Dual-Circuit Square Brake with Integrated Coil Carrier
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Solution Overview
Problem
Existing brake systems with two independent circuits require multiple screw connections, leading to complex designs and reduced friction efficiency, while aiming for a simpler, cost-effective solution that optimizes friction surfaces and sealing within the same external dimensions.
Innovation Solution
A single rectangular coil carrier housing with two oval coils and separate symmetrical armature disks, guided on four fastening screws, reduces the number of screw connections and increases friction radius, allowing for a compact dual-circuit brake design with enhanced friction lining pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two independent rectangular brakes with separate coil carrier housings are used, then dual-circuit braking function is achieved, but device complexity and number of screw connections increase
Solution Approach 1:
The patent merges two separate coil carrier housings into a single unified coil carrier housing that accommodates both oval coils and their respective armature disks. This integration reduces the number of screw connections from eight (four per brake) to four total, while maintaining the dual-circuit braking function through separate movable armature disks that can be independently guided on diagonally arranged fastening screws.
2Strength
If four screw connections per brake are used, then armature disks are securely guided, but friction radius is reduced and friction efficiency decreases
Solution Approach 1:
The patent employs asymmetric placement of fastening screws at the four corners of the rectangular coil carrier housing, with armature disks guided on diagonally opposite pairs of screws. This asymmetric diagonal arrangement maximizes the friction radius by positioning guidance points at the extreme corners of the housing, thereby increasing friction efficiency while maintaining secure armature disk guidance through the same four screw connections.
3Ease of manufacture
If a single unified coil carrier housing is used, then sealing and protection are simplified, but internal space for coils and armature disks must be optimized
Solution Approach 1:
The patent transitions from two separate three-dimensional brake assemblies to a single integrated rectangular coil carrier housing containing both oval coils and armature disks in a planar arrangement. This dimensional reorganization allows the housing to be sealed as one unified structure, simplifying protection from foreign bodies and dirt, while the internal space is efficiently utilized through the rectangular housing geometry that accommodates the oval coils and diagonally arranged armature disks.
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 achieves a simpler, cost-effective dual-circuit brake with improved friction surface utilization and reduced external dimensions, maintaining the same rotor size and torque, while enabling easier sealing and protection from foreign bodies.
Implementation Method 1
an electromagnetically coil-operated release device (40) having a rectangular coil carrier (1) with two oval coils (7, 7.1)
Implementation Method 2
two separate rectangular armature disks (2, 2.1) which, when the coil current fails, press by spring pressure on the common rotor (3)
Implementation Method 3
press by spring pressure on the common rotor (3) with a friction lining (4)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Disclosed is an electromagnetically released spring pressure brake that is to be mounted on a machine wall or similar. Said brake comprises a uniform rectangular coil support (1) with two preferably oval, adjacent coils (7, 7.1), to which two separately movable rectangular armature disks are assigned. Said armature disks apply pressure to a joint rotor encompassing two friction linings that are mounted on each side when the coils (7, 7.1) are de-energized. The rotor is axially movable on an axially toothed hub. Two respective fastening screws (9) are used for guiding each of the armature disks parallel along the central longitudinal axis (13, 13.1) thereof, on the radially largest possible diameter of the rotor. A manual lever (10) featuring manual releasing bolts is provided for each armature disk. The inventive brake is simple and inexpensive and has two separate braking circuits, allowing the friction surfaces to be better utilized as the rotor has a greater diameter while the outer dimensions of the brake remain the same. Alternatively, the outer dimensions can be reduced if the rotor is not modified. In order to do so, a uniform or monolithic square coil support is provided that comprises two adjacent coils therein and two separate, independently movable armature disks on both sides of the central brake rotor (3).