Electromagnetic Holding Brake Control With Two-Stage Coil Voltage
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Solution Overview
Problem
Electromagnetic holding brakes in compact drives experience high power consumption and heat generation due to unnecessarily high operating voltages, leading to performance loss.
Innovation Solution
A control system utilizing a DC/DC converter with 2-stage voltage control, converting variable input voltage to a predetermined switch-on voltage and then downregulating it to a lower holding voltage, optimized for electromagnetic compatibility and efficiency, to minimize power consumption and heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high voltage is supplied to the coil to ensure reliable release and holding of the brake, then the brake release reliability is improved, but power consumption and heat generation increase
Solution Approach 1:
The patent applies periodic action by using a two-stage voltage control strategy: initially applying high voltage to ensure reliable brake release, then switching to a lower holding voltage to maintain the released state. This temporal variation in voltage application reduces overall power consumption while ensuring reliable operation during the critical release phase.
Solution Approach 2:
The patent changes the voltage parameter over time through the DC/DC converter, which dynamically adjusts the coil voltage from a high initial value to a lower sustained value. This parameter change allows the system to achieve reliable brake release with high voltage temporarily, then maintain the released state with reduced voltage, thereby reducing power consumption and heat generation.
2Reliability
If high voltage is supplied to the coil to ensure reliable release and holding of the brake, then the brake release reliability is improved, but heat generation increases
Solution Approach 1:
The two-stage voltage control applies high voltage only during the initial release phase when it is most needed, then transitions to lower voltage for maintaining the released state. This periodic application of high voltage minimizes the duration of high heat generation while ensuring reliable brake release.
Solution Approach 2:
The DC/DC converter dynamically changes the voltage parameter supplied to the coil, reducing it after the initial release phase. This parameter change directly reduces the I²R losses in the coil, thereby reducing heat generation while maintaining the brake in the released position.
3Reliability
If high voltage is supplied to the coil to ensure reliable release and holding of the brake, then the brake release reliability is improved, but performance is lost due to heat generation
Solution Approach 1:
The patent uses periodic action by applying high voltage only during the brief release phase when reliability is critical, then switching to lower voltage during normal operation. This reduces overall heat generation in the drive system, preserving performance while ensuring reliable brake release when needed.
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 achieves low power consumption and reduced heat generation, ensuring reliable brake operation while maintaining high electromagnetic compatibility and efficiency.
Implementation Method 1
a DC/DC converter with an input and an output, said DC/DC converter being designed to convert a variable input voltage applied to the input into a predetermined switch-on voltage provided at the output and a predetermined holding voltage provided at the output
Implementation Method 2
a coil through which current flows during released operation, which coil pulls a metallic armature plate against the force of a spring that applies pressure to the armature plate
Data Source
AI summary
A control for an electromagnetic holding brake with a coil for releasing the holding brake and maintaining it in the released position, which requires a minimum brake coil voltage to maintain it in the re-leased position, having a DC-DC converter with an input and an output, the DC-DC converter being designed to convert a variable input voltage pre-sent at the input into a predetermined switch-on voltage provided at the output and a predetermined holding voltage provided at the output, the holding voltage corresponding to the minimum brake coil voltage, the DC-DC converter being designed to implement a 2-stage voltage control and, in a first stage, to maintain the switch-on voltage as a regulated DC voltage for a predetermined time, to downregulate the voltage from the switch-on voltage following a predetermined voltage curve to the holding voltage as regulated DC voltage, and to maintain it in a second stage.