EDDY CURRENT BRAKE

Abstract: In the brake a rotor composed of a ferromagnetic material and an electromagnet are so provided that the rotor intersects the magnetic flux to produce the braking power by the eddy current generated in the rotor. The rotor is provided with a non-magnetic metal layer (300) that has an electric conductivity greater than that of the rotor, and the outside of the coil of the electromagnet is surrounded by a pole casing (130) made of a ferromagnetic material, in order to obtain a larg braking torque. The brake is suited for use as an auxiliary brake for vehicles.

Description: FIELD OF THE ART The present invention relates to an eddy-current brake comprising a pair of rotors or a single rotor made of a ferromagnetic material and electromagnets arranged and designed to increase the eddy current generated in the rotor, in which said elements are arranged so that the rotor will cut off the magnetic flux and a large braking force will be produced by the eddy current generated in said rotor. BACKGROUND ART The conventional (FR-A-1 092 293 and US-A-3 263 107) eddy-current brakes had the defect that their weight per braking torque developed was large in comparison with the brakes of other systems. FIG. 11 of the accompanying drawings illustrates in section a typical example of conventional disc type eddy-current brakes. In this brake, as shown in the drawing, flange couplings 1, 2 are joined to the axle to be braked. Main shaft 3 is joined to said couplings 1, 2 so that they won't rotate relative to each other but will be able to rotate integrally with the axle to be braked. Also, discs 4, 5 are fixed to said main shaft 3 so that they won't rotate relative to each other. Electromagnets 10, each comprising a coil 6 and magnetic pole 7, are provided radially on the same circumference of a circle centered by main shaft 3. Said electromagnets 10 are fixed to a fixing plate 9 in a stelliform arrangement with a slight spacing from said discs 4, 5. Main shaft 3 is also rotatably secured to said fixing plate 9 through ball bearings 8. This fixing plate 9 itself is fixed immovably to a brake block. Thus, normally, discs 4, 5 rotate together with the axile to be braked. In this state, electromagnets 10 are not electrified. They are electrified when the axle is to be braked. The magnetic line of force generated by each said electromagnet 10 forms a closed curve involving magnetic pole 7 and disc 4 or 5, and an eddy current is generated in said discs 4 and 5 to produce a force acting oppositely to the direction of rotation, viz. braking force, on said discs 4 and 5. Thus, in the eddy-current brakes, rotors made of a ferromagnetic material and magnets are provided in such an arrangement that each rotor will cut off the magnetic flux and a braking force will be produced by an eddy current generated in said rotor. In this system, therefore, the smaller the electric resistance of the material of the rotors, i.e., discs 4, 5 in FIG. 11, the greater becomes the braking torque developed provided that the other conditions, namely wire size and number of turns of coil 6, electric current applied thereto and space between magnetic pole 7 and disc 4 (5) are the same. However, as it is an essential codition that discs 4, 5 be made of a magnetic material, no remarkable difference is produced in the torque developed no matter what type of magnetic material is used. Thus, it has been the common problem to the conventional eddy-current brakes that there can not be obtained a large braking troque in comparison with the brakes of other systems no matter what material is used for the rotors, viz. discs 4, 5. Also, in the conventional eddy-current brake illustrated in FIG. 11, each electromagnet 10 is constituted by a magnetic pole 7 projecting axially from the center of bottom plate 11 and a coil 6 comprising a copper wire wound up on said magnetic pole 7, and such electromagnets 10 are disposed opposing to and slightly spaced-apart from discs 4, 5 so that the opposite polarities are positioned alternately to each other. Therefore, the magnetic line of force generated by each said electromagnet 10 describes a closed curve that passes magnetic pole 7 of the adjacent electromagnets 10, fixing plate 9 and one of the discs 4 or 5. Thus, because of the long magnetic path, the intensity of the magnetic field formed is weak. The object of this invention is to provide an eddy-current brake which is free of said problems of the prior art and capable of developing a large braking torque per unit weight. SUMMARY OF THE INVENTION In the present invention, a metallic layer formed from a non-magnetic