Electromagnetic Spring Brake Structure for Small Air Gap Torque
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electromagnetic spring-applied brakes have limited energy density and service life due to restricted friction radius of the brake rotor and large air gaps resulting from component tolerances, which also limit the achievable brake torque.
Innovation Solution
The solution involves replacing spacer bushings with spacer strips that are integrally formed or permanently connected to the coil carrier, allowing for a larger friction radius of the brake rotor and a precise, small air gap through a specific production method that coordinates the spacer strips and flange plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If spacer bushings are used to connect the coil carrier to the flange plate and rotate the armature disc, then the brake can be assembled with standard components, but the outer diameter and friction radius of the brake rotor are limited
Solution Approach 1:
The patent merges the functions of the spacer bushing and the armature disc rotational support into a single integrated structure. The coil carrier is designed with a recess that directly receives and supports the armature disc, eliminating the need for separate spacer bushings. This integration allows the brake rotor to extend to a larger outer diameter, maximizing the friction radius while maintaining structural simplicity.
2Force
If large air gap is provided to accommodate component tolerances, then the brake can be assembled with standard tolerances, but the force of the magnetic circuit and brake torque are limited
Solution Approach 1:
The patent applies preliminary action by pre-setting the air gap through the designed depth of the recess in the coil carrier. The recess is dimensioned to provide the optimal air gap distance between the coil carrier and armature disc, eliminating the need for large tolerance buffers. This allows the magnetic circuit to operate at maximum force while accommodating standard component tolerances through the precise recess geometry.
3Area of stationary object
If separate cylindrical bolts are used for rotational fixing of the armature disc, then the armature disc can be securely fixed, but the manufacturing outlay is increased and the pole surface area is reduced
Solution Approach 1:
The patent combines the functions of separate mounting bolts into the integrated recess structure of the coil carrier. The recess itself provides the rotational fixing function through its geometric constraint, eliminating the need for additional cylindrical bolts. This merger maximizes the pole surface area of the coil carrier while simplifying the manufacturing process by reducing the number of separate components and assembly steps.
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
This design and production method enhance the energy density and service life of the electromagnetic spring-applied brake by maximizing the friction radius of the brake rotor and minimizing the air gap, while also reducing manufacturing costs.
Implementation Method 1
at least one solenoid
Implementation Method 2
at least one compression spring
Implementation Method 3
at least one brake rotor, which in a preferred embodiment is provided with friction linings on both planar faces
Data Source
AI summary
The invention relates to an electromagnetic spring pressure brake (BR) which is inexpensive to produce and has an optimized power density and a long service life. This is achieved in that a coil support (1) and a flange plate (9) are connected together by means of narrow spacing strips (2) with a short radial extension, wherein the spacing strips (2) likewise take on the rotationally fixed and axially movable guidance of the armature disc (4). The invention additionally relates to a production method in which a connection is produced between the coil support (1), the spacing strips (2), and the flange plate (9) such that the smallest possible air gap (L) is produced between the coil 10 support (1) and the armature disc (4) when the spring pressure brake (BR) is closed in a reliable manner with respect to the process.