Motor Brake Engaging Plate Mechanism for Debris-Free Emergency Stops
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing motor brakes using friction plates suffer from wear debris dispersion, slipping, and reliance on friction coefficient and spring characteristics, leading to unreliable emergency halts and high electrical consumption.
Innovation Solution
A brake mechanism utilizing a fixed and movable engaging plate with engagement protrusions and recesses, mechanically engaging to halt the motor shaft, and a self-holding solenoid for minimal power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a friction plate is used in a non-excitation actuated type electromagnetic brake, then the brake can halt the motor using spring force, but wear debris is generated from the friction plate and dispersed onto the encoder disk leading to faults
Solution Approach 1:
The invention extracts and removes the friction plate from the brake system entirely. Instead of using a friction plate that generates wear debris, the patent employs a magnetic attraction mechanism where the armature plate is directly attracted to the yoke by magnetic force, eliminating the source of wear debris while maintaining the braking function.
Solution Approach 2:
The invention replaces the mechanical friction-based braking system with a magnetic field-based system. The friction plate and spring mechanism are substituted by a magnetic attraction system where the armature plate is held against the yoke by magnetic force during braking, eliminating mechanical wear while achieving the same halting effect.
2Reliability
If a friction plate is used in a non-excitation actuated type electromagnetic brake, then the brake can be actuated by spring force, but oily matter such as grease mist adheres to the friction plate and prevents proper halting
Solution Approach 1:
The invention removes the friction plate from the system, eliminating the surface that attracts and retains oily matter. The braking function is achieved through magnetic attraction between the armature plate and yoke, which does not involve friction surfaces that can be contaminated by grease mist.
Solution Approach 2:
The mechanical friction-based actuation system is replaced with a magnetic field-based system. The spring force that previously acted on the friction plate is replaced by magnetic attraction force acting on the armature plate, eliminating the adhesion problem caused by oily matter while maintaining the actuation capability.
3Power
If a friction plate is used with spring characteristics, then the brake can generate braking force, but the braking characteristics depend on friction coefficient and spring characteristics requiring individual design for each motor
Solution Approach 1:
The invention creates a universal brake mechanism that can be applied to different motors without individual design adjustments. The magnetic attraction system between the armature plate and yoke provides consistent braking force characteristics across different motor types, eliminating the need to tailor the design to specific motor characteristics.
Solution Approach 2:
The spring-based mechanical system with friction-dependent characteristics is replaced by a magnetic field-based system. The magnetic attraction force provides predictable and consistent braking force that is independent of friction coefficients, allowing for standardized design across different motor applications.
4Use of energy by moving object
If a self-holding type solenoid is used to move the movable-side engaging plate, then electrical power consumption is minimized, but the solenoid must be designed to hold the plate in both halt cancelation and halt positions
Solution Approach 1:
The solenoid design is segmented into distinct functional components: a coil for generating magnetic force, a permanent magnet for self-holding capability, and a plunger for mechanical actuation. This segmentation allows the solenoid to achieve minimal power consumption while maintaining the ability to hold positions without continuous energization.
Solution Approach 2:
The self-holding type solenoid uses a permanent magnet to maintain the plunger in the attracted position without requiring continuous electrical power. The system serves itself by using the magnetic field stored in the permanent magnet to hold the engaging plate in position, eliminating the need for continuous energization and minimizing power consumption.
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
Eliminates wear debris issues and ensures reliable emergency halts with reduced electrical power usage by mechanical engagement, independent of friction coefficient and spring characteristics.
Implementation Method 1
a solenoid for moving the movable-side engaging plate in the direction of the center axis to a halt cancelation position where the movable-side engaging plate is set apart from the fixed-side engaging plate and to a halt position where the movable-side engaging plate is engaged with the fixed-side engaging plate
Data Source
Figure 1
Figure 2(A)~2(B)
Figure 3(A)~3(E)
AI summary
A brake (3) for a motor comprises: a fixed-side engaging plate (30) fixed to a motor shaft (4); a movable-side engaging plate (20) coaxially opposed to the fixed-side engaging plate (30) along the direction of a center axis (3a); and a self-holding type solenoid (10) that moves, in the direction of the center axis, the movable-side engaging plate (20) to a halt cancelation position (20A) separated from the fixed-side engaging plate (30) and a halt position (20B) where engagement with the fixed-side engaging plate (30) occurs. When the motor is halted, the solenoid (10) is driven to move the movable-side engaging plate (20) from the halt cancelation position (20A) to the halt position (20B). The movable-side engaging plate (20) which has reached the halt position (20B) is mechanically engaged with the fixed-side engaging plate (30), and the motor shaft (4) is forcibly halted.