Everything you need to know about the material, performance, and selection of brake linings – including expert tips from ATEK Drive Solutions.
How do industrial brake linings differ from standard automotive brake linings?
Industrial brake linings are designed for significantly higher loads, temperatures, and specific environmental conditions than automotive linings. They often use specialized material mixtures, such as sintered metals or high-performance organics, to ensure reliability in demanding applications such as crane systems or heavy machinery, where temperatures can exceed 750°C. What role does the ECE-R90 standard play for brake linings in the industrial sector?
Although originally developed for automotive purposes, the ECE-R90 standard also serves as
an important quality indicator in the industry.brake linings It defines minimum requirements for friction coefficient, strength, and production conformity.Reputable manufacturers like ATEK Drive Solutions often exceed these standards through their own, more stringent testing procedures. Renommierte Hersteller wie ATEK Drive Solutions übertreffen diese Standards oft durch , which take application-specific loads into account.How does the material composition affect the performance of brake linings in the industry?
The material composition is
crucial for the performance of industrial brake linings. Specific mixtures of metals, ceramic fibers, and organic materials determinefriction stability at high temperatures (up to 800°C), wear resistance, and mechanical robustness. ATEK Original. ATEK Original brake linings for example, uses over 20 different materials for optimal performance..
What advantages do modern warning systems for industrial brake linings offer?
Modern warning systems, such as electric sensors, allow for proactive maintenance planning for. brake liningsThey report in advance (e.g., at 25% remaining lining thickness) when a change is due, helping to prevent unplanned downtimes and costly consequential damages to brake discs or drums. How can the selection of the right brake linings influence the Total Cost of Ownership (TCO)?.
Wie kann die Auswahl der richtigen Bremsbeläge die Total Cost of Ownership (TCO) beeinflussen?
The right brake linings can significantly reduce the TCO. More durable linings, even if more expensive to purchase, reduce. Langlebigere Beläge, auch wenn im Einkauf teurer, reduzieren maintenance intervals, assembly effort, and downtimes.A logistics customer, for example, saved 300 euros annually per forklift by using higher quality brake linings,despite a 15% higher purchase price.
Are there special brake linings for extreme environmental conditions such as dust or chemicals?
Yes, specially adapted brake linings are developed for extreme conditions such as high dust exposure (e.g., cement plants) or chemical influences. The selection of friction material considers factors such as ambient temperature, humidity, and specific contaminations , to ensure a, um eine reliable braking performance. ATEK Drive Solutions offers tailored solutions for this. What are typical signs that industrial brake linings need to be replaced?.
Typical signs include a
decreasing braking effect, unusual noises (squeaking, grinding), longer braking distances, or warnings from wear sensors. Ignoring these signs can lead to. Ein Ignorieren dieser Anzeichen kann zu increased safety risks and costly damages to the entire braking system.
Why is the axle-specific replacement of brake linings important?
The axle-specific replacement of brake linings (that is, always both sides of an axle simultaneously) is crucial for even braking performance and driving stability.Differently worn linings on one axle can lead to uneven braking, vehicle drift, and increased wear. Material selection and precise manufacturing
Die are crucial for their performance and reliability in industrial applications, especially under von brake linings, extreme conditions such as temperatures above 750°C. Effective.
Ein effektives wear management,supported by modern warning systems and compliance with quality standards like ECE-R90, not only ensures safety, but can also extend maintenance intervals by up to 40% and reduce environmental impact.
Considering the Total Cost of Ownership (TCO) instead of the pure purchase price of brake linings, makes economic sense. High-quality linings can significantly lower the annual cost per unit (e.g., €300 per forklift) and reduce repair costs due to avoided consequential damages by a factor of 3-5..Learn how to select the right brake linings for your specific requirements to ensure optimal performance, safety, and longevity of your drive systems.
Choosing the right brake linings is crucial for the performance of your systems. We’ll show you what to consider. Do you need individual advice? Contact our experts now at Contact !
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Material composition and types of brake linings
Diversity of materials and their properties
The choice of materials – metals for heat dissipation, ceramics for stability, organic substances for friction properties – is crucial. The specific material mixture, often consisting of over 20 different substances like in ATE Original brake linings, predominantly determines the friction coefficient, heat resistance, and lifespan of these important braking components. For demanding industrial brakes this is a key aspect of design and material selection.
