Segmented Elevator Disc Brake Assembly for Fault-Tolerant Braking
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Solution Overview
Problem
Existing elevator brake systems are inadequate in ensuring passenger safety, as they may operate on a single mechanical brake unit, leading to potential failures and uncontrolled movements, and emergency brakes are often activated too late to prevent injuries or fatalities.
Innovation Solution
A disc brake assembly with two or more small-sized operating brake units, each comprising multiple brake plates, which allows for shared braking torque and includes a monitoring system to ensure reliable operation, reducing the impact of a single unit failure and providing fault tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single mechanical brake unit is used in elevator systems, then the device complexity is reduced, but the reliability of the brake system deteriorates due to potential mechanical failures
Solution Approach 1:
The brake system is divided into multiple independent brake units (at least two), each with its own brake plates and actuation mechanism. This segmentation allows the system to maintain reliability through redundancy while keeping each individual unit relatively simple in structure.
Solution Approach 2:
Each brake unit is designed with different local characteristics (different brake plate arrangements, different actuation points) so that they can independently contribute to the overall braking function. This local differentiation ensures that failure of one unit does not compromise the entire system.
2Reliability
If mechanically doubled brake units are used simultaneously in normal operation, then the reliability is improved through redundancy, but the device complexity increases and mechanical failures may go undetected
Solution Approach 1:
The system includes a monitoring device that continuously checks the operational status of each brake unit before and during braking operations. This preliminary detection capability allows the system to identify potential failures early, preventing undetected mechanical failures from compromising safety.
Solution Approach 2:
The monitoring device provides feedback about the operational status of each brake unit to the control system. This feedback mechanism enables real-time assessment of brake unit health and allows for adaptive control, maintaining reliability while managing system complexity through intelligent monitoring rather than purely mechanical redundancy.
3Reliability
If emergency brakes are used to stop the elevator car, then the reliability is improved for preventing uncontrolled movement, but the harmful factors increase due to late activation causing passenger injuries
Solution Approach 1:
The monitoring device continuously assesses the operational status of brake units before emergency situations arise. This preliminary monitoring enables the system to detect potential failures early and switch to备用 brake units proactively, ensuring that functional brake units are available when emergency braking is needed, thereby reducing passenger injury risk.
Solution Approach 2:
The system prepares countermeasures in advance by having multiple brake units ready and monitored. If one brake unit shows signs of failure, the system can pre-position or pre-activate alternative brake units to counteract potential uncontrolled movement, preventing the harmful effect of late emergency braking activation.
4Reliability
If multiple brake plates are used in each brake unit, then the reliability is improved through torque distribution, but the device complexity increases
Solution Approach 1:
The brake system is segmented into multiple brake plates within each brake unit, arranged at different positions around the brake disc. This segmentation distributes the braking torque across multiple contact points, improving reliability through load distribution while keeping each individual brake plate relatively simple in structure.
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 solution provides a reliable, cost-effective, and space-efficient brake system with reduced deceleration fluctuations, quieter operation, easier maintenance, and enhanced safety by minimizing the impact of brake unit failures and ensuring stable torque distribution.
Implementation Method 1
each having at least two brake plates (8a, 8b) arranged to be pressed against the brake disc (3)
Data Source
AI summary
An elevator disc brake assembly includes at least two separate operating disc brake units mounted substantially sequentially on the periphery of the brake disc of an elevator driving machinery where the brake disc and a traction sheave are rotated by a drive motor of the driving machinery. At least one of the disc brake units includes two or more separate brake plates to be pressed against the brake disc.