Rotary Brake System for Linear Stage Power Failure Safety
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Solution Overview
Problem
Automated systems, particularly those using linear motors, face challenges in maintaining control and preventing movement during power failures, as unpowered linear motors provide little to no braking, leading to undesirable motion or falling of movable parts, especially when oriented vertically.
Innovation Solution
A translation apparatus incorporating a rotary brake system that converts rotational braking torque into linear braking force, with a fail-safe default state applying maximum braking torque in the event of power failure, ensuring the stage and attached items remain stationary, even when the track is vertically oriented.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a linear motor is used to provide motive force to the movable portion, then the automated system can achieve precise linear motion control, but the movable portion becomes vulnerable to falling during power failure because unpowered linear motors provide substantially no braking
Solution Approach 1:
The patent combines a linear motor with a brake mechanism in a hybrid drive system. The brake mechanism is integrated with the linear motor assembly, allowing the linear motor to provide precise motion control during normal operation while the brake mechanism provides reliable braking and holding capability during power failure, thus merging the advantages of both systems.
Solution Approach 2:
The linear motor system is designed to perform multiple functions: during powered operation, it provides precise linear motion control; during power failure, the integrated brake mechanism activates to provide braking and holding functions. This multi-functionality ensures both motion precision and safety without requiring separate independent systems.
2Device complexity
If no braking system is used and the motive force is simply stopped, then the system structure remains simple, but the movable portion will fall when oriented vertically
Solution Approach 1:
The brake mechanism is designed to automatically activate upon power failure, applying braking force in advance to prevent the movable portion from falling. This preliminary anti-action counteracts the gravitational force that would otherwise cause the vertical portion to descend, ensuring safety without requiring complex active control systems.
Solution Approach 2:
The brake mechanism is designed to self-activate during power failure through spring-loaded or gravity-actuated mechanisms that automatically engage the brake without requiring external power or control signals. This self-service capability provides passive safety, preventing falling through the brake's inherent design rather than through active control.
3Reliability
If a conventional rotary electric motor with drive mechanism is used, then braking is provided during power failure, but the system cannot achieve the same level of linear motion precision as a linear motor
Solution Approach 1:
The patent merges the advantages of conventional rotary motors (reliable braking through back-EMF and mechanical friction) with the precision of linear motors by using a hybrid configuration where the linear motor handles precision motion control and the integrated brake mechanism handles safety braking, achieving both precision and reliability.
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 rotary brake system effectively prevents unwanted motion and falling by automatically applying maximum braking torque during power failures, maintaining stability and safety in automated systems, regardless of the track orientation.
Implementation Method 1
a rotary brake selectively operable to apply a braking torque to the rotatable member
Data Source
AI summary
The translation apparatus comprises an elongate track, an elongate fixed member and a stage. The fixed member extends parallel to the track in a fixed lengthwise position relative to the track. The stage is mounted on the track and is capable of movement along the track. The stage comprises a motive force generator, a rotatable member and a rotary brake. The motive force generator is operable to move the stage along the track. The rotatable member is coupled with the fixed member in a manner that converts motion of the stage along the track into rotation of the rotatable member. The rotary brake is selectively operable to apply a braking torque to the rotatable member. The coupling between the rotatable member and the fixed member converts the braking torque applied to the rotatable member into a braking force applied to the stage.