1. Integrated manufacturing of electromagnetic-mechanical precision coupling system

① High-precision magnetic circuit system integrated processing

Special soft magnetic materials (such as electrical pure iron DT4C, mild steel) are used for precision machining of magnetic yokes, armatures and magnetic conductivity

ring, to ensure that the magnetic circuit air gap control accuracy is ≤ 0.03mm, the flatness of the magnetic conductive surface ≤ 0.005mm, and the magnetic flux density uniformity is ≥ 95%, achieving efficient electromagnetic conversion and fast response (release/suction time ≤ 10ms).

② Precision forming and surface treatment of friction sub-components

High-precision flat surface grinding (flatness ≤ 0.005mm, parallelism ≤0.008mm) is carried out on the brake disc/plate, and special wear-resistant anti-friction coatings (such as sintered copper-based, modified phenolic resin-based) are applied, and the friction coefficient is stable at 0.35-0.45 (dry type) or 0.08-0.12 (wet type) to ensure that the braking torque accuracy is ± 5%.

③ The spring pressure system is precisely regulated and manufactured

Produce disc springs or coil springs using high fatigue strength spring wires (such as 60Si2MnA), and achieve pressure dispersion through precise heat treatment and pressure grouping ≤3% to ensure the consistency of braking torque between batches.

2. Safety redundancy and reliability enhancement design and manufacturing

① Dual-channel redundant braking system integrated manufacturing

Precision manufacturing of independent humbuckers, double armatures and pressure equalization mechanisms to achieve dual redundancy of electromagnetic and mechanical. In the event of a single circuit failure, the backup channel can provide a customized torque not lower than the rated torque 70% safe braking, which meets the requirements of functional safety level above SIL2/PLd.

② Automatic wear compensation and clearance monitoring structure

Integrated manufacturing wear compensation gasket automatic adjustment mechanism or gap sensor mounting interface to monitor friction plate wear in real time to ensure stable braking torque and response time throughout the life cycle.

③ Fail-safe structure implementation

Through the precise cooperation of the principle of losing power braking and the mechanical self-locking structure, it ensures that the brake can automatically and reliably engage in abnormal situations such as power failure and control failure to achieve zero speed maintenance.

3. Dynamic thermal management and vibration and noise control

① Efficient heat dissipation and thermal isolation structure manufacturing

Design and manufacture heat insulation gaskets or heat dissipation channels between the magnetic yoke and the friction pair, use thermal adhesive to fill the air gap, and process the brake disc with internal ventilation grooves or heat dissipation fins to control the continuous braking temperature rise $\Delta { \sf T } { \le } 8 0 ^ { \circ } { \sf C }$ Within.

②  Vibration reduction and noise reduction and smooth engagement control

Micro texture optimization of the armature joint surface (laser micro-pit or precision grinding), and the integration of micro dampers in the spring assembly effectively reduce the impact noise and chatter during brake engagement, and the noise level is ≤ 65dB(A).

4. Integration of full-function testing and safety certification

① Comprehensive test bench verification of braking performance

Equipped with a professional test bench, it can perform static braking torque, dynamic braking response time, minimum holding voltage, insulation resistance, durability ( |>100 10,000 cycles) and generate a uniqueness test report.

② Environmental adaptability simulation test

Support for high and low temperature cycling ( (−40∘C∼+125∘C) ), humidity heat, vibration, salt spray and other environmental reliability tests to ensure that the brakes meet all kinds of severe working conditions.

③ Conformity certification support

Manufacturing processes and product performance support compliance with international safety and electromagnetic compatibility standards such as IEC 61800-5-2, ISO 13849, UL/CE, etc.