Hydraulic Elevator Brake Torque Adjustment
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Solution Overview
Problem
High-rise, high-speed elevator systems require complex and noisy electromagnetic brakes, which are not easily adjustable for optimal braking torque and pose risks of excessive deceleration and passenger injury, and lack manual release functionality for emergency situations.
Innovation Solution
A hydraulic brake system with pressure limiting valves and electromagnetic control, including a hand-operated pump and push valve, to manage hydraulic fluid flow and adjust braking torque, reduce noise, and enable manual operation during power outages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electromagnetic brakes are used to stop and hold the elevator car, then the braking function is achieved, but the system becomes complex and noisy with limited adjustability
Solution Approach 1:
The patent replaces electromagnetic brakes with a hydraulic brake system that uses hydraulic fluid pressure to actuate brake calipers. The hydraulic brake unit includes a reservoir, pump, pressure regulator, and control valves that manage fluid flow to provide smooth, adjustable braking force on the brake disc, eliminating the complexity and noise of electromagnetic brake components while maintaining reliable stopping and holding functions.
2Reliability
If electromagnetic brakes are used to stop the elevator car, then braking is achieved, but excessive noise is generated during operation
Solution Approach 1:
The hydraulic brake system uses fluid pressure to gradually apply braking force through the brake calipers, avoiding the sudden engagement and mechanical impact that causes noise in electromagnetic brakes. The hydraulic fluid acts as a cushion, providing smooth pressure application and release that eliminates the noisy engagement characteristic of electromagnetic brake systems.
Solution Approach 2:
The hydraulic system provides beforehand cushioning by using the compressibility and flow characteristics of hydraulic fluid to cushion the braking action. The fluid pressure builds gradually and can be regulated to apply braking force smoothly, preventing the sudden impact and noise that occurs when electromagnetic brakes engage directly with the brake disc.
3Reliability
If electromagnetic brakes are used, then braking is achieved, but the braking torque cannot be easily adjusted after installation
Solution Approach 1:
The hydraulic brake system provides adjustable braking torque through the pressure regulator valve, which can be adjusted to change the maximum hydraulic pressure in the system. This allows the braking torque to be precisely tuned by adjusting the pressure setting, and the system can be adapted to different braking requirements by modifying the pressure regulator settings without changing the physical brake components.
4Reliability
If electromagnetic brakes are used, then braking is achieved, but manual release for emergency movement is not possible
Solution Approach 1:
The hydraulic brake system incorporates a manual release mechanism that allows operators to bypass the automatic control system and directly manipulate the brake calipers through the hydraulic lines. By using the manual release valve or pump, operators can control the hydraulic pressure to release or apply the brakes manually, enabling emergency movement of the elevator car 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 hydraulic brake system provides adjustable braking torque, reduces noise, and allows manual operation, enhancing safety and reliability by enabling precise control and emergency movement of elevator cars.
Implementation Method 1
A hydraulic brake unit is operably connected to the one or more brake calipers. The hydraulic brake unit includes one or more valves control hydraulic fluid flow during engagement of the brake calipers to the brake disc.
Implementation Method 2
the one or more valves include a pressure limiting valve to maintain hydraulic fluid pressure in the brake unit within a selected range, thereby limiting braking torque of the braking system.
Implementation Method 3
the braking system further includes a hand-operated pump to pressurize the hydraulic brake unit in the case of a power outage.
Implementation Method 4
the braking system further includes a hand-operated push valve to relieve hydraulic pressure in the hydraulic brake unit.
Implementation Method 5
the third electromagnetic valve directs hydraulic fluid flow to a flow control valve to reduce a hydraulic fluid flow rate in the brake unit, thereby reducing brake caliper to brake disc impact force and noise.
Data Source
AI summary
A braking system for an elevator includes a brake disc and one or more sets of brake calipers interactive with the brake disc. A hydraulic brake unit is operably connected to the one or more brake calipers. The hydraulic brake unit includes one or more valves to control hydraulic fluid flow during engagement of the brake calipers to the brake disc. An elevator includes a car, one or more sheaves, and a suspension member connected to the car and routed over the sheaves. A machine drives motion of the elevator car. A braking system located at the machine includes a brake disc and one or more brake calipers. A hydraulic brake unit is operably connected to the brake calipers and includes one or more valves to control hydraulic fluid flow during engagement of the brake calipers to the brake disc.