material having a greater electro-conductivity than the rotor material is bonded to that face of the rotor which opposes the magnetic poles of the electromagnets. This technical means contributes to the increase of eddy current generated in the rotor, which leads to an increased braking torque. Also, the coil of electromagnet is enclosed by a magnetic pole case made of a ferromagnetic material and so designed that its selectional area where the magnetic line of force passes will be equal to or greater than the cross-section of the magnetic pole. This arrangement makes it possible to substantially halve the magnetic path of electromagnet as compared with the conventional mechanism, and accordingly the intensity of the magnetic field produced by the electromagnets is almost doubled. Further, since the eddy current generated by one piece of electromagnet increases because of the generation of extra eddy current by the magnetic pole case, the braking torque developed is enlarged. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a sectional view of a disc type eddy-curren brake in accordance with this invention. FIG. 2 is a schematic layout of electromagnets in said brake. FIG. 3 is a sectional view of a drum type eddy-current brake in accordance with this invention. FIG. 4 is a schematic layout of electromagnets in the brake of FIG. 3. FIG. 5 is a sectional view of electromagnet. FIG. 6 is a plane view thereof. FIG. 7 is a sectional view illustrating an example of practical adaptation thereof. FIG. 8 is a plane view thereof. FIG. 9 is a perspective view of the metallic layer provided in the disc type eddy-current brake. FIG. 10 is a perspective view of the metallic layer provided in the drum type eddy-current brake. FIG. 11 is a sectional view of a conventional disc type eddy-current brake. BEST MODE FOR CARRYING OUT THE INVENTION Marked differences between the eddy-current brake according to this invention shown in FIG. 1 and the conventional eddy-current brake shown in FIG. 11 lie in the characteristic design of electromagnets 200 in this invention as compared with the electromagnets 10 in the conventional brake and in the provision of metallic layer 300 in this invention, which is not provided in the conventional brake. Flange couplings 1A, 2A, main shaft 30 joined thereto, discs 40, 50, ball bearings 80 and fixing plate 90 are identical with those in the conventional brake. Electromagnets 200, as illustrated in FIGS. 5 and 6, are basically composed of a circular flat bottom plate 110 made of a ferromagnetic material, a cylindrical magnetic pole case 130 formed integral with said bottom plate 110 so that said case erects parallel to the axis of the electromagnet from the outer edge of said bottom plate 110, and a columnar magnetic pole 120 also formed integral with said bottom plate 110 so that said magnetic pole projects vertically outwards from the center of said bottom plate 110. A coil 60 of copper wire is provided around said magnetic pole 120. Said magnetic pole case 130 is so designed that the area of its open end 131 parallel to the said bottom plate 110 will be equal to or greater than the cross-sectional area of the magnetic pole 120 which has the same sectional configuration as said case 130. A typical example of practical adaptation of said electromagnets 200 is shown in FIGS. 7 and 8. Magnetic pole case 130 is so formed that it is smallest in diameter at its edge conjugate to the bottom plate 110 and gradually enlarges in diameter toward its open end 131 so that said open end 131 can have a large area. Also, openings 132 are formed by cutting out the opposing portions of peripheral wall parallel to each other. These openings 132 are intended to facilitate ventilation so as to prevent rise of temperature of electromagnets 200. Discs 40, 50 are provided with a metallic layer 300 at their faces opposing the electromagnets 200, along a stretch equal to or greater than the maximum diameter of the open end 131 of said magnetic pole case 130. Said metallic layer 300 is composed of a non-magnetic material, such as copper, having a greater electroconductivity than said discs 40, 50. Such metallic layer 300 is formed as a thin ring-shaped flat plate and disposed in opposition to and slightly spaced-apart from electromagnets 200. FIGS. 3 and 4 illustrate another embodiment of this invention as it was embodied as a drum type eddy-current brake. This drum type eddy-current brake features the enlarged sectional area of the magnetic circuit in comparison with the disc type eddy-current brake to increase the braking torque developed. In this drum type brake, the single