Self-Amplifying Disc Brake With Two-Step Spring Actuation
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Solution Overview
Problem
Existing safety brake designs are complex, space-inefficient, and costly to manufacture, with a high number of parts, which hinders their effectiveness and simplicity.
Innovation Solution
A self-amplifying safety brake design featuring a spring assembly oriented perpendicular to the disc's axis, a sleeve assembly, a lever-cam assembly, and a hydraulic cylinder-based spring compressor that decompresses and recompresses the spring assembly in two steps to amplify braking force, using a two-step brake activation mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional safety brake designs are used, then braking function is provided, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent combines multiple brake plates (first and second brake plates) and spring assemblies (first and second spring assemblies) into a single integrated braking system. The brake plates are positioned on opposite sides of the disc and work simultaneously, while the spring assemblies are integrated with the brake plates to provide both actuation and amplification functions, reducing the overall number of separate components needed.
Solution Approach 2:
The amplification assembly serves multiple functions: it amplifies the braking force through mechanical advantage, acts as a structural connector between brake plates and spring assemblies, and provides a compact mounting structure. The lever-cam mechanism provides both the amplification function and the mechanical linkage function, eliminating the need for separate amplification and linkage components.
2Reliability
If traditional safety brake designs are used, then braking function is provided, but manufacturing cost increases
Solution Approach 1:
By merging the amplification mechanism with the brake actuation system, the patent reduces the total number of parts that need to be manufactured, assembled, and quality-checked. The integrated design allows for fewer manufacturing steps and lower assembly costs while maintaining reliable braking function.
Solution Approach 2:
The braking system is segmented into modular components (brake plates, spring assemblies, amplification assembly) that can be manufactured separately and then assembled. This segmentation allows for standardized manufacturing processes and easier quality control, reducing overall manufacturing cost.
3Reliability
If traditional safety brake designs are used, then braking function is provided, but space efficiency decreases
Solution Approach 1:
The amplification assembly is positioned within the space between the first and second brake plates, effectively nesting components within each other. The spring assemblies are integrated with the brake plates, and the lever-cam mechanism is positioned to utilize the available space efficiently, minimizing the overall volume occupied by the braking system.
Solution Approach 2:
The patent utilizes the radial dimension by positioning brake plates on opposite sides of the disc, effectively using the thickness of the disc as available space. The spring assemblies are oriented perpendicular to the disc axis, utilizing the axial dimension efficiently. This multi-dimensional arrangement minimizes the overall volume required for the braking system.
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 safety brake with improved effectiveness by rapidly activating initial braking and amplifying it through a two-step mechanism, enhancing the braking force without increasing the number of parts.
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; movement of the sleeve assembly in a first co-axial direction compresses the spring assembly at the first spring end
Implementation Method 2
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 to amplify braking
Implementation Method 3
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 4
a brake plate for frictionally engaging the disc
Implementation Method 5
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
Data Source
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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, and to translate movement of the sleeve assembly in the second coaxial direction into movement of the brake plate toward the disc; and an amplification assembly including: 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 and move the sleeve assembly in the second co- axial direction to amplify braking by further moving the brake plate toward the disc.