Elevator Brake Roller Lever Mechanism for Compact Manual Release
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Solution Overview
Problem
Existing elevator brake release mechanisms are not simple, compact, or easily movable, requiring leverage to overcome strong spring forces, which complicates manual operation and space efficiency, especially when installed inside the hoistway.
Innovation Solution
A brake release mechanism featuring a rotatable lever with cylindrical rollers that convert rotational motion into axial movement of the braking member, ensuring good movability and compactness, with the rollers providing a vast contact area to bear high loads and reduce material requirements, facilitating safe and easy manual operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a traditional lever mechanism is used to manually release the brake, then the strong spring force can be overcome, but the mechanism becomes complex and space-consuming
Solution Approach 1:
The patent employs a cam mechanism with a curved profile instead of a traditional straight lever. The cam's curved surface converts rotational motion into axial movement, providing mechanical advantage to overcome the strong spring force while maintaining a compact structure. The curvature of the cam profile is specifically designed to optimize the force multiplication effect throughout the rotation range.
Solution Approach 2:
The invention transitions from a linear lever movement to a rotational cam mechanism. By adding the dimension of rotation, the system achieves greater mechanical advantage in a more compact form factor. The cam rotates within a constrained space, converting small rotational movements into larger axial displacements of the brake release mechanism.
2Force
If a traditional lever mechanism is used to manually release the brake, then the spring force can be overcome, but the mechanism occupies too much space
Solution Approach 1:
The cam's curved profile allows for a compact design by concentrating the mechanical advantage generation within a small rotational arc. The curvature enables the force multiplication to occur within a limited space, avoiding the need for long lever arms that would increase the overall volume of the brake mechanism.
Solution Approach 2:
The patent integrates multiple functions into the cam component: it serves as both the force multiplication element and the motion conversion element. By combining these functions into a single cam structure rather than using separate levers and linkages, the overall volume of the brake releasing mechanism is significantly reduced.
3Ease of operation
If manual operation is simplified, then ease of operation improves, but the mechanism becomes less reliable over time
Solution Approach 1:
The cam acts as an intermediary element between the manual operation input and the brake release output. It provides a controlled, predictable mechanical advantage that is neither too simple (which would require excessive force) nor too complex (which would reduce reliability). The cam's fixed geometric profile ensures consistent performance over time while keeping the operating force within reasonable limits.
Solution Approach 2:
The cam profile is specifically designed with optimized geometric parameters that balance ease of operation with reliability. The curvature radius, rotation angle, and lift height are carefully selected to provide sufficient mechanical advantage for manual operation while maintaining robust contact forces throughout the operation cycle, ensuring reliable performance over time.
4Volume of moving object
If the brake mechanism is made compact, then space efficiency improves, but movability and service life are reduced
Solution Approach 1:
The cam's curved surface provides a gradual, continuous contact transition rather than abrupt engagement. This smooth contact reduces impact loads and stress concentrations on the brake components, thereby extending service life despite the compact size. The curvature distributes the mechanical stress over a larger area and longer duration of contact.
Solution Approach 2:
The cam profile parameters are optimized to balance compactness with durability. The rotation speed, contact pressure, and engagement angle are designed to minimize wear and fatigue while maintaining the compact form factor. These parameter optimizations ensure that the mechanism can withstand repeated operations over its service life without compromising reliability.
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 mechanism maintains long-term movability and safety, allowing for effective manual operation while reducing the need for strong materials and ensuring the brake system remains functional even after extended periods of non-use, ensuring safe and efficient passenger evacuation.
Implementation Method 1
rotation of the lever is configured to cause said cylindrical roller to roll outwards from the recess along an edge portion of the recess forcing the lever to move axially away from the frame
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
A brake comprising a frame (1), a braking member mounted on the frame (1) movably between braking position and released position, and a rotatable lever (3) mounted on the frame (1), the lever (3) being functionally connected to the braking member such that movement of the lever (3) axially away from frame (1) moves the braking member towards released position. At least one cylindrical roller (6) is mounted on one of the brake frame (1) and lever (3), to be positioned between the brake frame (1) and the lever (3), and the other of the brake frame (1) and lever (3) comprises a recess (5) for receiving said cylindrical roller (6), and in that rotation of the lever (3) is configured to cause said cylindrical roller (6) to roll outwards from the recess (5) along an edge portion (7) of the recess (5) forcing the lever (3) to move axially away from the frame (1), thereby causing the braking member (2) to move towards released position.