The present invention relates to an air-cooled disk brake, particularly for industrial applications, as defined in the preamble of claim 1.

Such brakes are used in particular machines that have the purpose of unwinding sheet material from appropriate coils.

Since sheets have to be unwound almost constantly "under tension", said brakes are exposed to accelerated wear of brake parts due to the high operating temperatures for continuous regulation of the braking torque.

Therefore, there is the need for highly versatile brakes, allowing more effective cooling of brake parts as compared with common available brakes.

Therefore, the object of the present invention is to provide an air-cooled brake disk that has such structural and functional features as to fulfill the above needs, while obviating the drawbacks of prior art.

This object is fulfilled by an air-cooled disk brake for industrial applications as defined in claim 1.

Further characteristics and advantages of the disk brake of the present invention will be apparent from the following description of preferred embodiments thereof, which are given by way of illustration and without limitation with reference to the accompanying figures, in which:

- Figure 1 is an exploded view of the brake of the present invention;

- Figure 2 is a perspective view of the friction unit of the brake of Figure 1 ;

- Figures 3 a, 3 b are perspective views of the flange halves that form the main brake body;

- Figure 4 is a perspective view of a flange half of Figures 3a, 3b;

- Figures 5, 6 and 9 are perspective and sectional views of the brake disk of Figure 1, according to a first embodiment;

- Figures 7, 8 and 10 are perspective and sectional views of the brake disk of Figure 1 , according to a second embodiment. Referring to the annexed figures, numeral 1 generally designates a pneumatically operated brake of the present invention.

As used in the present disclosure and the annexed claims, the term "air-cooled" brake, as opposed to vented disk brakes is intended to designate a disk brake that is cooled by forced air flow, e.g. by appropriate ventilation systems. Furthermore, the brake of the present invention particularly finds use in industrial fields, and is adapted to be associated with shafts of machines and/or equipment such as unwinders, belt conveyors, etc. In view of the above, it shall be noted that the brakes of the invention are not designed for use in vehicles in general.

According to a preferred embodiment, the brake 1 comprises a main body 100 having two interconnectable circular flanges 110, 120 that define an interior housing volume for the various parts of the brake, as set forth below.

The two flanges 110, 120 extend in a roughly longitudinal direction X-X and, in their operably connected state, the preferably have a substantially cylindrical shape with a central hole, i.e. a toroidal shape.

Referring to the example as shown in Figure 1, there are a front flange 110 (to the right of the point of observation in the figure) and a rear flange 120 (to the left of the point of observation in the figure) the latter being preferably adapted to be associated with airflow generating means 180 for ventilation of the brake 1 as explained in detail below.

The front flange 110 and the rear flange 120 are in facing, opposed relationship.

The flanges 110, 120 are integrally connected together by suitable coupling arrangements, not shown in detail and known to the skilled person, to define the main body 100.

The brake 1 comprises a brake disk 200 interposed between the flanges 1 10, 120 and adapted to be rotated about its own longitudinal axis x ₁ which is also the axis of a shaft of an industrial apparatus.

The braking action of the brake 1 is provided by at least one friction unit 130 having at least one longitudinally sliding friction member 132 which is designed to engage with the brake disk 200.

Friction elements 132 include pads made of known materials such as, for example, aramid, resin, ceramic, aluminum oxide, graphite and coal.

The friction unit 130 also comprises at least one pneumatic actuator 134, which is designed to control the longitudinal movement of the friction element 132 on the brake disk 200.

For easy access to the interior of the main body 100 of the brake 1, each flange 1 10, 120 is advantageously composed of at least two flange halves 111, 112, 121, 122, preferably having a substantially semicircular shape.

These flange halves may be selectively removed to access the relevant sector of the inner volume of the body for appropriate maintenance, such as replacement of the friction material.

Particularly, referring to the example of Figure 3a, the front flange 110 is composed of a first front flange half 111 and a second front flange half 112, which may be reversibly connected to each other. Likewise, the rear flange 120 is composed of a first rear flange half 121 and a second rear flange half 122, which may be reversibly connected to each other.

It shall be noted that the front flange and the rear flange are connected to each other by rods (not shown) extending in the longitudinal direction X-X, as is known to the skilled person.

In this example, the first front flange half 1 11 faces the first rear flange half 121 and the second front flange half 1 12 faces the second rear flange half 122.

Each flange half 111, 112, 121, 122 comprises one to six seats 11 1a, ... 1 1 If, 1 12a, ... 112f, 121a, ... 12 If, 122a, ... 122f, each seat being adapted to accommodate one pneumatic actuator 134.

Preferably, each flange half 1 1 1, 1 12, 121, 122 comprises up to six seats 11 1a, ... 11 If, 112a, ... 112f, 121a, ... 121f, 122a, ... 122f for the pneumatic actuators 134.

