Modular Line-Replaceable Brake for Actuator Maintenance
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Solution Overview
Problem
Existing brake systems for actuators are difficult to maintain due to the need for disassembly, which leads to extended downtime and exposure to foreign object debris, and are not easily adaptable to changing operational demands, resulting in inefficiencies and increased wear.
Innovation Solution
A line replaceable brake system with an environmentally sealed modular design that includes a drive coupling, braking disks, and an armature for easy inspection and replacement, featuring a window for visual inspection of wear and captive hardware for rapid, contaminant-free installation and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If brake elements are inspected by removal and disassembly, then wear verification is possible, but system downtime is extended and foreign object debris risk increases
Solution Approach 1:
The brake system is segmented into a modular brake component that can be independently removed from the actuator. This allows the brake element to be inspected, worn, or replaced without disassembling the entire actuator, reducing system downtime and foreign object debris risk while maintaining wear verification capability
Solution Approach 2:
A window is provided in the brake housing that acts as an intermediary, allowing visual inspection of the brake element through the housing wall. This enables wear verification without physical disassembly, eliminating both downtime and contamination risks
2Measurement precision
If brake elements are disassembled for inspection, then wear can be verified, but foreign object debris exposure increases
Solution Approach 1:
The brake system is segmented into a modular brake component with a sealed housing. This segmentation allows the brake element to be inspected through the sealed housing window without exposing internal components to foreign object debris, eliminating contamination risk while maintaining inspection capability
Solution Approach 2:
The window in the brake housing serves as an intermediary that enables optical inspection of the brake element without physical access. This intermediary mechanism allows wear verification while the sealed housing prevents foreign object debris exposure
3Productivity
If actuators are designed with proprietary arrangements, then system integration is optimized, but adaptability to changing demands decreases
Solution Approach 1:
The brake component is designed as a universal modular unit with standardized mounting interfaces that can be adapted to different actuator types. This universality allows the same brake design to serve multiple applications while maintaining optimized integration for each specific system
Solution Approach 2:
The brake system incorporates a modular design that allows dynamic reconfiguration and replacement. The brake component can be easily removed and replaced with different brake elements to adapt to changing operational demands while maintaining integration with the actuator
4Ease of repair
If brake systems require disassembly for maintenance, then component access is possible, but maintenance complexity increases
Solution Approach 1:
The brake system is segmented into a self-contained modular component that can be independently accessed and replaced. This segmentation eliminates the need to disassemble the actuator for brake maintenance, simplifying the maintenance procedure while maintaining component accessibility
Solution Approach 2:
The brake element is extracted as a separate replaceable component within the brake housing. This extraction allows the brake element to be maintained independently through simple removal and replacement procedures without requiring disassembly of the actuator or brake housing
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 solution allows for in-field inspection and rapid replacement of brake components without disassembling the actuator, reducing downtime, preventing foreign object debris exposure, and optimizing brake performance by reducing wear and maintenance costs.
Implementation Method 1
an armature in the integral brake housing configured to engage or disengage the one or more braking disks with the drive coupling
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
A system including a modular brake component having: - a modular brake component having an integral brake housing configured to mount to a motor; - a drive coupling within the integral brake housing configured to mechanically couple with an output shaft of the motor; - one or more braking disks arranged in the integral brake housing configured to brake movement of the drive coupling when engaged; - an armature in the integral brake housing configured to engage or disengage the one or more braking disks with the drive coupling; - captive mounting hardware arranged in the integral brake housing and configured to mount the modular brake component directly on a back of one of the following: the motor or an actuator; and the motor is implemented in the actuator.