rotor is formed as a drum 500 consisting of a peripheral wall portion 510 parallel to main shaft 400, a bottom wall portion 520 formed integral with and crossing main shaft 400 at right angles and an open portion 530 opening at the end opposite from said bottom wall portion 520. A metallic layer 800 is formed on the inner surface of said peripheral wall portion 530 of the drum 500. As shown in FIG. 10, said metallic layer 800 is formed as a thin-walled cylinder on the entirety of the inner surface of said peripheral wall portion 510. This layer is composed of a non-magnetic material, such as copper, having a greater electro-conductivity than the peripheral wall portion 510 of the drum 500. Also, thin ring-shaped fins 540 are provided at a substantially same pitch around the outer surface of said peripheral wall portion 510. It is desirable that such fins 540 be also provided on the outer surface of the bottom wall portion 520. These fins 540 are formed integral with the drum 500 and serve for preventing the rise of temperature of the drum 500. Electromagnets 600 are the same as the ones shown in FIGS. 7 and 8. The fixing plate 9 used in the conventional brake shown in FIG. 11 is replaced by a fixing plate 700 having a cylindrical portion 720 and a bottom portion 710 at an end of said cylindrical portion 720, said bottom portion 710 being secured to a brake block. Said fixing plate 700 itself is fixed so that it won't rotate with other elements and also won't move easily. Said fixing plate 700 has its cylindrical portion 720 placed concentrically inside the drum 500 so that the open end thereof will oppose the inner face of the bottom wall portion 520 of said drum 500 with a slight spacing therebetween. The outer diameter of said cylindrical portion 720 is made smaller than the inner diameter of the peripheral wall portion 510 of said drum 500, and electromagnets 600 are disposed radially between said cylindrical portion 720 and the peripheral wall portion 510 of said drum 500. The bottom plates 610 of said electromagnets 600 are detachably secured to the outer peripheral surface of said cylindrical portion 720 so that the magnetic pole 620 and the open end 631 of the magnetic pole case 630 will face the metallic layer 800 on the inner surface of said peripheral wall portion 510 with a slight spacing therebetween. INDUSTRIAL APPLICABILITY The eddy-current brake of this invention is suited for use as an auxiliary brake for the main brake system in a vehicle.

Claims: An eddy-current brake comprising at least one rotor (40,50;500) made of a ferromagnetic material and electromagnets (200;600), in which said rotor (40,50;500) is so disposed that it will cut off the magnetic flux and a braking torque is produced by the eddy current generated in said rotor, characterized in that a metallic layer (300;800) formed from a non-magnetic material having a greater electroconductivity than said rotor is provided on that side of said rotor which faces the magnetic poles (120;620) of said electromagnets (200;600) and the coil (60) of each said electromagnet is enclosed by a magnetic pole case (130;630) formed from a ferromagnetic material and disposed facing said metallic layer (300;800) with a slight spacing therebetween, said magnetic pole case (130;630) is composed of a disc-shaped bottom plate (110;610) and a frusto-conical cylindrical body extending spreadingly from the outer peripheral edge of said bottom plate (110;610) so that it will have the maximum diameter at its top open end. An eddy-current brake according to claim 1, wherein a pair of rotors (40,50) are formed as discs mounted on the main shaft (30) transversely thereto so as to be rotatable integrally with said main shaft (30), each of said discs (40,50) having provided on its inside flat surface a thin ring-shaped metallic layer (300). An eddy-current brake according to claim 1, wherein a single rotor (500) is provided, said rotor being formed as a bottomed cylinder having a peripheral wall portion (510) parallel to the main shaft (400) and a bottom wall portion (520) formed integral with and transversely to the main shaft (400) so as to be rotatable integrally therewith, said peripheral wall portion (510) having provided on its inner peripheral surface a thin cylindrical metallic layer (800).

Inventors: CHIBA SHUUICHI TOKYO-BUHIN KOG, MATSUI NORIO, SANJO ISAO TOKYO-BUHIN KOGYO K, CHIBA, SHUUICHI TOKYO-BUHIN KOGYO KABUSHIKI, MATSUI, NORIO, SANJO, ISAO TOKYO-BUHIN KOGYO KABUSHIKI KAISHA
Applicants: TOKYO BUHIN KOGYO CO LTD, TOKYO-BUHIN KOGYO CO., LTD.
Application year: 1987
Main classification: H02K49
IPC codes: H02K49