Ferromagnetic Composite Damper for Machinery Brake Noise
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Solution Overview
Problem
Existing brake noise damping solutions, such as using elastic materials or paper and glue, are ineffective in maintaining consistent magnetic force and proper brake operation due to variations in manufacturing tolerances and electromagnet current, leading to noise and improper brake function.
Innovation Solution
A damping arrangement using a ferromagnetic composite material, comprising a flexible polymer matrix with embedded magnetically soft particles, is integrated into the magnetic circuit of the brake to conduct magnetic flux, reducing reluctance and maintaining consistent magnetic force and brake operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a damper made of elastic material or paper and glue is added to the air gap to prevent direct contact between metal surfaces, then noise is damped, but the hysteresis air gap varies due to manufacturing tolerances and the brake may not stay open properly when electromagnet current varies
Solution Approach 1:
The patent applies composite materials by combining ferromagnetic particles with a polymer matrix to create a ferromagnetic polymer composite damper. This composite structure provides both noise damping through the polymer matrix and magnetic flux conduction through the ferromagnetic particles, ensuring consistent brake operation while maintaining the hysteresis air gap.
Solution Approach 2:
The patent changes the material parameters of the damper by using ferromagnetic polymer composite material with specific properties: saturation magnetization between 0.5-5.0 kA/m and permeability between 1.05-1.5 times the permeability of free space. These parameter specifications ensure the damper maintains proper magnetic circuit properties while providing noise damping.
2Reliability
If the hysteresis air gap grows or electromagnet current decreases, then the force of attraction of the electromagnet decreases, but the brake may no longer stay open properly
Solution Approach 1:
The ferromagnetic polymer composite damper acts as an intermediary element in the magnetic circuit. It provides a controlled magnetic path that compensates for variations in air gap and current, maintaining consistent magnetic flux and electromagnet attraction force under varying operating conditions.
3Object-generated harmful factors
If a damper is added to prevent direct metal contact, then noise is reduced, but the total reluctance of the magnetic circuit increases, reducing the force of attraction produced by the electromagnet
Solution Approach 1:
The ferromagnetic polymer composite material combines the noise-damping properties of polymer with the magnetic flux-conducting properties of ferromagnetic particles. This composite structure allows the damper to reduce noise while maintaining low magnetic reluctance, preserving the electromagnet's power-producing properties.
Solution Approach 2:
The damper is positioned specifically in the magnetic circuit where it provides localized noise damping while its ferromagnetic properties ensure it does not significantly increase the total magnetic reluctance. The local application of ferromagnetic material optimizes both noise reduction and magnetic flux conduction.
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 ferromagnetic composite damper enhances noise damping, maintains a stable hysteresis air gap, and improves the power-producing properties of the electromagnet, ensuring the brake stays open effectively and reduces noise.
Implementation Method 1
The damping arrangement is made to be conductive to magnetic flux, and the damping arrangement is fitted on the pathway of the magnetic flux of the electromagnet of the brake
Implementation Method 2
The damping arrangement comprises a damper, which contains a magnetizable material. This type of damper is made of a ferromagnetic composite material
Implementation Method 3
current is connected to the electromagnet comprised in the machinery brake and the magnet pulls the brake pad off the braking surface
Implementation Method 4
the force of attraction of the electromagnet decreases as the hysteresis air gap grows and/or the current of the magnetizing coil decreases
Implementation Method 5
when the current of the electromagnet decreases, the force exerted by the spring finally exceeds the force of attraction of the electromagnet, and the brake activates
Implementation Method 6
The damper can be made of an elastic material, such as rubber; the damper can also be made of e.g. paper and glue
Implementation Method 7
Ferromagnetic composite material comprises a binder material, i.e. a flexible matrix, preferably a polymer matrix
Data Source
Figure 1
AI summary
The invention relates to a brake (1), which comprises : a frame part (2); an armature part (3) supported by the frame part in a manner that allows movement; an electromagnet (5) for opening the brake; and also a damping arrangement (4) for damping the noise of the brake. The aforementioned damping arrangement (4) is made to be conductive to magnetic flux, and the aforementioned damping arrangement (4) is fitted on the pathway of the magnetic flux of the electromagnet (5) of the brake.