Synthesis of Double-Action Brake Elements for Screw Conveyors

The article presents the synthesis and design of braking elements for double-action overrun clutches intended for use in screw conveyors. The performance and reliability of such conveyors significantly depend on the appropriate configuration and accurate calculation of their key structural, kinematic, and dynamic parameters. A critical issue addressed is the jamming of bulk materials between the rotating screw surface and the stationary housing, which can lead to damage of transported goods, mechanical failures, and productivity losses. To mitigate these problems, a novel design of a double-action overrun clutch with integrated cylindrical braking sectors is proposed. The clutch assembly includes a drive sprocket rigidly connected to an outer race, inside of which a rolling bearing is mounted on a drive shaft. Between the sprocket and an external cup, a segmented cylindrical braking element with expansion springs is installed. This configuration ensures controlled torque transfer and provides reverse rotation capability in case of screw jamming, allowing the conveyor system to self-release from overload conditions. A key focus of the study is the implementation of automated assembly synthesis using the “reverse synthesis method” introduced by V.A. Pasichnyk. This approach models the disassembly process to derive feasible assembly sequences, significantly reducing computational complexity and enabling the analysis of assemblies with more than 30 parts. The method utilizes binary constraint matrices (BCOM) to represent mechanical relationships and constraints between components. The process is integrated into a SolidWorks-based CAD/CAM environment, supported by custom-developed software that generates motion restriction maps and automates the identification of mechanical joints and contacts. The resulting models include 3D visualizations of the clutch and separator, detailed constraint tables, and assembly/disassembly graphs. This methodology enhances the automation, precision, and efficiency of the mechanical design process. It is particularly valuable for conveyor system applications where rapid prototyping and simulation are essential for operational reliability and safety.