Referring to the embodiment as shown in Figure 3a, the first front flange half 111 comprises six seats 1 11a, 111b, 111c, 11 Id, 11 le, 11 If, which are arranged, as a whole, in side- by-side relationship along the circumference of the flange half 11 1 in the region bounded by the inside diameter di and the outside diameter d ₂ of the flange half 11 1. Particularly, the seats 1 1 1a, 1 1 If are formed on the inner surface, orthogonal to the longitudinal direction X-X of the flange half 11 1 and have a substantially cylindrical shape. Each seat 1 11a, 1 1 If accommodates one respective pneumatic actuator 134 by form-fit.

As described concerning the first front flange half 111, the second front flange half 1 12 comprises six seats 112a, 112b, 112c, 112d, 1 12e, 112f, which are arranged, as a whole, in side- by-side relationship along the circumference of the flange half 112 in the region bounded by the inside diameter d _\ and the outside diameter d ₂ of the flange half 1 12. Particularly, the seats 1 12a, 1 122f are formed on the inner surface, orthogonal to the longitudinal direction X-X of the flange half 112 and have a substantially cylindrical shape. Each seat 112a, 112f accommodates one respective pneumatic actuator 134 by form-fit.

The above considerations shall obviously apply to the first rear flange half 121 and the second rear flange half 122.

Namely, referring to the example as shown in Figure 3 b, the first rear flange half 121 comprises six seats 121a, 121b, 121c, 12 Id, 12 le, 12 If, which are arranged, as a whole, in side- by-side relationship along the circumference of the flange half 121 in the region bounded by the inside diameter d _\ and the outside diameter d ₂ of the flange half 121. The seats 121a, 121f are formed on the inner surface, orthogonal to the longitudinal direction X-X of the flange half 121 and have a substantially cylindrical shape. Each seat 121a, 121f accommodates one respective pneumatic actuator 134 by form-fit.

Finally, the second rear flange half 122 has six seats 122a, 122b, 122c, 122d, 122e, 122f, which are arranged, as a whole, in side-by-side relationship along the circumference of the flange half 111 in the region bounded by the inside diameter dj and the outside diameter d ₂ of the flange half 122. Particularly, the seats 122a, 122f are formed on the inner surface, orthogonal to the longitudinal direction X-X of the flange half 122 and have a substantially cylindrical shape. Each seat 122a, 122f accommodates one respective pneumatic actuator 134 by form-fit. As shown in the examples of Figures 3a, 3b, the seats 111a, ... 11 If of the first front flange half 112 face the seats 1 12a, ... 112f of the second front flange half 1 12. Likewise, the seats 121a, ... 121 f of the first rear flange half 122 face the seats 122a, ... 122f of the second rear flange half 1 12.

Referring to the example of Figure 2, it shall be further noted that the friction unit 130 of the brake 130 is composed of:

- two pneumatic actuators 134, and

- one friction element 132.

This will improve consumption of the friction element 132 when it is engaged with the brake disk 200.

In one embodiment, the brake 1 of the invention comprises up to six friction units 130 for each flange half 111, 112, 121, 122. Therefore twelve friction units 130 per brake may be provided as a whole.

Also, due to the modularity of the friction units 130, each friction element 132 may be moved independently of the others, thereby ensuring a more effective braking action, as required in certain particular industrial applications.

Each friction unit 130 comprises a pad plate 136 for supporting the friction element 132. Advantageously, the brake 1 comprises at least one pair of magnets 133 interposed between the pad plate 136 and the pneumatic actuator 134, Thus, the friction element 132 may be retained on the pad plate 136 without using coupling elements.

As mentioned above, the brake 1 has airstream generating means 180 for ventilation of the disk 200, which are associated with the main body 100.

In the example of Figure 1, the generating means 180 include a fan connected to the front flange 1 10 and protected by a cover 190 that is also designed to be fixed to the front flange 110.

Referring to the examples as shown in Figures 5, 6, 7 and 8, the brake disk 200 comprises first 210 and second 220 coaxial rings, connected to each other by a plurality of radially directed vanes 207.

The brake disk 200 is also provided with a central hub 240, which is adapted to be keyed to the shaft of an industrial apparatus, and is integrally fixed to at least one of said rings 210, 220.

The rings 210, 220 have substantially the same shape and size and each has an outer surface 210a, 220a and an inner surface 210b, 220b. In the illustrated embodiments, the outer surface 210a, 220a is the one designed for engagement with the friction elements 132.

In one embodiment, the central hub 240 is integrally fixed to at least one of said rings 210, 220.

The brake disk 200 comprises a plurality of radially directed connection elements 205, for connecting the central hub 240 to at least one of the rings 210, 220.

Preferably, the central hub 240 is fixed to one of the rings 210, 220 of the disk 200 at its inside circumference.

Referring to the examples of Figures 9 and 10, the brake disk 200 advantageously has at least one air inlet 250 between the central hub 240 and at least one of said rings 210, 220. As better explained below, such inlet is designed to convey the airstream to the surfaces 210a, 210b, 220a, 220b of the rings 210, 220, to cool them.

