Plane Braking Device for Electric Winches
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Solution Overview
Problem
Existing electric winch braking devices suffer from small braking areas, easy slipping, rapid wear of parts, and high maintenance costs due to friction-based braking mechanisms, leading to short service life and instability.
Innovation Solution
A plane braking device with a multi-plane friction braking system using polyhedron-shaped core shafts, wedge pieces, and elastic elements, which increases the braking area and force while minimizing direct contact with the gear box, allowing for easy replacement of braking plates when worn, thus reducing maintenance costs and extending service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If single tapered face braking is used, then the braking device structure is simple, but the braking area is small and braking force is insufficient
Solution Approach 1:
The braking device is divided into multiple independent braking plates (first braking plate, second braking plate, etc.) arranged in sequence around the core shaft. Each braking plate provides an independent friction surface, segmenting the braking function to increase total braking area while maintaining structural simplicity through modular arrangement.
Solution Approach 2:
The braking system transitions from a single tapered face (2D surface) to multiple braking plates arranged axially around the core shaft, adding the axial dimension to the braking area. This multi-dimensional arrangement significantly increases the total friction surface area without proportionally increasing structural complexity.
2Device complexity
If direct friction between metal parts is used, then the braking device achieves simple structure, but the parts are easy to be worn and service life is short
Solution Approach 1:
The braking plates are designed as replaceable consumable parts that wear during operation. When the braking plates become worn, they can be easily replaced without affecting other components of the braking device or the gear box. This allows the main structural components to have long service life while the inexpensive braking plates absorb the wear.
Solution Approach 2:
The braking plates serve as intermediary friction elements between the core shaft and the external environment. These intermediary plates concentrate all friction and wear on themselves, protecting the core shaft and gear box from direct contact and wear, thereby extending the service life of critical components.
3Power
If braking plate directly acts on gear box tapered face, then the braking effect is achieved, but the tapered face is easily worn and replacement cost is high
Solution Approach 1:
The braking plates are designed as inexpensive, easily replaceable components that bear the brunt of friction and wear. When worn, only these cheap plates need replacement, not the expensive gear box or core shaft, significantly reducing maintenance costs.
Solution Approach 2:
The braking plates act as intermediary friction elements that protect the gear box tapered face from direct contact. All wear occurs on the replaceable braking plates rather than on the gear box, preserving the expensive components and reducing repair costs.
4Force
If multi-plane friction braking system is used, then the braking area and braking force are increased, but the device structure becomes more complex
Solution Approach 1:
Multiple braking plates are arranged in sequence around the core shaft and are all driven simultaneously by the rotation of the core shaft. The braking force from each plate merges together to provide total braking effect, achieving high braking force without requiring complex individual actuation mechanisms for each plate.
Solution Approach 2:
The core shaft serves multiple functions: it transmits rotational motion to all braking plates simultaneously, provides the friction surface for braking, and acts as the central structural element holding all components together. This multi-functionality reduces the need for additional separate components, maintaining structural simplicity despite the multi-plate configuration.
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 provides a more stable and secure braking system with increased braking force, reduced wear on parts, and lower maintenance costs by concentrating friction wear on replaceable braking plates, enhancing the operational security and longevity of the electric winch.
Implementation Method 1
an elastic element, two ends of which are fastened to the hollow gear shaft and the wedge shape piece B respectively, to push the wedge shape piece B to rotate
Implementation Method 2
a left end face of the wedge shape piece A is a cam face formed by double tapered faces, a right end face of the wedge shape piece A is limited axially by a C-ring, and an outer double flange structure is arranged with homogeneous distribution on the outer surface along an outer circumference face of the wedge shape piece A; a wedge shape piece B setting on the hollow gear shaft, wherein a right end face of the wedge shape piece B is a cam face formed by double tapered faces which engage with the wedge shape piece A
Data Source
AI summary
The present invention discloses a plane braking device for electric winches and electric winch which disposes a section of hollow gear shaft, a section of core shaft, a fixing ring, a wedge shape support, a stopping piece, a braking plate, an elastic element, a wedge shape piece B, a wedge shape piece A, a braking clutch base and so on in a gear box of an electric winch. When a motor works, the section of core shaft of the motor drives the braking clutch base and the wedge shape pieces A, B to rotate, until a gap is formed between the adjacent braking plate and stopping piece between the braking clutch base and the wedge shape piece B, so that the braking effect disappears. When the motor stops suddenly, a heavy load lifted by a tight wire drum provides a reverse pulling force so that the wedge shape piece B produces a reverse thrust force to push the friction planes of the braking plate and the stopping piece, so the plane braking effect is achieved quickly. Based on the plane braking plate, the present invention can increase the braking area and the braking force and achieve safe braking. Furthermore, when there is wear of parts in long usage, so it only needs to replace the braking plate made of friction materials, which can simplify maintenance, reduce the parts costs and ensure service life of the gear box.