Multi-Stage Actuating System for Industrial Truck Braking
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Solution Overview
Problem
Industrial truck braking systems face high wear and high production costs due to frequent use of electromagnetic spring-loaded brakes, which are insufficient for real-world braking demands and require expensive infinitely controllable systems.
Innovation Solution
A multi-stage actuating system with a housing divided by perforated intermediate walls and a multi-part piston, where spring elements exert forces through actuation spaces connected by a pressure medium arrangement, allowing for controlled braking without wear and independent of pressure fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If electromagnetic spring-loaded brakes are used for service braking, then braking force is improved, but wear increases due to frequent use
Solution Approach 1:
The braking system is divided into multiple independent stages (first stage, second stage, etc.), each with its own piston, spring element, and actuation space. This segmentation allows the total braking force to be distributed across multiple wear-free components, eliminating the need for frequent replacement of single-point wear elements while maintaining high braking capability.
Solution Approach 2:
The invention uses a hydraulic actuation system where a pressure medium (hydraulic fluid) is supplied to multiple actuation spaces to generate force on the piston parts. This hydraulic mechanism replaces the electromagnetic actuation, providing smooth, controllable, and wear-free actuation of the braking elements through fluid pressure transmission.
2Ease of operation
If infinitely controllable braking systems are used, then braking control precision is improved, but production cost increases
Solution Approach 1:
The system provides continuous and infinitely adjustable braking control through the hydraulic actuation mechanism. The braking force can be dynamically adjusted by controlling the hydraulic pressure supplied to each stage, allowing precise modulation of braking torque without requiring complex electronic control systems or expensive actuators.
Solution Approach 2:
The invention combines multiple simple braking stages with identical or similar construction into a single integrated system. Each stage uses the same basic components (piston, spring element, actuation space), simplifying manufacturing and maintenance while achieving complex braking control through their coordinated hydraulic actuation.
3Use of energy by moving object
If regenerative braking devices are used, then energy efficiency is improved, but braking power becomes insufficient in real operation
Solution Approach 1:
The spring elements are pre-loaded during system assembly or maintenance to store elastic potential energy. This preliminary action ensures that when hydraulic pressure is applied, the braking force is immediately available without delay, providing sufficient braking power from the first moment of actuation while maintaining energy efficiency through the stored spring energy.
Solution Approach 2:
The braking system combines the energy efficiency of regenerative braking with the high power capability of mechanical spring-loaded brakes. The hybrid approach uses regenerative braking for energy recovery during normal operation and supplements it with the multi-stage spring-hydraulic system when maximum braking power is required, achieving both energy efficiency and sufficient braking force.
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 achieves reliable, wear-free braking with adjustable forces, ensuring maximum braking effect and reduced maintenance costs, while being resistant to temperature and viscosity fluctuations.
Implementation Method 1
a plurality of spring elements, with each of the spring elements in one of the chambers is arranged in the housing and is supported on the one hand on the collar portion of the piston part associated with this chamber
Implementation Method 2
the actuation system also includes a pressure medium arrangement which is set up to selectively supply the actuation spaces with a pressure medium, the spring elements acting on the different piston parts being set up to exert a respective spring force
Data Source
Figure 1
AI summary
Multi-stage actuation system (10) for a braking device of a forklift truck, comprising a housing (12) which includes a through-opening (12c) for a piston (16) on one side and which is internally divided into a plurality of chambers (14a, 14b) by at least one partially perforated partition wall (12e), a multi-part piston (16) wherein each of the piston parts (16a, 16b) is substantially received in one of the chambers (14a, 14b) in the housing (12) and is only partially perforated by the respective perforation of a partition wall (12e) delimiting the chamber (14a, 14b).the through-opening (12c) protrudes and has a collar section (16a1, 16b1) which serves as a contact surface for a respective spring element (18a, 18b); and a plurality of spring elements (18a, 18b), each of the spring elements (18a, 18b) being arranged in one of the chambers (14a, 14b) in the housing (12) and being supported on one side by the collar section (16a1, 16b1) of the piston part (16a, 16b) associated with that chamber (14a, 14b) and on the other side by one of the intermediate walls (12e) or the end wall (12a) opposite the through-opening (12c) of the housing (12), wherein the collar sections (16a1, 16b1) of the piston parts (16a, 16b) each terminate flush with the inner wall (12d) of the housing (12), so that each of the collar sections (16a1, 16b1), the corresponding piston part (16a, 16b), the inner wall (12d) and the intermediate wall (12e) orThe end wall (12b) of the housing (12) having the through-opening (12c) forms an actuation chamber (20a, 20b), wherein each of the actuation chambers (20a, 20b) is provided with a pressure medium connection (22a, 22b) and the actuation system (10) further comprises a pressure medium arrangement which is configured to selectively supply the actuation chambers (20a, 20b) with pressure medium.