Tension-Dependent Brake Actuation for Cable Management
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Solution Overview
Problem
Current cable management systems, such as those in the IDECM system, require multiple high-friction rotors and stators to generate sufficient braking torque, which is inefficient and requires tight assembly tolerances, and cannot maintain a load at intermediate torque ratings or provide a no-torque condition without power application.
Innovation Solution
A cable management system with a spool, a brake rotor, and a feedback and control system that adjusts the spool's rotation rate based on cable tension, using a single brake pad and a linkage assembly to alter braking force through a lever and sheave mechanism, allowing for more efficient torque control and reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If multiple high-friction rotors and stators are used to generate sufficient braking torque, then the braking torque capacity is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines multiple friction surfaces into a single brake assembly with one rotor and one brake pad. The brake pad is designed with a large friction surface area that contacts the rotor, consolidating the function of multiple rotors and stators into a single integrated unit, thereby reducing device complexity while maintaining braking torque capacity
Solution Approach 2:
The patent employs a spring-loaded brake assembly where the spring force dynamically adjusts the brake pad contact pressure against the rotor. This dynamic mechanism allows the single brake assembly to generate variable braking torque as needed, replacing the static multiple-friction-surface design and enabling torque modulation without additional components
2Force
If multiple rotors and stators are used to provide braking torque, then the torque capacity is improved, but the assembly tolerances and manufacturing precision requirements increase
Solution Approach 1:
By merging multiple friction interfaces into a single brake pad-rotor interface, the patent eliminates the need for precise alignment and assembly of multiple rotors and stators. The single brake assembly design reduces the cumulative tolerance stack-up that would occur with multiple components, thereby lowering manufacturing precision requirements while maintaining sufficient braking torque
3Force
If a solenoid actuated brake is designed to hold cable at maximum torque capacity, then the holding capability is improved, but the ability to hold at intermediate torque ratings is worsened
Solution Approach 1:
The spring-loaded brake assembly provides continuous variable braking torque by adjusting the spring compression force. The spring can be pre-loaded to different forces, enabling the brake to hold the cable at any intermediate torque rating between zero and maximum capacity, thus providing adaptable torque control without requiring multiple discrete brake settings or additional actuators
4Force
If a large number of friction generating surfaces are used, then the braking torque is improved, but the power consumption and energy usage increase
Solution Approach 1:
The spring-loaded brake assembly is self-actuating through the spring force, eliminating the need for continuous electrical power to maintain braking torque. The spring automatically applies the brake pad to the rotor when cable tension exceeds the spring force, and releases when tension decreases, providing passive torque generation without electrical energy consumption
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 system achieves efficient control of spool rotation and cable payout with reduced electrical power usage, using fewer components and allowing for intermediate torque management without the need for multiple rotors and stators, enhancing operational flexibility and reliability.
Implementation Method 1
a brake pad mounted on the lever and engageable with the brake rotor
Implementation Method 2
a sheave which engages the cable segment and is rotatably mounted on the arm about a sheave axis
Data Source
AI summary
A cable management system and method of use are provided in which brake actuation which controls a cable payout rate may be dependent on cable tension. A control system may be provided for adjusting cable tension and braking force.