Solenoid Locking Mechanism for Failsafe Rotor Gear Braking
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Solution Overview
Problem
Traditional stepper motors used as failsafe braking mechanisms in rotary actuators are large, continuously operate, consume power, generate heat, increase system complexity, and are prone to failure.
Innovation Solution
A solenoid-driven lock mechanism with a spring-loaded plunger body and lock pins that engage with locking ribs on a rotor gear to prevent rotation when de-energized, and disengage to allow rotation when energized, providing a failsafe braking mechanism for electromechanical actuator assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stepper motors are used as failsafe braking mechanisms, then reliable braking is achieved, but device complexity, weight, and power consumption increase
Solution Approach 1:
The patent extracts the braking function from the continuous operation requirement of stepper motors. The solenoid-based lock mechanism is designed to engage only when braking is needed, separating the braking function from continuous motor operation. This reduces system complexity by eliminating the need for continuous stepper motor operation while maintaining reliable braking capability.
Solution Approach 2:
The patent inverts the traditional approach by using a spring-loaded mechanism that defaults to engagement (locked) state and only disengages when energized. This is opposite to the conventional stepper motor approach that requires continuous operation. The inversion allows the system to achieve reliable braking with minimal power consumption and reduced complexity.
2Reliability
If stepper motors operate continuously to provide braking, then reliable stoppage is ensured, but power consumption and heat generation increase
Solution Approach 1:
The patent implements periodic action by designing the solenoid to operate only when braking is required, rather than continuously. The spring-loaded lock mechanism maintains its engaged state passively and only requires periodic energization of the solenoid to disengage or re-engage, dramatically reducing power consumption while ensuring reliable stoppage when needed.
Solution Approach 2:
The spring-loaded mechanism provides self-service by automatically maintaining the locked state without continuous power input. The spring force naturally keeps the lock pins engaged with the locking ribs, and the system only requires minimal energy input from the solenoid to change state, eliminating the need for continuous power consumption.
3Force
If traditional actuators are used, then necessary braking torque is provided, but device size and complexity increase
Solution Approach 1:
The patent merges the braking function directly into the actuator assembly by integrating the solenoid-based lock mechanism with the existing rotor gear structure. The lock pins engage with locking ribs on the rotor gear, combining the braking function with the actuator's rotational mechanism. This integration provides necessary braking torque while reducing overall device complexity compared to separate braking systems.
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 solenoid-driven lock mechanism offers a reliable, compact, low-power consumption, and failsafe solution that reduces system complexity and weight, with a 100% duty cycle.
Implementation Method 1
a solenoid mounted to the housing and including a reciprocating shaft
Implementation Method 2
when the solenoid is de-energized, spring force pushes the spring-loaded plunger body toward the rotor gear and spring force pushes the at least one spring-loaded lock pin into contact with the at least one locking rib
Data Source
AI summary
A lock mechanism for an electromechanical actuator assembly, the lock mechanism including a housing, a solenoid mounted to the housing and including a reciprocating shaft, a rotor gear mounted on the reciprocating shaft and including locking ribs positioned on a face of the rotor gear, a spring-loaded plunger body coupled to one end of the reciprocating shaft, and spring-loaded lock pins carried by the plunger body. In use, energizing the solenoid causes the reciprocating shaft to push the spring-loaded plunger body away from the rotor gear thereby moving the lock pins out of contact with the locking ribs to permit rotation of the rotor gear.