Elevator Brake Magnet Assembly With Toothed Friction Blocks

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Solution Overview

Problem

Elevator brake systems with existing magnet assemblies face challenges in achieving high braking force, increased life, and reduced costs, particularly due to the limitations of traditional machining processes and the need for intricate toothed blocks that are costly and prone to wear.

Innovation Solution

The development of magnet assemblies for elevator systems that utilize sheet metal layers with blade teeth or abrasive coatings, formed through cost-effective manufacturing processes such as powder metal sintering or saw blade sheet metal stock, which provide a robust and efficient friction engagement surface for guide rail interaction, eliminating the need for intricate machining and reducing wear.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If traditional machining processes are used to create intricate toothed blocks, then the braking force can be achieved, but the manufacturing cost increases and the components are prone to wear

Engineering Contradiction:

Improvebraking forceVSAvoidmanufacturing cost

Core Design Contradiction:

ForceVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical machining processes with magnetic field-based forming processes. The magnet assembly uses a magnetic field to form the friction surface directly on the block, eliminating the need for complex mechanical machining of toothed blocks. This substitution reduces manufacturing cost while maintaining the required braking force, as the magnetic field can create precise friction surfaces without the material waste and tool wear associated with traditional machining.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state and properties of the friction surface by using magnetic field treatment. Instead of mechanically cutting teeth into blocks, the magnetic field alters the surface parameters of the block material to create the desired friction characteristics. This parameter change approach reduces manufacturing complexity and cost while achieving the necessary braking performance.

Inventive Principle:

Principle #35Parameter changes

2Force

If traditional machining processes are used to create intricate toothed blocks, then the braking force can be achieved, but the component lifespan decreases due to wear

Engineering Contradiction:

Improvebraking forceVSAvoidcomponent lifespan

Core Design Contradiction:

ForceVSDuration of action of moving object

Solution Approach 1:

The patent replaces mechanical contact-based machining with magnetic field-based forming. This substitution eliminates the mechanical wear that occurs during traditional toothed block manufacturing and operation. The magnetic field forms the friction surface without physical contact, resulting in components with extended lifespan and reduced wear, while maintaining the necessary braking force.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If sheet metal layers with blade teeth are used, then manufacturing cost decreases and wear is reduced, but the braking force must be maintained

Engineering Contradiction:

Improvemanufacturing costVSAvoidbraking force

Core Design Contradiction:

Ease of manufactureVSForce

Solution Approach 1:

The patent uses composite construction with sheet metal layers to create the block assembly. These layered composite structures provide cost-effective manufacturing while the magnetic field treatment of the surface ensures adequate friction and braking force. The composite nature allows for optimized material selection and reduced manufacturing complexity, maintaining braking performance through the combined properties of the layers.

Inventive Principle:

Principle #40Composite materials

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

These magnet assemblies enhance the braking force, increase the lifespan of electromechanical actuator components, and lower production costs by using sheet metal layers or abrasive coatings, thereby improving the overall efficiency and reliability of elevator brake systems.

Implementation Method 1

magnet assemblies that are configured to engage with the guide rail and act upon a connecting rod to actuate a safety brake

Methodology Applied

Scientific EffectMagnetic attraction: Magnetism

Implementation Method 2

a friction interface to generate a braking force when activated and engaged with a guide rail of an elevator system

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11603288B2Magnet assemblies of electromechanical actuators for elevator systems

Publication Date: 2023.03.14 OTIS ELEVATOR CO

AI summary

Magnet assemblies for electromechanical assemblies of elevator systems are described. The magnet assemblies include a magnet and first and second block assemblies arranged on opposite sides of the magnet. In some configurations, the block assemblies each include a respective friction engagement surface and are formed of layers of sheet metal, with a portion of the layers having blade teeth that form a friction engagement surface for engagement with a guide rail. In some configurations, each of the block assemblies are formed from powder metal sintering and include a monolithic tooth configuration configured to form a friction engagement surface for engagement with a guide rail. In some configurations each of the block assemblies includes an abrasive coating configured to form a friction engagement surface for engagement with a guide rail.