Integrated Clutch-Brake Electronics in Limited Magnet Housing Space
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electromagnetically actuated clutches and brakes face challenges in achieving a compact design while minimizing manufacturing costs, particularly due to the need for separate control electronics that require additional housing and complex wiring.
Innovation Solution
Integration of control electronics as an integral component within the clutch or brake mechanism, utilizing the existing annular space for the coil former to accommodate both the coil and control electronics, allowing for a compact design and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If control electronics are integrated within the magnet housing, then device compactness and manufacturing cost are improved, but the annular space for the coil former becomes more constrained
Solution Approach 1:
The control electronics are nested within the annular space of the magnet housing, specifically positioned between the coil former and the magnet housing base. This nesting arrangement allows the control electronics to occupy the same spatial envelope as the coil former without requiring additional external housing, thereby achieving compact integration while maintaining the functional integrity of both components.
2Reliability
If the coil former is dimensioned to bridge the air gap reliably, then actuation reliability is improved, but energy consumption increases due to high voltage requirements
Solution Approach 1:
The control electronics implement periodic action by applying high voltage only during the brief moment when the armature plate needs to overcome the air gap and spring pressure to transition between states. Once the armature plate is in its final position (either attracted to the magnet housing or held by springs), the control electronics reduce or eliminate voltage application. This periodic energization pattern maintains reliable actuation while significantly reducing overall energy consumption compared to continuous high-voltage application.
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 integration results in a compact design that simplifies installation, reduces energy consumption, and lowers manufacturing and assembly costs, while ensuring reliable operation and easy integration into limited spaces.
Implementation Method 1
When the coil former is energized, the magnet housing of the electromagnet becomes magnetized
Implementation Method 2
This causes the armature plate to be magnetically attracted by the magnet housing
Implementation Method 3
the compression spring elements supported by the magnet housing press the armature plate against the cover
Implementation Method 4
the brake disc is frictionally clamped between the cover and the armature plate under the compression spring load
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an electromagnetically actuated clutch, brake or clutch-brake combination with an electromagnet (2) comprising a magnet housing (7) and a coil body (8) received therein, a clutch or brake disc (3) which is axially displaceable on a shaft but nevertheless rotationally fixed, an armature plate (10) arranged between the magnet housing (7) and the clutch or brake disc (3) and a cover (11) arranged rotationally fixed on the magnet housing (7), wherein the armature plate (10) and the clutch or brake disc (3) are arranged between the magnet housing (7) and the cover (11), characterized by an integrated control electronics (13).