Rotary Encoder Brake Assembly With Spring Damping for Angle Limits
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Solution Overview
Problem
Existing rotary encoder designs lack a damping system for protection against high acceleration and external forces, and are not suitable for small devices with high precision control requirements or environmental impact resistance.
Innovation Solution
A rotary encoder mechanism integrated with an angle limit braking mechanism, featuring a spring damping system and a power-off brake, which includes a housing assembly with magnetic components and a metal disc assembly, ensuring operation within specified angular limits and protecting against overloads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a brake mechanism is combined with a motor and rotary encoder, then the device can achieve angular limit control, but the structure becomes complex and lacks damping protection
Solution Approach 1:
The patent combines the brake mechanism, rotary encoder, and damping system into a single integrated assembly. The brake mechanism includes a stator coupled to the motor shaft, a rotor with damping elements, and the encoder is mounted on the same shaft. This merging reduces the number of separate components and simplifies the overall mechanical structure while maintaining angular limit control functionality and adding protection against high acceleration and external forces.
Solution Approach 2:
The patent incorporates a damping system with elastic elements (springs) and damping elements (viscous dampers) that are pre-installed in the brake mechanism. These elements are positioned to absorb shocks and dampen vibrations before they can cause damage to the motor or encoder. The damping system activates automatically when external forces or high acceleration occur, providing beforehand protection without requiring additional control systems.
2Reliability
If a starter lock is added at the edge of the rotating assembly, then the braking mechanism can lock, but the size of the mechanism increases
Solution Approach 1:
The patent places the damping elements and spring mechanisms inside the existing brake mechanism housing, nesting them within the available internal space. The elastic elements are positioned between the stator and rotor assemblies, utilizing the radial and axial space already allocated for the brake mechanism. This nesting approach allows the inclusion of locking and damping functionality without increasing the overall external dimensions of the brake assembly.
Solution Approach 2:
The patent uses axial and radial dimensions within the brake mechanism housing to accommodate damping elements, rather than extending the mechanism in the rotational direction. The spring elements are arranged axially between the stator and rotor, and the damping elements are positioned radially, utilizing the three-dimensional space efficiently. This dimensional arrangement maintains a compact cylindrical form factor while incorporating additional functionality.
3Object-affected harmful factors
If damping elements are added to protect against high acceleration, then the device gains protection capability, but the structure becomes more complex
Solution Approach 1:
The patent integrates the damping system directly into the brake mechanism structure. The elastic elements (springs) and viscous dampers are incorporated as integral components of the brake assembly, sharing the same housing and mounting structure. The damping elements are positioned to work in conjunction with the brake pads and rotor, creating a unified system that provides both braking and damping functions without requiring separate structural frameworks.
Solution Approach 2:
The damping system is designed to operate automatically without external control or additional actuators. The spring elements and viscous dampers self-activate when subjected to high acceleration or external forces, providing protection through their inherent mechanical properties. The system requires no external power source, control electronics, or additional sensors, reducing structural complexity while maintaining effective protection capability.
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 provides precise control and protection against environmental impacts by damping excess acceleration and inertia, ensuring reliable operation in high-acceleration environments while maintaining compactness and integration ease.
Implementation Method 1
the spring mechanism acts to dampen the acceleration and inertia of the device
Implementation Method 2
A spring damping system
Implementation Method 3
The magnet housing includes an electromagnetic coil and powerful neodymium rare-earth permanent magnets
Implementation Method 4
The braking and locking mechanism operates based on the electrical input state: when no electricity is supplied, the brake locks
Implementation Method 5
powerful neodymium rare-earth permanent magnets
Implementation Method 6
The magnet housing includes an electromagnetic coil and powerful neodymium rare-earth permanent magnets
Data Source
AI summary
A rotational encoder combined with angle limit braking mechanism. The mechanism includes a braking system and a shock-absorbing spring mechanism integrated within the rotary encoder block to protect the device when operating within the desired angular travel limits. It is applied in scanning devices that require high angular position accuracy and stringent safety standards against external environmental impacts. The product of the invention is used in direct-drive motor mechanisms with high precision for angular travel limitation, such as robotic arms, fixed or mobile multi-sensor automated observation devices, and unmanned vehicles.