Stepped Torque Brake Assembly for Compact Progressive Shaft Braking
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Solution Overview
Problem
Existing braking devices for rotary shafts face limitations in braking force, size, and complexity of control systems, with significant space requirements and susceptibility to premature wear, especially in applications like electric industrial transport vehicles and hoisting systems.
Innovation Solution
The braking device arranges magnetic armatures in series along the longitudinal axis, with springs biasing each armature, and uses a single winding with control means to manage current and voltage, allowing for increased braking force while reducing size and simplifying control, and incorporates an elastically biased intermediate flange to prevent premature wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If magnetic armatures are arranged in series along the longitudinal axis with springs biasing each armature, then braking force is significantly increased, but device complexity increases
Solution Approach 1:
The patent combines multiple friction discs and magnetic armatures into a single compact assembly where components are radially arranged around a common axis. The friction discs are positioned between the magnetic armatures, creating an integrated structure that achieves high braking force through radial stacking rather than axial arrangement, thereby increasing force while controlling complexity.
Solution Approach 2:
The patent transitions from axial arrangement of components to radial arrangement around a common axis. By organizing friction discs and magnetic armatures in concentric layers rather than sequential axial positions, the design achieves high braking force within a compact axial footprint, effectively using the radial dimension to resolve the contradiction between force and complexity.
2Force
If concentric magnetic armatures are used with force transmission element, then braking force is increased, but radial space requirement increases significantly
Solution Approach 1:
The patent implements a nested arrangement where friction discs are positioned between concentric magnetic armatures, with each component radially stacked around the central axis. This nesting allows multiple friction surfaces to be engaged within a limited radial envelope, achieving high braking force without proportionally increasing radial space requirements.
Solution Approach 2:
The patent resolves the radial space issue by utilizing the axial dimension more effectively. Instead of spreading friction surfaces radially outward, the design stacks them axially between concentric armatures, allowing high braking force to be achieved within a compact radial footprint by transitioning to axial utilization of space.
3Force
If intermediate flange is rigidly connected to friction discs, then braking force transmission is improved, but premature wear of friction discs occurs
Solution Approach 1:
The patent incorporates an elastic element between the intermediate flange and the friction discs, positioned to absorb and distribute contact forces. This elastic cushioning element prevents direct rigid contact that would cause premature wear, while still effectively transmitting braking forces through the intermediate flange to the friction discs.
Solution Approach 2:
The patent introduces an elastic element as an intermediary component between the intermediate flange and the friction discs. This mediator element transmits forces while providing a compliant interface that reduces stress concentrations and prevents direct metal-to-friction material contact, thereby extending component life while maintaining force transmission efficiency.
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 configuration enhances braking force, reduces size, and simplifies control, ensuring progressive and efficient braking while minimizing wear and accommodating dimensional variations, thus improving performance and ease of assembly in constrained spaces.
Implementation Method 1
when the winding is supplied with current the magnetic armatures are magnetically biased towards the winding
Implementation Method 2
two series of springs mounted in a fixed housing... biased respectively, when idle, by the two series of springs
Implementation Method 3
two friction discs mounted axially slidable on the single shaft... one of the two magnetic armatures is pushed against one of the two friction discs that then engages the intermediate flange
Data Source
AI summary
A braking device of at least one rotary shaft (S) extending along an axis X includes an actuation unit (I) comprising at least one winding (B), two friction discs (D1, D2), an end flange (F1), an intermediate flange mounted between the two friction discs (D1, D2), and two magnetic armatures (A1, A2) biased by two series of springs (R1, R2). The magnetic armatures (A1, A2) are arranged in series along the longitudinal axis X, with each of the series of springs (R1, R2) respectively biasing a magnetic armature (A1, A2). A series of springs (R2) passes through the thickness of one of the two magnetic armatures (A1) in order to bias the other magnetic armature (A2).