Miniature Electromagnetic Brake Assembly Without Threaded Fasteners
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Solution Overview
Problem
Conventional electromagnetic brakes are limited in size due to the use of fasteners, which restrict the miniaturization of brakes and the generation of high braking torque, and often contaminate friction surfaces with thread locking adhesives.
Innovation Solution
The brake is assembled without conventional fasteners by using a fastener that bonds the pressure plate to the electromagnet, allowing for a smaller design while maintaining sufficient electromagnetic component size to generate high torque, and enabling precise air gap control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional fasteners (threaded fasteners, bolts, pins) are used to couple brake components, then the brake structure is mechanically secure, but the brake size cannot be reduced below a certain minimum due to fastener handling and assembly requirements
Solution Approach 1:
The patent replaces conventional mechanical fasteners (threaded fasteners, bolts, pins) with a bonding system using adhesive or interference fit features integrated into the component designs. This substitution eliminates the need for separate fastening elements, allowing the brake to be miniaturized while maintaining structural integrity and eliminating fastener handling requirements.
Solution Approach 2:
The patent integrates the fastening function directly into the brake component structures themselves, such as incorporating interference fit features into the electromagnetic component housings or using bonded joints as integral parts of the assembly. This merging of fastening and structural functions eliminates the need for separate fasteners and reduces overall brake size.
2Strength
If conventional fasteners are used in the brake, then the components are securely coupled, but the space required by fasteners limits the size of electromagnetic components and therefore the braking torque that can be generated
Solution Approach 1:
The patent replaces mechanical fastening systems with bonding mechanisms (adhesive bonding or interference fits) that provide equivalent or superior coupling strength without requiring additional space for fasteners. This allows electromagnetic components to be sized optimally for torque generation rather than being constrained by fastener clearance requirements.
Solution Approach 2:
The patent changes the coupling mechanism from discrete mechanical fasteners to continuous bonding interfaces, altering the physical parameters of the joint. This enables more efficient use of space within the brake assembly, allowing larger electromagnetic components that can generate higher braking torque.
3Reliability
If conventional fasteners with thread locking adhesives are used, then the fastener connection is secured, but the friction surfaces in the brake are contaminated
Solution Approach 1:
The patent extracts the thread locking adhesive application step from the assembly process by using bonding systems that do not require separate adhesive applications on threaded surfaces. This eliminates the source of contamination (thread locking adhesives) while maintaining secure connections through alternative bonding methods that do not contaminate friction surfaces.
Solution Approach 2:
The patent replaces the threaded fastener system with thread locking adhesives with a bonding system that uses interference fits or structural adhesives applied to non-friction surfaces. This substitution maintains connection reliability while eliminating the harmful effect of adhesive contamination on friction surfaces.
4Strength
If conventional fasteners are used for assembly, then the components are mechanically joined, but the assembly process is less efficient and more complex
Solution Approach 1:
The patent replaces multi-step mechanical fastening operations (drilling, threading, inserting fasteners, applying thread locking adhesives, torqueing) with simpler bonding operations such as applying adhesive or assembling interference fit features. This substitution maintains strong component joining while significantly improving assembly efficiency and reducing process complexity.
Solution Approach 2:
The patent designs bonding interfaces that can be assembled in fewer steps, potentially as part of modular component assemblies. This segmentation and integration of bonding features into the component design reduces the number of assembly operations required while maintaining secure component joining.
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 approach allows for the creation of a compact brake with high torque capability, efficient assembly, and prevents contamination of friction surfaces, while eliminating the tolerance stackup issues associated with conventional fasteners.
Implementation Method 1
The fastener conforms to a space between opposed surfaces of the pressure plate and the electromagnet and, upon hardening, bonds the pressure plate to the electromagnet.
Data Source
AI summary
A brake and method of assembly are provided. The brake includes a friction plate configured for coupling to a rotatable body for rotation with the rotatable body about an axis of rotation, a pressure plate disposed about the axis on a first side of the friction plate and fixed against rotation, and an armature plate disposed about the axis on a second side of the friction plate. An electromagnet is disposed about the axis on an opposite side of the armature plate relative to the friction plate. A spring biases the armature plate in a first axial direction towards the friction plate and away from the electromagnet to engage the brake. A fastener couples the pressure plate to the electromagnet. The fastener conforms to a space between opposed surfaces of the pressure plate and the electromagnet and, upon hardening, bonds the pressure plate to the electromagnet.