Industrial Robot Brake Structure for Low-Friction Torque Holding
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Solution Overview
Problem
Existing brake devices in industrial robots face issues such as high energy consumption, sensitivity to oil and grease, complex design, and potential for component breakage due to impact forces, especially in high-speed and high-torque applications.
Innovation Solution
A brake device with a low dynamic friction coefficient between frictional surfaces, decoupled from the actuator's normal force, using materials like oiled steel and graphite powder, and resilient engagement structures with apertures to reduce impact forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a pin brake is used to decouple the normal force from the actuator, then the device becomes more compact and effective, but the brake becomes sensitive to oil and grease contamination
Solution Approach 1:
The patent applies low friction materials (oiled steel, graphite powder) to the friction surfaces, converting the harmful effect of oil and grease contamination into a beneficial low-friction state. The brake surfaces are intentionally designed with low dynamic friction coefficient (<0.3) materials, so that contamination from oil and grease does not drastically reduce braking torque as it would with high-friction materials. This transforms the harmful contamination into a beneficial lubrication effect.
Solution Approach 2:
The patent changes the friction parameter by using materials with inherently low dynamic friction coefficients. Instead of relying on high friction between brake surfaces, the invention uses oiled steel and graphite powder coatings that maintain low friction even when contaminated with oil and grease. The pressing force is then dimensioned to compensate for the lower friction coefficient, ensuring adequate braking torque is achieved.
2Power
If high pressing force is applied to generate sufficient friction braking torque, then braking effectiveness improves, but energy consumption increases and heat generation occurs in standby mode
Solution Approach 1:
The patent implements a dynamic braking system where the pressing force is not continuously applied but only engaged when braking is required. The actuator selectively applies the pressing force between the friction surfaces only during braking operations, rather than maintaining constant pressure. This dynamic engagement eliminates energy consumption and heat generation during standby modes while providing sufficient braking torque when needed.
Solution Approach 2:
The braking system operates periodically rather than continuously. The actuator engages the friction surfaces only during specific braking events, creating periodic action rather than continuous force application. This periodic engagement reduces overall energy consumption and minimizes heat generation during non-braking periods when the system is in standby mode.
3Reliability
If resilient engagement structures are added to reduce impact forces, then component breakage risk decreases, but device complexity increases
Solution Approach 1:
The patent incorporates resilient engagement structures that provide cushioning before impact occurs. These structures are designed to deform elastically during engagement, absorbing impact forces before they reach the main components. The resilient elements act as pre-positioned shock absorbers that protect against high impact forces during brake engagement, reducing the risk of component breakage.
Solution Approach 2:
The patent uses composite material structures combining rigid and resilient elements. The brake assembly integrates both rigid structural components for strength and resilient materials for impact absorption. This composite approach provides the necessary mechanical strength while simultaneously reducing impact forces through the elastic deformation of resilient portions, achieving both reliability and controlled complexity.
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 brake device achieves safe, reliable, and compact operation with reduced maintenance needs, maintaining effective braking torque even with contamination, suitable for high-speed and high-torque applications.
Implementation Method 1
a dynamic friction coefficient between the first frictional brake surface and the second frictional brake surface is less than 0.3
Implementation Method 2
a force device arranged to press the first frictional brake surface and the second frictional brake surface against each other with a pressing force
Implementation Method 3
the engaging structure and/or the engageable structure is configured such that the engaging structure resiliently engages the engageable structure
Data Source
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AI summary
A brake device (20) comprising a first device (22); a brake element (24) having a first frictional brake surface (74a, 74b) and an engageable structure (30); a second device (26) movable relative to the first device; a second frictional brake surface (76a, 76b); a force device (40) arranged to press the first frictional brake surface and the second frictional brake surface against each other with a pressing force (50); and an actuator (28) connected to the first device, the actuator comprising an engaging structure (52) movable between a disengaged position (78) not engaging the engageable structure, and an engaged position (54) engaging the engageable structure to brake relative motion (56) between the first device and the second device; wherein a dynamic friction coefficient between the first frictional brake surface and the second frictional brake surface is less than 0.3, such as less than 0.15, or less than 0.1; and wherein the pressing force is dimensioned with respect to the dynamic friction coefficient.