Four-Segment Brake for Soft Emergency Braking
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Solution Overview
Problem
Existing electromagnetic spring-loaded brakes used in elevator and stage technology are not optimized for softer emergency braking, leading to sudden shocks and vibrations due to full braking torque application when one brake fails, requiring oversized and costly components.
Innovation Solution
A rectangular or square brake with four evenly distributed round coils and separate armature disks, allowing for independent operation and fault detection, is designed to achieve 133.33% braking torque when all functional, ensuring 100% torque with three operational circuits, reducing effective braking torque by 66.66% during emergency operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two identical brakes are arranged to provide redundant braking, then braking torque redundancy is improved, but emergency braking causes strong shocks and vibrations due to 200% braking torque application
Solution Approach 1:
The brake system is divided into four independent braking circuits (two per rectangular brake unit), allowing selective activation. Each circuit can be operated separately, enabling the system to apply braking torque from one brake only during emergency situations, thus maintaining redundancy while avoiding the harmful effect of simultaneous dual-brake application.
2Reliability
If brakes are designed for 200% braking torque to ensure 100% redundancy, then reliability is improved, but installation space and component size increase
Solution Approach 1:
The system segments the braking function into four independent circuits within a single integrated brake unit, eliminating the need for two separate brake assemblies. This achieves redundancy while optimizing installation space through a compact one-piece design.
Solution Approach 2:
The single brake unit with four independent circuits serves multiple functions: normal operation, redundant braking, and emergency braking. The integrated design combines what would traditionally require separate brake assemblies, reducing overall installation space while maintaining full redundancy capability.
3Object-affected harmful factors
If four independent brake circuits are used to reduce emergency braking torque to 133.33%, then shocks and vibrations are reduced, but device complexity increases
Solution Approach 1:
Four independent braking circuits are merged into a single integrated brake unit with a one-piece coil carrier and armature disk. This combining approach achieves the benefit of reduced emergency braking torque (133.33% instead of 200%) while minimizing the complexity increase through unified construction and shared mechanical components.
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 design achieves softer emergency braking with reduced vibrations and smaller, cheaper machine components, maintaining 100% braking torque redundancy with improved efficiency and cost-effectiveness.
Implementation Method 1
electromagnetically releasing spring-loaded brake
Implementation Method 2
the magnetic coil is not oval but divided into two circular coils per rectangular brake unit
Implementation Method 3
correspondingly loaded with springs to press against the brake rotor axially
Implementation Method 4
one surface of the friction lining being braked on the machine wall or the flange plate and the other surface of the friction lining being braked on the anchor plate
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
An electromagnetic, ventilated spring-operated brake, wherein the brake comprises a rectangular or square coil carrier (1) with four uniformly distributed magnet coils and four rectangular or square armature disks are assigned, which armature disks press against a common brake rotor (4) with two friction linings attached to each side, and the brake rotor (4) is axially movable on an axially toothed hub (6).