Electromagnetic Brake Control with Unified Safety and Normal Logic

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Solution Overview

Problem

Existing servo drivers require multiple connections and extensive maintenance to switch between safety control and normal control of electromagnetic brakes, leading to increased man-hours.

Innovation Solution

An electromagnetic brake controller that integrates both safety control and normal control functions into a single output terminal, using a brake control section, safety calculators, and a power disconnect switch to manage the electromagnetic brake's on-off states.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate control sections are used for safety control and normal control of electromagnetic brakes, then control reliability is improved, but device complexity and maintenance requirements increase

Engineering Contradiction:

Improvecontrol reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines safety control and normal control functions into a single integrated control section that manages both safety brakes and normal brakes through unified control logic. This merging reduces device complexity and maintenance requirements while maintaining the reliability benefits of separate control through logical separation within the integrated structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The control section is designed to perform multiple functions: it can operate in safety control mode, normal control mode, or both simultaneously. This multi-functionality allows a single control section to replace what would traditionally require separate dedicated control sections, reducing overall device complexity while maintaining control reliability through configurable operational modes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If separate control sections are used for safety control and normal control, then control functionality is improved, but maintenance man-hours increase

Engineering Contradiction:

Improvecontrol functionalityVSAvoidmaintenance man-hours

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

By merging safety control and normal control into a single control section, the patent reduces the number of connection targets and control pathways that require maintenance. This integration maintains full control functionality while significantly reducing maintenance man-hours compared to fully separate control sections.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The universal control section can operate in multiple modes (safety control only, normal control only, or both), providing adaptability and versatility while simplifying maintenance. A single control section handles all brake control functions, eliminating the need to maintain and troubleshoot multiple separate control systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If integrated control is used for both safety control and normal control, then device complexity is reduced, but control reliability may be compromised

Engineering Contradiction:

Improvedevice complexityVSAvoidcontrol reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Within the integrated control section, the patent implements logical segmentation by providing separate control inputs for safety brakes and normal brakes, and separate control pathways that can be independently activated. This allows the integrated structure to maintain the reliability benefits of separate control logic while achieving the complexity reduction of integration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control section is designed to be dynamically configurable, allowing it to operate in different modes (safety control mode, normal control mode, or both simultaneously) based on system requirements. This dynamic capability ensures that the integrated control maintains reliability by adapting to different operational contexts while keeping device complexity low.

Inventive Principle:

Principle #15Dynamics

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 controller reduces the number of connection targets, thereby decreasing maintenance man-hours, while effectively performing both safety and normal control operations over the electromagnetic brake.

Implementation Method 1

negative-actuated electromagnetic brake

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Data Source

PatentUS12294327B2Electromagnetic brake control device and control device

Publication Date: 2025.05.06 OMRON CORP

AI summary

An electromagnetic brake controller for controlling a negative-actuated electromagnetic brake includes an output terminal connectable to the electromagnetic brake and a brake control section that outputs, through the output terminal, a brake control signal to be provided to the electromagnetic brake. The brake control section outputs a brake control signal for releasing the electromagnetic brake in response to a normal brake command and a safety brake command both indicating ON and outputs a brake control signal for applying the electromagnetic brake in response to at least one of the normal brake command or the safety brake command indicating OFF. The electromagnetic brake controller performs both safety control and normal control over the electromagnetic brake connected to the output terminal.