Spring Brake Soldered Housing Connection
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Solution Overview
Problem
Existing electromagnetically releasable spring-loaded brakes face challenges with complex structural designs, high assembly effort, and limited rotor diameter due to solid connections between the magnet housing and counter-brake element, which require precise alignment and absorb varying loads, leading to potential mechanical stress and space constraints.
Innovation Solution
A soldered connection between the counter-brake element and the magnet housing, utilizing a metal inert gas (MIG) soldering process, provides a strong, precise, and thermally low-impact bond that compensates for manufacturing tolerances and allows for a more compact design with reduced thermal distortion, using copper-silicate solders for ductility and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid connection (welded or clamped) is used between the magnet housing and counter-brake element, then the connection strength is improved, but the assembly complexity and precision requirements increase
Solution Approach 1:
The connection area on the counter-brake element is segmented into multiple discrete bonding zones that are distributed around the periphery. This segmentation allows for simplified assembly where each zone can be bonded independently, reducing the overall assembly complexity while maintaining connection strength through the distributed nature of the bonded joints.
Solution Approach 2:
A soldering process is introduced as an intermediary method to create the connection between the magnet housing and counter-brake element. This intermediary bonding process eliminates the need for complex mechanical fastening or clamping arrangements, directly joining the components through material fusion at the connection areas, thereby reducing assembly complexity while ensuring strong connections.
2Strength
If a solid connection is used between the magnet housing and counter-brake element, then the connection strength is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The bonding process parameters are optimized to accommodate normal manufacturing tolerances. The soldering process is designed to be tolerant of position variations within standard machining tolerances, allowing the connection areas to be bonded effectively without requiring ultra-precise alignment. This parameter optimization enables strong connections while maintaining reasonable manufacturing precision standards.
Solution Approach 2:
The connection areas are positioned asymmetrically or at specific optimized locations on the counter-brake element where alignment sensitivity is minimized. By strategically locating the bonding zones away from critical alignment-sensitive regions, the design reduces the impact of manufacturing tolerances on overall assembly precision while maintaining connection strength.
3Power
If the rotor diameter is increased to improve brake performance, then the braking torque is improved, but the space requirements and connection complexity increase
Solution Approach 1:
The connection areas extend in the axial direction (parallel to the brake axis) rather than only in the radial direction. This dimensional change allows the connection to develop strength along the axis, enabling the use of larger rotor diameters for improved braking torque without proportionally increasing the radial space requirements or connection complexity.
Solution Approach 2:
The soldered connection provides a flexible and adaptive bonding solution that can accommodate variations in component dimensions and positioning. This dynamic bonding approach allows the brake design to optimize rotor diameter for maximum braking torque while the flexible soldering process absorbs dimensional variations, preventing connection complexity from increasing proportionally with rotor size.
4Temperature
If a soldered connection is used between the magnet housing and counter-brake element, then thermal distortion is reduced, but the manufacturing process complexity increases
Solution Approach 1:
The mechanical connection methods (welding, clamping, screwing) are replaced with a soldering process that uses controlled thermal energy to create bonds. This substitution reduces thermal distortion because soldering operates at lower temperatures than welding and provides more controlled, localized heating. The manufacturing process complexity is managed through standardized soldering procedures and fixtures that simplify the bonding operation.
Solution Approach 2:
The soldering process is performed in a controlled atmosphere (inert or protective gas environment) that prevents oxidation and contamination during bonding. This controlled environment reduces the need for complex post-processing steps and quality inspection procedures, thereby managing manufacturing process complexity while achieving clean, distortion-minimized bonds between the magnet housing and counter-brake element.
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 soldered connection enhances the brake's mechanical strength, reduces assembly complexity, and allows for a more compact and precise alignment of components, improving the brake's reliability and efficiency while minimizing thermal stress and space requirements.
Implementation Method 1
areas of the brake counter-element that are designed as connecting areas and extend along a direction parallel to the axis of the brake in the direction of the magnet housing and are bonded to surface areas of the brake housing pointing outwards in the radial direction by means of a soldered connection
Implementation Method 2
utilizing a metal inert gas (MIG) soldering process, provides a strong, precise, and thermally low-impact bond
Implementation Method 3
using copper-silicate solders for ductility and corrosion resistance
Data Source
Figure 1
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Figure 3
AI summary
Electromagnetically released spring-applied brake 810) comprising a magnet housing (12), a brake element (16), a rotor (18), and a brake counter element (20), wherein the rotor is configured to be torsionally rigidly connected to a shaft (22) to be braked. The brake element (16) is subjected to a spring force and is configured, by virtue of this spring force, to press the rotor against the brake counter element in a direction parallel to an axis of the brake to generate the braking effect, wherein an electromagnetic device for releasing the brake is arranged in the magnet housing. Areas of the brake counter element are configured as connecting areas (26) that extend in a direction parallel to the axis (A) of the brake towards the magnet housing and are materially bonded to radially outwardly projecting surface areas (28) of the brake housing.