Self-Amplifying Disc Brake with Compact Spring-Cam Assembly
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Solution Overview
Problem
Existing safety brake designs are complex, space-inefficient, and costly, with a high number of parts, which hinders their effectiveness and ease of manufacturing.
Innovation Solution
A self-amplifying safety brake design featuring a spring assembly, sleeve assembly, lever-cam assembly, and amplification assembly, utilizing a hydraulic cylinder for controlled compression and decompression to transmit force efficiently, reducing the number of parts and enhancing braking effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional safety brake designs are used, then braking function is achieved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent combines multiple brake plates (first brake plate, second brake plate, third brake plate) and spring assemblies (first spring assembly, second spring assembly) into a single integrated brake system. The brake plates are stacked and connected through a common actuating mechanism, merging multiple braking functions into one compact assembly, thereby reducing the overall number of separate parts while maintaining reliable braking performance.
Solution Approach 2:
The actuating mechanism serves multiple functions: it simultaneously actuates both the first and second brake plates through the connecting mechanism, and also controls the spring assemblies for engagement and disengagement. This multi-functional design reduces the need for separate actuating components for each brake plate, simplifying the overall device structure.
2Reliability
If traditional safety brake designs are used, then braking function is achieved, but space efficiency decreases
Solution Approach 1:
The brake plates and spring assemblies are arranged in a nested, stacked configuration where the first brake plate, second brake plate, and third brake plate are positioned one above another, with spring assemblies integrated between them. This nesting arrangement allows multiple braking elements to occupy a compact vertical space, significantly reducing the overall volume of the brake assembly compared to traditional side-by-side or distributed arrangements.
3Reliability
If traditional safety brake designs are used, then braking function is achieved, but manufacturing cost increases
Solution Approach 1:
The brake system is divided into modular segments: separate brake plates, separate spring assemblies, and a common actuating mechanism. Each brake plate and spring assembly can be manufactured independently as standard components, allowing for simplified production processes, easier quality control, and the ability to manufacture parts separately and assemble them into the complete brake system, thereby reducing overall manufacturing cost.
4Force
If self-amplifying mechanism is implemented, then braking force is amplified, but device complexity increases
Solution Approach 1:
The spring assemblies are pre-compressed and stored in the engaged position, ready to provide immediate braking force. When the actuating mechanism is activated, the springs automatically expand to apply the brake plates to the drum, providing force amplification without requiring complex active control systems. The preliminary storage of energy in the springs simplifies the control mechanism while delivering high braking force.
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 design achieves a simpler, space-efficient, and cost-effective two-step brake activation mechanism that amplifies braking force, providing improved braking performance with fewer parts and reduced manufacturing complexity.
Implementation Method 1
a spring assembly oriented perpendicular to an axis of rotation of the disc, the spring assembly comprising a first spring end and a second spring end; a sleeve assembly co-axially housing the spring assembly, wherein movement of the sleeve assembly in a first co-axial direction compresses the spring assembly at the first spring end
Implementation Method 2
The spring compressor may comprise a hydraulic cylinder. The hydraulic cylinder may comprise: a cap; a barrel; a piston in the barrel; a first chamber defined by the piston, the cap, and the barrel, the first chamber comprising a first port;
Implementation Method 3
a lever-cam assembly associated with the sleeve assembly and the brake plate, the lever-cam assembly configured to translate movement of the sleeve assembly in the first coaxial direction into movement of the brake plate away from the disc
Implementation Method 4
a brake plate for frictionally engaging the disc
Implementation Method 5
an amplification assembly comprising: a spring end adjacent the second spring end; a brake end adjacent the brake plate, whereby force against the brake plate from engagement with the disc is transmitted from the brake end to the spring end to compress the spring assembly at the second spring end
Data Source
AI summary
A self-amplifying safety brake for a disc is provided. The brake includes: a housing; a spring assembly oriented perpendicular to an axis of rotation of the disc, the spring assembly including a first spring end and a second spring end; a sleeve assembly co-axially housing the spring assembly, wherein movement of the sleeve assembly in a first co-axial direction compresses the spring assembly at the first spring end and movement of the sleeve assembly in a second co-axial direction decompresses the spring assembly at the first spring end; a spring compressor configured to move the sleeve assembly in the first and second co-axial directions; a brake plate for frictionally engaging the disc; a lever-cam assembly associated with the sleeve assembly and the brake plate, the lever-cam assembly configured to translate movement of the sleeve assembly in the first coaxial direction into movement of the brake plate away from the disc.