Electromagnetic Motor Braking with False-Trigger Discrimination
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Solution Overview
Problem
Current braking systems in test apparatuses with electromagnetic motors are prone to false-triggering events, leading to unnecessary shutdowns and safety concerns due to their inability to accurately differentiate between actual and false undesired movements of the output shaft, resulting in frequent and potentially hazardous interruptions.
Innovation Solution
A control system utilizing frequency domain analysis through Fourier transforms and finite impulse response (FIR) filters to differentiate between true failure events and false-failure events, combined with a solid-state relay circuit switch for rapid braking engagement, and a mechanical brake design with a self-energizing mechanism for improved response time and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If velocity monitoring with SSM and STO mechanism is used to prevent undesired movement, then safety is improved, but false-triggering events increase due to inability to differentiate between actual and false undesired movements
Solution Approach 1:
The braking system is divided into multiple independent braking methods (mechanical brake, e-brake, and electrical brake with STO) that can be selectively applied. The control system segments the velocity signal analysis into frequency domain components using Fourier transforms, allowing differentiation between false-triggering events (low frequency) and actual undesired movements (high frequency).
Solution Approach 2:
The system continuously monitors velocity and acceleration signals, performs real-time frequency domain analysis using Fast Fourier Transform (FFT), and adjusts braking application based on the spectral content. The feedback loop distinguishes between benign vibrations (low frequency components) and dangerous movements (high frequency components), enabling intelligent braking decisions that reduce false-triggering while maintaining safety.
2Reliability
If mechanical brake response time is reduced to arrest output shaft within 2mm, then safety is improved, but brake wear and heat generation increase
Solution Approach 1:
The control system dynamically selects and adjusts the braking method based on real-time conditions. For minor corrections, the e-brake is applied with modulated force. For emergency stopping, the mechanical brake is engaged with optimized pressure profiles. This dynamic adaptation allows rapid response when necessary while minimizing energy dissipation during normal operation.
Solution Approach 2:
The e-brake serves as an intermediary braking mechanism between the electrical motor and the mechanical brake. It provides a softer, more controllable braking force that can handle minor speed corrections and position adjustments, reducing the need for aggressive mechanical brake application and thereby reducing wear and heat generation.
3Speed
If e-brake is used for rapid deceleration, then response time is improved, but braking force consistency deteriorates due to electromagnetic induction variability
Solution Approach 1:
The system merges multiple braking mechanisms (e-brake and mechanical brake) into a unified braking system. The e-brake provides rapid initial deceleration, while the mechanical brake ensures consistent final stopping. The control system coordinates both brakes to achieve smooth, consistent deceleration profiles, compensating for e-brake variability through mechanical brake supplementation.
Solution Approach 2:
The control system dynamically adjusts the braking parameters including e-brake current magnitude and duration, mechanical brake pressure, and the timing of brake application based on real-time velocity and acceleration measurements. This parameter optimization ensures consistent braking force delivery across varying operating conditions.
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 system significantly reduces false-triggering events, ensuring the output shaft is arrested only when necessary, thereby minimizing operator intervention and apparatus damage, while enhancing the braking system's response time and reliability.
Implementation Method 1
The coil assembly comprises a plurality of separate coil loops, an electric current signal applied through the coil assembly induces a magnetic field which interacts with the magnetic material's magnetic field and therefore a force on the output shaft is generated
Implementation Method 2
An additional means for braking a moving output shaft of an electromagnetic motor is through electromagnetic induction whereby motion of the output shaft within the coil assembly induces eddy currents in the output shaft so as to generate an electromagnetic braking force
Implementation Method 3
motion of the output shaft within the coil assembly induces eddy currents in the output shaft so as to generate an electromagnetic braking force
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A mechanical brake for arresting movement of an output shaft of a motor. The mechanical brake comprises: a pivotally mounted plate having a space for receiving the output shaft of the motor; and an electrically operated holding device contacting a free end of the plate and arranged to hold the plate in an open position to permit movement of the output shaft and to permit the plate to pivot to a jamming position. The electrically operated holding device comprises: a first electrically actuated device for controlling the movement of the plate between the open position and the jamming position; and a second electrically actuated device configured to provide a lifting action to the plate to release the plate from the jamming position.