Solenoid Brake Control for Large-Inertia Rotating Tools
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Solution Overview
Problem
Large-sized grinders face difficulties in effectively braking the tool bit due to increased inertia and heat generation, leading to degraded brake characteristics and component service life, especially when a handlebar and switch are positioned far from the brake mechanism, complicating the cooling flow passage and making electric brake employment challenging.
Innovation Solution
A rotating tool equipped with a motor, switch, rotation shaft, and electrical actuator, where the electrical actuator controls the brake mechanism to brake the rotation shaft upon switch OFF and releases the brake after a predetermined time, utilizing a solenoid and cam plate to simplify the mechanism and reduce heat impact, and incorporating a clutch mechanism to disconnect power between the output and rotation shafts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical brake mechanism is used with a long-distance coupled structure, then the brake can be applied to the tool bit, but the structure becomes complicated and cooling flow passage fails
Solution Approach 1:
The patent replaces the mechanical slider-coupled brake mechanism with an electrical actuator (solenoid) that directly actuates the brake operation plate. This substitution eliminates the complex long-distance mechanical coupling while maintaining reliable brake application to the rotation shaft, resolving the contradiction between braking reliability and mechanism complexity.
Solution Approach 2:
The patent introduces an electrical actuator as an intermediary between the control system and the brake mechanism. This intermediary component enables direct actuation of the brake operation plate without requiring complex mechanical linkages, thereby simplifying the overall structure while ensuring reliable brake application.
2Ease of operation
If the brake mechanism is positioned far from the operation member, then the handlebar can be disposed at the rear, but the slider conjunction with the operation member becomes difficult to ensure
Solution Approach 1:
The patent replaces the mechanical slider linkage with an electrical actuator that can be positioned near the brake mechanism rather than the operation member. This allows the handlebar to be disposed at the rear for ease of operation while the electrical actuator provides direct, simple actuation of the brake mechanism without complex intermediate linkages.
3Productivity
If a large tool bit is used, then the grinding capacity increases, but the inertia increases and heat generation in the brake mechanism increases
Solution Approach 1:
The patent replaces the mechanical brake actuation system with an electrical actuator that can provide more precise and controlled brake application. This substitution reduces unnecessary mechanical friction and heat generation in the actuation mechanism itself, allowing the brake to effectively stop large tool bits with high inertia while minimizing heat generation in the actuation system.
4Speed
If the brake mechanism operates continuously, then the tool bit can be stopped quickly, but the heat generation degrades brake characteristics and component service life
Solution Approach 1:
The patent employs a control system that operates the electrical actuator in periodic cycles rather than continuously. The actuator is activated only when braking is required (when the operation member is released), and the control unit manages the timing and duration of brake application. This periodic operation allows for quick braking when needed while minimizing continuous heat generation that would degrade brake characteristics and reduce component service life.
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
Ensures reliable braking with reduced energy consumption, simplifies the structure by eliminating the need for a coupled mechanism between the brake and operation member, improves responsiveness, and minimizes heat-related failures, allowing for efficient braking of large tool bits with reduced time lag.
Implementation Method 1
The electrical actuator is a solenoid
Data Source
AI summary
A grinder includes a brake mechanism configured to brake a spindle and an electrical actuator (a solenoid) that actuates the brake mechanism. The solenoid actuates the brake mechanism in conjunction with a turning OFF of a switch from a driving state of a motor, and releases an actuation of the brake mechanism after a lapse of a predetermined period of time from the turning OFF of the switch.