The manufacturing process: precision for safety
The manufacturing process of brake linings, from mixing raw materials to applying them to the backing plate, can involve over 20 individual steps. Deviations can impair friction values or the structure of the friction materials. This precision, as exemplified by Brembo, ensures consistent quality and reliability, which is required for safe operation under heavy loads in braking systems. Power, wear, and environmental aspects
Leistung, Verschleiß und Umweltaspekte
Performance requirements under extreme conditions
Industrial environments, such as in the steel industry with brake lining temperatures exceeding 750°C in crane systems, impose high material requirements. A stable friction coefficient of up to 800°C is important for predictable braking performance. Modern brake linings for industrial applications must ensure this stable friction coefficient and also be mechanically robust to withstand cracking under load. More about the brake technology can be found here.
- High demands on materials in industrial environments, e.g., temperatures over 750°C.
- Necessity of a stable friction coefficient up to 800°C for reliable braking performance.
- Mechanical robustness to avoid cracking under load.
- Extension of maintenance intervals through optimized brake lining formulations.
- Cost savings and reduction of downtimes through effective wear management.
- Minimizing environmental impact through reduced wear and fine dust from brake pads.
Wear management and environmental aspects
Optimized brake linings, part of comprehensive wear management, can extend maintenance intervals, as tests at ATEK Drive Solutions show by up to 40%. A well-thought-out wear management not only saves the budget through lower downtimes, but also reduces wear and thus environmental impact from fine dust – an important aspect in the selection of brake linings, and other friction materials.Warning systems, legal regulations, and purchasing recommendations
Modern warning systems for brake linings
Proactive alerts for replacing brake linings are common in modern systems. Electric sensors that issue a signal, for example, at 25% remaining lining thickness, allow for planned maintenance and prevent costly consequential damages such as damage to brake discs or drums, as well as unplanned downtimes. Acoustic or visual indicators can complement these.
- Modern warning systems enable proactive alerts for brake lining changes.
- Electric sensors that trigger at around 25% remaining lining thickness facilitate planned maintenance.
- By timely replacing worn linings, costly consequential damages and unplanned downtimes are avoided.
- Acoustic or visual indicators can complement the electric sensors.
- The ECE-R90 standard serves as an important quality indicator for brake linings in the industry.
- This standard defines clear requirements for friction coefficient, strength, and production conformity.
- Reputable manufacturers often exceed these standards through their own, stricter testing procedures for their brake components.
Legal requirements and quality characteristics
The ECE-R90 standard, originally developed for automotive purposes, also serves as an established quality indicator in the industry. It defines requirements for friction coefficient, strength, and production conformity.brake linings Reputable Renommierte like ATEK Drive Solutions often exceed these standards through their own, stricter testing procedures that cover additional application-specific load scenarios to ensure a high safety level for their friction linings. brake manufacturersSpecial applications and adaptations
Adaptation to operating location and conditions
The requirements for brake linings vary greatly, for example, between cement plants (dust exposure) and the pharmaceutical industry (low dust). The selection must consider factors such as ambient temperature, humidity, load cycles – sometimes over 50,000 per year – and chemical influences, for example, from process fluids, in the friction materials. ATEK offers tailored different types of brakes. an.
- Adjustment of brake pads to specific locations and operating conditions (e.g. dust exposure, low-dust environments).
- Consideration of critical factors such as ambient temperature, humidity, and high load cycles (over 50,000/year).
- Consideration of chemical influences from process fluids during the material selection of brake linings.
- Development of special solutions such as low-noise linings for stage technology (sound level reduction >10 dB(A)).
- Customized brake solutions for extreme loads in rail vehicles and wind power plants.
- Use of special materials such as sintered metal for increased temperature and wear resistance of brake pads.
Examples of special solutions in brakes
For special application areas, brake linings developed with special properties, e.g. low-noise linings for stage technology that reduce the sound level by more than 10 dB(A). For rail vehicles or wind power plants, we at ATEK Drive Solutions develop customized solutions that withstand extreme loads and service lives. This is done, for example, through sintered metal (temperature, wear resistance) or special industrial disc brakes, which rely on optimized friction pairings.Costs and changing brake pads
Cost considerations: More than just the purchase price
The cost-effectiveness of brake linings is not only measured by the purchase price. A logistics customer saved 300 euros per forklift annually through more durable linings, despite a 15% higher price. Considering the Total Cost of Ownership (TCO), which also includes maintenance intervals, assembly effort, and downtime, shows that high-quality brake linings, can save costs in the long run.
Signs for replacement and consequences of neglect
Ignoring worn-out brake linings has serious consequences. Initial signs are often diminished braking effect or unusual noises. In addition to performance loss and increased safety risks, significant damage to the brake disc or drum often results if the replacement of brake pads is neglected. Their replacement can increase repair costs by a factor of 3-5, as service experiences show. Also find out about changing brake pads.
