Robot Actuator Brake Using Deformation Instead of Friction
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Solution Overview
Problem
Existing brakes for industrial robot actuators are susceptible to reduced braking effectiveness due to contamination with oil and variability in friction with wear, leading to inconsistent performance.
Innovation Solution
A brake design that utilizes deformation of one element instead of friction between two elements, featuring a star-shaped wheel with radially extending elastomer or polymer legs and a cylindrical pin that engages and releases by moving between the legs, with a solenoid-actuated mechanism to maintain braking effect regardless of contaminants like oil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If friction-based braking is used between brake pads and brake disc, then braking effect is achieved, but braking effectiveness strongly decreases when contaminated with oil
Solution Approach 1:
The patent replaces the traditional friction-based mechanical braking system with a deformation-based braking mechanism. Instead of relying on friction between brake pads and disc, the invention uses the elastic deformation of spring elements to store and release braking energy, thereby eliminating the harmful effect of oil contamination on braking effectiveness.
Solution Approach 2:
The invention changes the fundamental parameter of braking from friction force to elastic deformation. By using spring elements that deform elastically under load, the system achieves braking effect through material deformation rather than surface friction, making the braking performance independent of contaminant presence.
2Reliability
If friction-based braking is used, then braking effect is achieved, but friction varies with wear of friction material
Solution Approach 1:
The patent substitutes the wear-prone friction material system with a deformation-based spring mechanism. The spring elements deform elastically to provide braking force and return to their original shape, avoiding the progressive wear that causes friction variation in traditional systems.
Solution Approach 2:
The invention uses elastomer or polymer legs that can be replaced as consumable parts, rather than relying on long-lasting friction materials that degrade over time. These elements provide consistent performance until they reach the end of their service life, at which point they can be replaced.
3Reliability
If existing brakes are used, then braking is achieved, but particles are generated during operation
Solution Approach 1:
The patent replaces the friction-based system that generates particles with a deformation-based system using elastomer or polymer legs. The elastic deformation mechanism does not produce particulate wear, thereby eliminating the harmful particles generated by traditional brake operation.
4Extent of automation
If high transmission ratio gearbox is used, then actuation is achieved, but damaging forces occur within the gearbox
Solution Approach 1:
The invention applies braking force progressively through the deformation of spring elements, rather than applying full braking force abruptly. This partial action approach prevents excessive forces from damaging the gearbox while still achieving the required actuation and braking effect.
Solution Approach 2:
The elastomer or polymer legs act as cushioning elements that absorb and distribute braking forces before they reach the gearbox. This beforehand cushioning protects the gearbox from damaging forces while maintaining the actuation capability.
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 braking effect is largely unaffected by contaminants, ensuring consistent performance even in the presence of oil, and allows for adjustable braking energy absorption to prevent damage in high transmission ratio gearboxes.
Implementation Method 1
The legs are configured to bend aside such that the second element comes in between an adjacent pair of legs if braking energy needed to stop the relative movement between the first and the second elements exceeds a threshold value
Implementation Method 2
the second element is actuated by means of a solenoid such that the brake is released when the solenoid is activated, and the brake is engaged when the solenoid is not activated
Data Source
Figure 1~2
AI summary
A brake (10) for an actuator (150) of an industrial robot (110) comprises a first element (20) with a plurality of legs (30) arranged at regular intervals, and a second element (90)configured to get in between a pair of legs (30) to engage the brake (10) and to thereby oppose a relative movement between the first and the second elements (20, 90), the second element (90) further being configured to get out from between the pair of legs (30) to release the brake (10) and to thereby allow a free relative movement between the first and the second elements (20, 90). The legs (30) are configured to bend aside such that the second element (90) comes in between an adjacent pair of legs (30) if braking energy needed to stop the relative movement between the first and the second elements (20, 90) exceeds a threshold value. The braking effect is dominantly based on deformation (internal friction) of the first element (20) instead of friction between the first and second elements (20, 90), and therefore a contaminant like oil does not have a strong influence on the braking effect.