For the airstream to be conveyed to the surfaces 210a, 210b, 220a, 220b of the rings 210, 220 effectively, the central hub 240 advantageously has a substantially irustoconical shape extending between a larger base 240a and a smaller base 240a along the axis x^

In the illustrated example, the second ring 220 is the ring that faces the rear flange 120.

Here, the larger base 240a of the central hub 240 is connected to the second ring 220 at the inside circumference thereof, by the connection elements 205. It shall be noted that the airstream generated by the generating means 180 is adapted to mainly impinge (longitudinally, along the axis ) upon the area of the air inlet 250 between the central hub 240 and the first ring 210.

Referring to the example as shown in Figure 6, the connection elements 205 are radially arranged between the central hub 240 and the second ring 220. Thus, first outlets 251 are provided between the connection elements, for directing the inflowing airstream toward the outer surface 220a of the second ring 220. In short, a first ventilation channel is formed between the air inlet 250 and each of the first outlets 251, to convey part of the airstream to the outer surface 220a of the second ring 220.

Preferably, the diameter of the rear base central hub 240 is substantially equal to the diameter of the inside circumference of the second ring 220.

Referring to the examples of Figures 5 to 8, the first and second rings 210, 220 have an outer diameter d ₃ preferably ranging in length from 50 mm to 600 mm.

Referring to the examples of Figures 5 and 7, the inner diameter d of the first and second rings 210, 220 ranges in length from 50 mm to 500 mm.

In the example of Figure 6, the brake disk 200 has five connection elements 205 and five respective first outlets 251.

A plurality of radial grooves 241 (acting as chutes) are formed on the lateral surface of the central hub 240, to form the first ventilation channels.

Advantageously, surface portions are defined between the grooves 241 of the central hub

240, to define second ventilation channels.

Each of the second ventilation channels allows a further portion of the airstream generated by the generating means 180 to be conveyed from the air inlet 250 to the vanes 207 of the brake disk 200. Thus, the inner surfaces 210b, 220b of the rings 210, 220 can be cooled.

Concerning ventilation, and the resulting cooling effect on the outer surface 210a of the first ring 210, the brake disk 200 has a plurality of tabs 263 for directing part of the airstream generated by the generating means 180 toward the outer surface 210a of the first ring 210. Namely, the tabs 263 are fixed to the inside circumference of the first ring 210.

The tabs 263 radially extend, as ramps, to a predetermined length. Thus, part of the airstream generated by the generating means 180 is conveyed toward the outer surface 210a of the first ring 210 to cool it. In one embodiment, the central hub 240 has a hyperboloid structure. Preferably, the central hub 240 has a one-sheeted hyperboloid structure.

Referring to the embodiments of Figures 6 and 8, the larger base 240a of the central hub 240 projects beyond the outer surface 220a of the second ring 220. Particularly, the larger base 240a and the outer surface 220a are placed on separate and parallel planes.

According to a second embodiment, as shown in Figures 7, 8 and 10, the brake disk 200 (as described with reference to the first embodiment, of Figures 5, 6 and 9) comprises, in addition to first 210 and second 220 rings, also a third ring 230. Such rings 210, 220, 230 are coaxial and connected together by two sets of pluralities of radially directed vanes 208, 209, disposed between said rings. Namely, the third ring 230 is disposed between the first 210 and the second 220 rings. The first set of vanes 208 is circumferentially arranged between the first 210 and the second 230 rings. The second set of vanes 209 is circumferentially arranged between the second 220 and the third 230 rings.

The provision of a third ring 230 allows two separate and parallel ventilation channels to be formed between the first 210 and the third 230 rings and between the second 220 and the third 230 rings. Basically, in such second configuration, part of the airstream generated by the generating means 180 is conveyed from the air inlet 250 to the sets of vanes 208, 209 arranged between the rings 210, 220, 230 of the brake disk 200.

Advantageously, the brake disk 200 is made of one piece.

As clearly shown in the above description, the brake of the present invention fulfills the needs and obviates the drawbacks of the prior art as set out in the introduction of this disclosure.

Instead of or in addition to the above, the air-cooled pneumatically operated brake for industrial applications comprises:

- a fixable body extending along a longitudinal axis, and having a first flange and a second flange;

- connection means for connecting said first flange with said second flange, to define a seat;

- at least one brake disk and at least one friction unit accommodated in said seat and operatively designed for cooperation;

- said first flange and said second flange comprise at least two parts each, said connection means reversibly connecting respective pairs of parts of said first flange and said second flange.

Obviously, the embodiments and examples as disclosed and illustrated herein shall be only intended by way of example, and those skilled in the art will appreciate that a number of changes and variants may be made to the disk brake of the invention as described hereinbefore, including for instance a combination of said embodiments and examples to meet specific needs, without departure from the scope of the invention, as defined in the following claims.