Electromagnetic Active Brake Spring-Loaded Engagement
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Solution Overview
Problem
Existing electromagnetic brake systems require constant energy to maintain the braking state, leading to high energy consumption and increased costs, especially in applications where frequent braking is not necessary, such as in static or slowly moving machinery.
Innovation Solution
The electromagnetic active brake design uses a spring-loaded mechanism where the electromagnet is only energized briefly to initiate the braking process, allowing the brake to remain engaged without continuous power, utilizing a spring compressor to amplify the braking force and maintain contact with the brake pad, thus reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electromagnet is used to maintain the brake in the engaged state, then the braking force is reliably applied, but the energy consumption increases significantly due to continuous power requirement
Solution Approach 1:
The patent inverts the conventional approach by designing the brake to be engaged by default (spring-loaded) and requiring energy only to disengage. This reverses the typical brake design where energy is needed to maintain the braking state, thereby eliminating continuous energy consumption while maintaining reliable braking capability.
Solution Approach 2:
The brake system uses its own spring mechanism to maintain the engaged state without external energy input. The spring automatically keeps the brake pads pressed against the brake disk, and the system only requires minimal energy input when disengagement is needed, making the system self-sustaining in its primary function.
2Use of energy by moving object
If a spring-loaded mechanism is used to maintain brake engagement without continuous power, then energy consumption is reduced, but the braking force may be insufficient without continuous electromagnetic actuation
Solution Approach 1:
The patent combines the spring-loaded mechanism with a minimal electromagnetic actuator to create a hybrid system. The spring provides continuous mechanical force for engagement, while the small electromagnetic actuator only needs to provide brief pulses to overcome the spring force during disengagement, achieving both energy efficiency and sufficient braking force.
Solution Approach 2:
The spring is pre-loaded to store mechanical energy that continuously maintains the brake in the engaged state. This preliminary action of pre-compressing the spring eliminates the need for continuous electromagnetic actuation, as the stored mechanical energy performs the work of maintaining braking force indefinitely until disengagement is required.
3Force
If pneumatic or hydraulic systems are used instead of electromagnetic brakes, then braking force is strong and reliable, but the complexity of energy supply and securing systems increases
Solution Approach 1:
The patent extracts the complex energy supply and securing systems from the brake mechanism by using a simple spring-loaded design with minimal electromagnetic actuation. This removes the need for pneumatic or hydraulic infrastructure, reducing system complexity while maintaining effective braking force through the spring-mechanism combination.
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 significant energy savings, requiring only 3% of the energy compared to pneumatic or hydraulic systems, while providing a strong clamping force and compact size, making it suitable for continuous operation in machinery like wind turbines and centrifugal casting facilities.
Implementation Method 1
the electromagnet is only energized briefly to initiate the braking process
Implementation Method 2
utilizing a spring compressor to amplify the braking force and maintain contact with the brake pad
Implementation Method 3
providing a strong clamping force and compact size
Data Source
AI summary
An electromagnetic active brake which is de-energized in the brake standby state, including—a brake body (1), —a brake device with at least two opposing brake shoes (9, 12) which are spaced from a component to be braked in the de-energized state of the active brake, —and an electromagnet (5) which is arranged in the brake body (1) and the armature (6) of which interacts with a brake lever (2). The armature (6) of the electromagnet (5) is rigidly connected to a spring compressor (3) which is guided in the brake body (1) and which is moved by the armature (6) in the axial direction of the armature (6) when the electromagnet (5) is energized and in this manner clamps a spring (16) against an abutment (20) that interacts with the brake lever (2) and is arranged in an axially adjustable manner in the direction of the path of the spring compressor (3). The active brake according to the invention is highly energy-saving and thus economical.