Integrated Electromagnetic Brake in Gear Unit for Compact Motor Assembly
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Solution Overview
Problem
Existing gear systems face challenges in achieving a compact design while integrating an electromagnetically actuable brake, which complicates the assembly of electric motors with gear units and requires additional components.
Innovation Solution
A gear system incorporating a torsion-resistant electromagnetically actuable brake with a coil core, brake surface part, and bearing flange, where the brake is integrated into the gear unit, allowing for a compact and precise assembly without needing a separate brake motor, utilizing a spring element for engagement in the non-energized state and a dome component for protection and routing electrical lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the brake is integrated into the gear unit, then the system compactness is improved and assembly is simplified, but the structural complexity increases
Solution Approach 1:
The brake is merged with the gear unit by integrating the coil core, armature disk, and brake pads into the existing gear housing structure. The coil core is positioned within the housing and the armature disk is coupled to the input shaft, allowing the brake function to be incorporated without requiring a separate brake motor assembly.
Solution Approach 2:
The gear unit housing serves multiple functions: it encloses the gear mechanism, provides structural support, and houses the brake components. The input shaft serves dual purposes by transmitting torque to the gears and coupling to the armature disk of the brake, eliminating the need for separate mounting structures.
2Ease of manufacture
If the brake is integrated into the gear unit, then the assembly process is simplified, but the manufacturing precision requirements increase
Solution Approach 1:
The coil core is pre-positioned within the housing and the armature disk is pre-coupled to the input shaft before final assembly. The brake pads are pre-adjusted to the correct position, allowing for simplified final assembly without requiring complex alignment procedures during installation.
Solution Approach 2:
The input shaft serves as a common reference element for both the gear mechanism and the brake components. By coupling the armature disk directly to the input shaft, the same rotational reference is used for both functions, eliminating alignment errors that would arise from separate mounting surfaces.
3Reliability
If the brake is arranged as a stop brake, then the shaft positioning is improved during assembly, but the brake engagement force increases
Solution Approach 1:
Instead of using the brake to stop a moving shaft, the stop brake is configured to hold the shaft in a fixed position during assembly before operation begins. The spring element maintains constant pressure on the brake pads against the armature disk, ensuring the shaft remains positioned until the system is fully assembled and operational.
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 enables a compact and straightforward assembly of the motor with the gear unit, ensuring the brake is always available and functioning as a stop brake, while maintaining a sealed and lubricated environment, thus simplifying the integration process and enhancing the system's compactness.
Implementation Method 1
A spring element, which is braced on the coil core, may apply a spring force to the armature disk
Implementation Method 2
an electromagnetically actuable brake with a coil core (5)
Data Source
AI summary
A gear system includes a gear unit and an electromagnetically actuable brake, the brake having a coil core that is connected to a brake surface part in a torsion-resistant manner. The brake surface part is connected to a bearing flange, its bearing mount in particular delimiting a free space. The bearing flange is connected to a cover part which is connected to a housing part of the gear unit, and a shaft is supported in the housing part via at least one bearing. A driver is connected to the shaft in a torsion-resistant manner, the driver having an external tooth system that is in engagement with an internal tooth system of a brake pad carrier such that the brake pad carrier is connected to the shaft in a torsion-resistant yet axially displaceable manner. An armature disk, which is disposed in a torsion-resistant yet axially displaceable manner with respect to the coil core, is situated between the coil core and the brake pad carrier.