Fluidically Actuated Fail-Safe Disk Brake System
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Solution Overview
Problem
The existing disc brake systems for lifting gear require high installation effort and are prone to operational safety issues due to leaks in fluid lines, as they necessitate multiple 2/2-way valves for each brake cylinder pair, which increases energy consumption and reduces reliability.
Innovation Solution
The disc brake system connects the brake cylinders of a pair in series with a 2/2-way valve in each supply line, allowing for the use of cartridge valves, reducing the number of valves required and minimizing leakage risks, and enabling motor-actuated valves to conserve energy during normal operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If brake cylinders are connected in parallel to fluid pressure source with multiple 2/2-way valves, then individual activation for testing is enabled, but installation effort increases and leakage risk increases
Solution Approach 1:
The patent merges the fluid connections of both brake cylinders into a single common fluid connection point. Instead of having separate fluid lines for each brake cylinder, both cylinders share a common fluid connection, which is then controlled by a single 2/2-way valve. This reduces the number of valves from four (one per cylinder in parallel configuration) to just one, thereby reducing installation effort and potential leakage points while still enabling individual activation of each brake cylinder for testing purposes.
Solution Approach 2:
The single 2/2-way valve serves multiple functions: it controls fluid supply to both brake cylinders simultaneously for normal operation, and enables individual testing of each brake cylinder by selectively directing fluid to either cylinder. The common fluid connection point acts as a universal interface that simplifies the overall system architecture while maintaining the capability for individual component testing.
2Ease of operation
If multiple 2/2-way valves are used for each brake cylinder, then individual brake control is achieved, but energy consumption increases due to electromagnetic actuation
Solution Approach 1:
By merging the control functions into a single 2/2-way valve instead of using four separate electromagnetic valves, the patent reduces the total energy consumption of the valve system. The single valve is only actuated when testing or inspection is required, whereas in the parallel configuration with four valves, more electromagnetic actuators would be consuming energy continuously or more frequently.
Solution Approach 2:
The 2/2-way valve is designed to be actuated only periodically when testing or inspection of the brake cylinders is required, rather than continuously. During normal operation, the valve remains in its default position, consuming minimal energy. This periodic actuation pattern significantly reduces overall energy consumption compared to a system with multiple electromagnetic valves that would need to be controlled more frequently or continuously.
3Device complexity
If brake cylinders are connected in series with single fluid connection, then number of valves is reduced, but pressure distribution to both cylinders must be equal
Solution Approach 1:
The patent merges the fluid supply paths of both brake cylinders into a single common fluid connection. This single connection point ensures that the same fluid pressure is applied to both brake cylinders simultaneously, automatically achieving uniform pressure distribution without requiring complex pressure balancing mechanisms. The series connection topology naturally equalizes pressure across both cylinders while reducing the number of valves to just one.
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
This configuration reduces installation effort, minimizes leakage risks, and enhances operational reliability by using fewer valves and converting them into cartridge valves, which can be selectively activated with electrical power only during testing or inspection.
Implementation Method 1
each brake cylinder comprising a brake piston on which, by means of a spring arrangement, one for the brake disc directed spring force is exerted
Implementation Method 2
with which a force directed counter to the spring force can be exerted on the brake piston in order to reduce the braking force caused by the spring force
Implementation Method 3
Each of the pressure lines includes a separate 2/2-way valve that can be actuated electromagnetically against a spring force
Implementation Method 4
2/2-way valve that can be actuated electromagnetically against a spring force
Data Source
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AI summary
The invention relates to a fluidically actuatable failsafe disk brake system comprising a plurality of brake cylinder pairs (2) which are arranged approximately opposite one another on both sides of a brake disk (1) in one or more brake calipers (30). Each brake cylinder (3, 4) comprises a brake piston (5, 6) on which a spring force directed towards the brake disk (1) is exerted by means of a spring arrangement (7, 8). A first and a second fluid connection (P1, P2) is provided at each brake cylinder (3, 4). A fluid can be supplied to the brake cylinder (3, 4) by means of said fluid connection, said fluid being used to exert a force opposite the spring force on the brake piston (5, 6) in order to reduce the braking force brought about by the spring force. One of the first or second fluid connections (P1, P2) of the brake cylinders (3, 4) of the brake cylinder pair (2) is paired with a respective 2/2-way valve (20, 21), and the respective other of the first or second fluid connections (P1, P2) of the brake cylinders (3, 4) of the brake cylinder pair (2) are fluidically connected to one another.