Automatic load brake having wear-induced locking mechanism

1. An automatic load brake having a wear-induced locking mechanism for a hoist, comprising:

a first shaft defining an annular hollow portion and a radially outer surface;

a second shaft defining an engagement portion and a radially inner surface, the radially inner surface configured to engage the radially outer surface;

a first reaction plate coupled to the first shaft;

a second reaction plate coupled to the second shaft; and

a plurality of friction discs coupled to a cup, with at least one of the plurality of friction discs disposed between the first reaction plate and the second reaction plate,

wherein each of the plurality of friction discs includes a first wear surface disposed on one side of the friction disc and a second wear surface disposed on the opposite side of the friction disc,

wherein the first shaft and the second shaft are in frictional disengagement prior to the first wear surface of the friction disc and the second wear surface of the friction disc experiencing thinning,

wherein, in response to the first wear surface of at least one of the plurality of friction discs and the second wear surface of the at least one of the plurality of friction discs experiencing thinning, the engagement portion of the second shaft is configured to translate an axial distance into the annular hollow portion of the first shaft and thereby lock to the engagement portion of the second shaft.

2. The load brake of claim 1 , wherein the radially outer surface is oriented at a first angle with respect to a longitudinal axis extending through the load brake.

3. The load brake of claim 2 , wherein the radially inner surface is oriented at a second angle with respect to the longitudinal axis.

4. The load brake of claim 3 , wherein the first angle is within a tolerance of about one degree to about three degrees of the second angle.

5. The load brake of claim 3 , wherein the first angle equals the second angle.

6. The load brake of claim 4 , wherein a tangent of the first angle is equal to or less than a coefficient of friction between the radially outer surface and the radially inner surface when the radially outer surface is engaged with the radially inner surface.

7. The load brake of claim 4 , wherein the first angle is less than or equal to about seven degrees.

8. The load brake of claim 1 , wherein the cup is coupled to a sprag clutch.

9. The load brake of claim 8 , wherein the second shaft is coupled to a ring gear configured to be driven by a motor.

10. The load brake of claim 9 , wherein the first shaft is coupled to an output shaft configured to drive a cable drum.

11. The load brake of claim 10 , wherein the radially outer surface is oriented at a first angle with respect to a longitudinal axis extending through the load brake, the radially inner surface is oriented at a second angle with respect to the longitudinal axis and the first angle is within a tolerance of about one degree to about three degrees of the second angle.

12. The load brake of claim 11 , wherein a tangent of at least one of the first angle and the second angle is equal to or less than a coefficient of friction between the radially outer surface and the radially inner surface when the radially outer surface is engaged with the radially inner surface.

13. A drive train for a hoist having an automatic load brake with a wear-induced locking mechanism, comprising:

a housing;

an output shaft rotatably disposed within the housing and configured to rotate a cable drum, the output shaft defining an annular hollow portion and a radially outer surface, the output shaft configured to translate axially along a longitudinal axis;

a driving shaft rotatably disposed within the housing and defining an engagement portion and a radially inner surface, the radially inner surface configured to engage the radially outer surface;

a cup rotatably disposed within the housing;

a first reaction plate connected to the output shaft;

a second reaction plate connected to the driving shaft; and

at least one friction disc connected to the cup and disposed between the first reaction plate and the second reaction plate,

wherein the at least one friction disc comprises a plurality of friction discs includes a first wear surface disposed on one side of the friction disc and a second wear surface disposed on the opposite side of the friction disc,

wherein the first shaft and the second shaft are in frictional disengagement prior to the first wear surface of the friction disc and the second wear surface of the friction disc experiencing thinning,

wherein, in response to the first wear surface of the at least one of the plurality of friction discs and the second wear surface of the at least one of the plurality of friction discs experiencing thinning, the engagement portion of the second shaft is configured to translate an axial distance into the annular hollow portion of the first shaft and thereby lock to the engagement portion of the driving shaft.

14. The drive train of claim 13 , wherein the driving shaft is coupled to a ring gear configured to be driven by a motor.

15. The drive train of claim 14 , wherein the radially outer surface is oriented at a first angle with respect to the longitudinal axis, the radially inner surface is oriented at a second angle with respect to the longitudinal axis and the first angle is within a tolerance of about one degree to about three degrees of the second angle.

16. The drive train of claim 15 , wherein a tangent of at least one of the first angle and the second angle is equal to or less than a coefficient of friction between the radially outer surface and the radially inner surface when the radially outer surface is engaged with the radially inner surface.

17. The drive train of claim 16 , wherein the radially outer surface is configured to engage the radially inner surface following thinning of the first wear surface of at least one of the plurality of friction discs and the second wear surface of at least one of the plurality of friction discs.

18. A method of braking a hoist having an automatic load brake with a wear-induced locking mechanism, comprising:

operating the hoist having a first shaft defining an annular hollow portion and a radially outer surface in axial alignment with a second shaft defining an engagement portion and a radially inner surface, the radially inner surface configured to engage the radially outer surface, the first shaft and second shaft being in frictional disengagement; and

urging the first shaft toward the second shaft in response to thinning of a plurality of friction discs, including at least one of the plurality of friction discs coupled to a cup and disposed between a first reaction plate coupled to the first shaft and a second reaction plate coupled to the second shaft, such that the engagement portion of the second shaft is configured to translate an axial distance into the annular hollow portion of the first shaft and thereby lock to the engagement portion of the second shaft.

19. The method of claim 18 , wherein the cup is coupled to a sprag clutch, the second shaft is coupled to a ring gear configured to be driven by a motor and the first shaft is coupled to an output shaft configured to drive a cable drum.

20. The method of claim 19 , wherein the radially outer surface is oriented at a first angle with respect to a longitudinal axis extending through the automatic load brake, the radially inner surface is oriented at a second angle with respect to the longitudinal axis and a tangent of the first angle is equal to or less than a coefficient of friction between the radially outer surface and the radially inner surface when the radially outer surface is engaged with the radially inner surface.