Electromagnetic Motor Brake Release With Dual-Coil Lever Actuation
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Solution Overview
Problem
Existing electric motors with electromagnetically actuatable brakes face challenges in efficiently releasing and maintaining the brake in a released state, often requiring high current consumption which leads to resource wastage.
Innovation Solution
The electric motor incorporates a coil received in a magnet body with a brake lining carrier and armature disk, where a second electromagnet and lever mechanism allow for rapid brake release and reduced current consumption by maintaining the released state with less current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a single electromagnet is used to release the brake, then the brake release function is simple, but high current consumption is required to maintain the released state
Solution Approach 1:
The brake actuation system is segmented into two distinct electromagnets: a first electromagnet (coil and magnet body) that generates the main magnetic field to press the armature disk away from the brake lining carrier, and a second electromagnet that acts on the lever to provide mechanical advantage. This segmentation allows the system to use lower current by combining electromagnetic force with mechanical leverage, resolving the contradiction between energy efficiency and functional simplicity.
Solution Approach 2:
A lever mechanism is introduced as an intermediary between the second electromagnet and the armature disk. The lever pivots on the magnet body and translates the force from the second electromagnet into amplified force on the armature disk. This intermediary mechanical element enables the system to maintain brake release with reduced current consumption while adding controlled complexity to the actuation mechanism.
2Reliability
If high current is used to maintain brake release, then the brake release state is reliably maintained, but resources are wasted and environmental impact increases
Solution Approach 1:
The system dynamically switches between two electromagnet configurations: during brake engagement, the first electromagnet operates at full capacity; during brake release, the second electromagnet with lever mechanism takes over, requiring significantly lower current. This dynamic operation mode allows reliable maintenance of the released state while minimizing energy waste, directly addressing the contradiction between reliability and energy loss.
Solution Approach 2:
The system changes the operational parameters by switching between two different electromagnet configurations with different current requirements. The first electromagnet operates with high current for brake engagement, while the second electromagnet operates with low current for maintaining release. This parameter change enables reliable brake release state maintenance with reduced energy loss and environmental impact.
3Volume of moving object
If the lever is positioned close to the magnet body, then the structure is compact, but the second electromagnet cannot effectively pull the lever
Solution Approach 1:
The lever is positioned radially outward from the magnet body rather than axially close to it, utilizing the radial dimension to achieve effective lever arm length. This dimensional arrangement allows the second electromagnet to pull the lever with sufficient force while maintaining a compact overall structure, resolving the contradiction between compactness and force generation.
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 rapid brake release and maintains the released state with lower current consumption, thereby saving resources and reducing environmental impact.
Implementation Method 1
the coil and the electric motor, that is, for example the winding of the electric motor, are connected in parallel so that energization occurs simultaneously
Implementation Method 2
The air space between lever and a coil core of the second electromagnet disappears when the second electromagnet is energized with electrical current
Implementation Method 3
Spring supported on the magnet body press onto the armature disk
Implementation Method 4
a lever is pivotably, e.g., rotatably, mounted relative to and/or on the magnet body. The lever is connected to the armature disk, e.g., by a rod
Data Source
AI summary
In an electric motor having electromagnetically actuatable brake, the brake has a coil received in a magnet body. A brake lining carrier is connected, rotation-fast but axially displaceable, to a rotor shaft of the electric motor, and an armature disk is connected, rotation-fast but axially displaceable, to the magnet body. The armature disk is arranged axially between the brake lining carrier and the magnet body. Springs supported on the magnet body press on the armature disk. A second electromagnet is arranged on the magnet body. A lever is pivotably mounted relative to and/or on the magnet body. The lever is connected to the armature disk, such that in a first rotational position of the lever, the armature disk is pressed towards the brake lining carrier, and in a second rotational position of the lever, the armature disk is kept pulled towards the magnet body.