Motor Brake Mechanism with Meshing Parts and Controller
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Solution Overview
Problem
Existing motors with brakes face challenges in size reduction without compromising braking force and suffer from high power consumption due to continuous power feed to the plate driving mechanism.
Innovation Solution
A motor with a brake mechanism that includes a controller to switch between braked and released states using an electromagnetic brake, reducing power consumption by only energizing coils when necessary, and incorporating a reduction gear to maintain braking force with a smaller motor diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the motor diameter is reduced to achieve size reduction, then the motor size is reduced, but the braking force is reduced
Solution Approach 1:
The patent transitions from friction-based braking (surface contact) to meshing-based braking (tooth engagement). The movable meshing part with protrusions engages with the fixed meshing part's recesses, utilizing dimensional engagement rather than surface friction. This allows effective braking force generation with a smaller motor diameter while maintaining reliability.
Solution Approach 2:
The patent replaces the friction plate mechanism with a meshing gear mechanism. Instead of relying on friction between contact surfaces, the system uses interlocking protrusions and recesses that mechanically engage to provide braking force. This substitution enables size reduction while preserving or enhancing braking effectiveness.
2Ease of operation
If continuous power is supplied to the plate driving mechanism to maintain brake release during motor operation, then the brake remains released during motor driving, but power consumption increases
Solution Approach 1:
The patent employs periodic or intermittent power supply to the coil rather than continuous power supply. The coil is energized only when brake release is required (during motor driving), and de-energized when braking is needed. This periodic action significantly reduces power consumption while maintaining proper brake operation during motor driving.
Solution Approach 2:
The spring mechanism provides self-service by automatically maintaining brake release through spring force when the coil is de-energized, eliminating the need for continuous power supply. The system uses the spring's stored energy to keep the movable meshing part separated from the fixed meshing part during motor operation, reducing reliance on continuous electrical power.
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
The solution enables size reduction of the motor while maintaining braking force and reducing power consumption by efficiently controlling the braking mechanism through selective coil energization and using a reduction gear to manage torque and rotation speed.
Implementation Method 1
an electromagnetic brake mechanism provided with a movable yoke with which the movable meshing part is integrally formed, a pair of fixed yokes in which both-side leg parts each having a U-shaped cross section are arranged so as to face the movable yoke through a gap, permanent magnets respectively arranged to parts of the respective fixed yokes so that same magnetic poles face each other, and a pair of coils wound in the same direction and arranged opposite to each other between the both-side leg parts of the respective fixed yokes so that air-core parts face the movable yoke, and the magnitude of attractive forces of the both-end leg parts of the pair of fixed yokes is changed by energizing at least any of the pair of coils to move the movable yoke with the movable meshing part in the axial direction
Data Source
AI summary
A controller controls switching between a braked state in which a movable meshing part 7 comes close to and meshes with a motor meshing part 6 and a brake released state in which the movable meshing part 7 is separated from the motor meshing part 6.