one side of the brake disc, an elastic member (130) configured to elastically press the armature disc to the one side of the brake disc to a direction in which the armature disc is in close contact with the brake disc, and an inductor (140) configured to separate the armature disc from the brake disc by an electrical signal. The brake disc includes a tube portion (111) mounted on the drive shaft, and a plate portion (115) provided to extend in an outward direction of the tube portion to be opposite to the armature disc. The tube portion and the plate portion are provided as a single member in which the tube portion and the plate portion are integrally formed with each other.