Magnetic Brake Structure for Roller Shutter Motor Positioning

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Solution Overview

Problem

Existing brake devices for roller shutters are complex, noisy, and difficult to assemble, leading to issues with continuous rotation and inaccurate positioning due to rotor inertia.

Innovation Solution

A brake device using a magnetic brake mechanism with a permanent magnet and magnetic conductor arranged in a N-poles N-slots structure, which includes a shell seat and magnetic conductive elements to provide rapid braking and reduce noise and vibration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mechanical brake device is used to stop the rotor, then the braking function is achieved, but the structure becomes complex and noise increases

Engineering Contradiction:

Improvebraking functionVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the traditional mechanical brake device with a magnetic brake mechanism. The magnetic brake uses magnetic fields generated by the motor to directly brake the rotor, eliminating the need for separate mechanical brake components such as brake blocks, springs, and adjustment mechanisms. This substitution of mechanical system with electromagnetic system resolves the contradiction by maintaining reliable braking function while significantly simplifying the overall structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If a mechanical brake device is used to stop the rotor, then the braking function is achieved, but assembly difficulty increases

Engineering Contradiction:

Improvebraking functionVSAvoidassembly ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the brake function with the motor structure itself. The magnetic brake components (stator and rotor) are integrated into the motor's existing structure, where the motor stator serves as the brake stator and the motor rotor serves as the brake rotor. This merging eliminates the need for separate brake device assembly and reduces assembly complexity, resolving the contradiction between achieving reliable braking and ease of assembly.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If a mechanical brake device is used to stop the rotor, then the braking function is achieved, but noise and vibration increase

Engineering Contradiction:

Improvebraking functionVSAvoidnoise and vibration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical contact-based braking with electromagnetic braking. The magnetic brake uses magnetic field interaction between the stator and rotor to produce braking torque without physical contact or mechanical friction. This eliminates the noise and vibration associated with mechanical brake components rubbing against each other, resolving the contradiction between achieving reliable braking and reducing harmful noise and vibration.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Speed

If high-speed rotation is achieved, then motor performance is improved, but positioning accuracy decreases due to rotor inertia

Engineering Contradiction:

Improverotation speedVSAvoidpositioning accuracy

Core Design Contradiction:

SpeedVSMeasurement precision

Solution Approach 1:

The patent employs periodic magnetic field reversal through commutation to achieve both high-speed rotation and rapid braking. The commutation system periodically switches the current direction in the armature windings, creating alternating magnetic fields that drive continuous rotation at high speed. When braking is required, the commutation is reversed to create opposing magnetic fields that rapidly decelerate the rotor, enabling accurate positioning despite high-speed operation and rotor inertia.

Inventive Principle:

Principle #19Periodic action

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 magnetic brake device effectively stops the rotor and connected load immediately, reducing noise and vibration, ensuring accurate positioning and preventing resonance, with a self-locking frequency below 200Hz.

Implementation Method 1

the brake device comprises a permanent magnet and a magnetic conductor... the permanent magnet comprises N magnetic poles, the magnetic conductor comprises N slots arranged at circumferential interval, the brake device forms a structure of N poles and N slots

Methodology Applied

Scientific EffectMagnetic attraction: Magnetism

Data Source

PatentEP4583378A1Roller shutter equipment, motor and brake device

Publication Date: 2025.07.09 JOHNSON ELECTRIC INTERNATIONAL AG

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AI summary

The invention discloses a roller shutter equipment, a motor and a brake device, The brake device is used for braking rotor. The brake device includes a permanent magnet and a magnetic conductor, one of the permanent magnet and the magnetic conductor is used for connecting the rotor and the other one is used for connecting the stator. The permanent magnet includes N magnetic poles, the magnetic conductor includes N slots, the brake device constitutes a N poles N slots structure, where N is an integer greater than 1. The brake device is applied to motor and roller shutter equipment, it realizes rapid braking, at the same time it can effectively reduce the vibration frequency of the motor and avoid the vibration frequency of the cover shell of the roller shutter equipment. It avoids resonance, ensures normal operation of the motor and reduces motor noise during operation.