Split Friction Disk Layout for Thin High-Capacity Electromagnetic Brakes
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Solution Overview
Problem
Existing electromagnetic brakes have low braking capacity and large thickness, which cannot meet the requirements of modern applications with limited installation space, and thinner components lead to issues like reduced magnetic field, material weakness, noise, and structural instability.
Innovation Solution
A friction disk with a split structure composed of multiple friction monomers and an elastic component that allows each monomer to move radially, providing additional braking surfaces and a non-stacked layout to reduce thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the traditional stacking assembly method is used for electromagnetic brake components, then the structure is simple and easy to manufacture, but the axial thickness becomes large
Solution Approach 1:
The patent transitions from traditional axial stacking arrangement to a radial arrangement where friction monomers are distributed around the central shaft. This dimensional change allows the brake components to be arranged in the radial direction rather than axially, significantly reducing the axial thickness while maintaining structural integrity and ease of assembly.
Solution Approach 2:
The friction disk is divided into multiple independent friction monomers that are radially distributed around the central shaft. Each monomer can be independently manufactured and assembled, simplifying the manufacturing process while enabling a compact radial layout that reduces overall axial thickness.
2Length of stationary object
If the thickness of brake components is reduced to meet space requirements, then the installation space requirement is satisfied, but the magnetic field strength decreases and structural integrity is compromised
Solution Approach 1:
By arranging friction monomers radially around the shaft rather than stacking them axially, the patent reduces axial thickness without compromising the radial dimensions where magnetic field generation and structural strength are critical. This dimensional reconfiguration allows thin axial profile while maintaining reliable magnetic circuits and structural integrity.
Solution Approach 2:
The patent integrates multiple functions into the radial arrangement: friction monomers serve both as friction surfaces and as structural elements that maintain radial positioning. The elastic components simultaneously provide pre-tightening force and accommodate radial movements, merging multiple functions into compact integrated structures.
3Device complexity
If traditional friction disk structure is used with only two shaft end surfaces for friction, then the structure is simple, but the braking capacity is low
Solution Approach 1:
The friction disk is segmented into multiple friction monomers radially distributed around the shaft. Each monomer provides its own friction surface(s), transforming a single low-capacity friction interface into multiple concurrent friction interfaces, thereby significantly increasing total braking capacity while maintaining relatively simple individual monomer structures.
Solution Approach 2:
The patent adds radial distribution of friction surfaces as a new dimension to the braking system. Instead of relying solely on axial friction surfaces, the radial arrangement of multiple monomers creates additional friction interfaces in the radial plane, increasing braking capacity without proportionally increasing overall complexity.
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 solution enhances braking capacity by utilizing additional friction surfaces and maintains structural integrity while reducing the brake's thickness, improving reliability and noise performance.
Implementation Method 1
the magnetic yoke generates magnetic force under the excitation of the coil to attract the armature
Implementation Method 2
the elastic component being configured with a pre-tightening force to make the plurality of friction monomers close to the central space
Implementation Method 3
both shaft end surfaces rub with external objects to generate braking force
Data Source
AI summary
The disclosure provides a friction disk and a brake including a magnetic yoke iron core, a first movable plate, a friction disk, a first coil, at least one second coil, an armature and an elastic part; the magnetic yoke iron core includes a first mounting space, a second mounting space and at least one third mounting space distributed coaxially; the first movable plate is located in the first mounting space and close to a first shaft end; the friction disk is located in the first mounting space; the first coil is arranged in the second mounting space; the at least one second coil correspondingly is arranged in the at least one third mounting space; the armature is located at the second shaft end; the elastic part has a pre-tightening force that enables the armature to be far away from the magnetic yoke iron core.