Discover the advantages of active lever brakes for demanding industrial applications – from flexible configurations to customized solutions.
What is an active lever brake and its main advantage for industrial applications?
An active lever brake is powered externally, for example, pneumatically or hydraulically, to achieve a braking effect. Its main advantage lies in its function as operating brake for precise control and dynamic braking processes in industrial machines, unlike passive safety brakes, which are usually spring-actuated.
How do I benefit from ATEK’s modular system for active lever brakes?
ATEK’s modular system allows millions of configurations for active lever brakes. You receive a solution tailored exactly to your needs regarding actuation type, braking force, and size, often with short delivery times thanks to a large inventory of approximately 400,000-500,000 individual parts.
For which industrial applications are ATEK’s active lever brakes particularly suited?
ATEK’s active lever brakes are ideal for machine and plant construction, the packaging industry, logistics systems where, for example, they can increase the throughput of rack handling devices by up to 15%, stage technology and all applications that require dynamic motion control and precise, repeatable stopping are required.
What are the main differences between active and passive lever brakes?
The main difference lies in the activation: Active lever brakes require an external power source (e.g., compressed air, hydraulic pressure) for brake actuation and are mainly used as operating brakes. Passive brakes, on the other hand, often work through spring force (stored energy) and are used as safety or holding brakes (fail-safe principle).
Can ATEK develop customized active lever brakes for specific requirements?
Yes, ATEK Drive Solutions specializes in developing customized special solutions for active lever brakes, even in small series. Based on a thorough analysis of your application requirements, our engineers design the optimally fitting and economical braking solution.
What maintenance aspects are critical for active lever brakes, especially with the ABR system?
In addition to regularly checking brake pad wear (recommended minimum thickness often 2 mm) and the tightness of pneumatic/hydraulic components, at the Active Caliper Reset (ABR) the replacement of the ABR springs is mandatory with every brake pad change. This ensures the function of the pad retraction, minimizes residual drag, and prevents noise development.
How do active lever brakes contribute to increased operational efficiency?
Through their fast response times and the ability to precisely control braking forces active lever brakes enable optimized and faster machine cycles. In logistics, for example, this can increase the material handling by up to 15%. Future systems also aim for energy savings of around 5% through optimized braking cycles.
What future trends are emerging in the development of active lever brakes?
A clear trend is towards electromechanical systems, which offer improved control, diagnostic capabilities, and energy efficiency (expected forces > 400 kN). Other important developments include the integration of sensors for intelligent braking functions, the use of lightweight materials (composite materials, aluminum) and a strong focus on sustainability by minimizing energy consumption and maximizing lifespan.
Active lever brakes are externally powered (e.g., pneumatically, hydraulically, electromechanically) and serve as dynamic operating brakes for precise control and reliable deceleration in various industrial applications, unlike passive safety systems.
ATEK Drive Solutions provides highly customizable active lever brakes through a modular system that allows for millions of configurations and rapid delivery times; customized solutions can increase the machine efficiency, e.g., in logistics, by up to 15%.
Proper maintenance, particularly the regular replacement of ABR springs with each pad change, is crucial for longevity and optimal performance. Future trends focus on energy-efficient electromechanical systems and intelligent integration that can reduce energy consumption by about 5% .Learn all about active lever brakes: functionality, application areas, benefits, and how ATEK Drive Solutions supports you with innovative solutions.
Are you looking for a reliable and powerful braking solution for your industrial application? Active lever brakes offer precision and control. Contact us at ATEK Drive Solutions, to find the optimal solution for your requirements.
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Introduction to active lever brakes
What distinguishes a active lever brake?
Active lever brakes: external activation (manual, pneumatic, etc.) for precision, unlike passive. Controlled activation in normal operation, not emergency stop. Example: packaging machines. Understand industrial brakes.
Core functions and initial application examples
These energy-actuated lever brakes control movements, brake reliably. Main function: deceleration, holding. Machine tools: precise positioning. ATEK systems: up to 340,000 N. different brake types.
Distinction from passive brake systems
Application determines choice. Passive (spring pressure): fail-safe safety brakes. Active brake systems with leverage: operating brakes. Main purpose: dynamic motion control. Rietschoten Elephant Brake: operating brake for machine cycles. Passive: safety brakes in elevators.Functionality and application areas Active lever brakes
Variety of actuation types
Actuation: manual, pneumatic, hydraulic, electromechanical. Pneumatics (KTR): up to 31 kN; hydraulics (EB): up to 340,000 N. Choice based on force, infrastructure. Electromechanical (floating caliper): up to 380 kN.
- Active lever brakes can be manually, pneumatically, hydraulically, or electromechanically actuated, depending on the force requirements and infrastructure.
- The performance varies depending on the actuation type: Pneumatics (e.g., KTR) up to 31 kN, hydraulics (e.g., EB) up to 340,000 N, and electromechanical systems (e.g., floating caliper) up to 380 kN.
- They find wide application in the industry, including in machine construction, packaging systems, stage technology, and logistics for precise positioning and response.
- A specific example in logistics is stopping rack handling devices, which can increase throughput by up to 15%.
- Als dynamic lever brakes control motion sequences and allow for precise braking maneuvers.
- The design must take critical factors such as heat generation and wear into account, as is evident in wind turbines, where actively actuated brakes are used for the rotor blade and passive as safety systems.
Typical areas of application in the industry
Use: machine construction, packaging, stage. Precision for positioning, response. Logistics: stopping rack handling devices, handling +15%. Solutions for industrial brakes.
The role as a dynamic operating brake
Such operating brakes control dynamics, allow for precise braking. Design: heat, wear. Wind power: active braking mechanisms for the rotor blade, passive as safety. different lever brakes.Technical aspects and design of Active lever brakes
Modularity as the key to flexibility
ATEK’s modular system: adaptation (actuation, calipers, disc), millions of configurations. Modularity: variety, quick delivery (inventory: 500,000 parts). Special solutions.
Performance characteristics for demanding tasks
Fast response for dynamics. Rietschoten Elephant Brakes without servo: consistent, direction-independent performance. Advantage: reversing drives (textiles, up to 40,000 N). Basics of brake technology.
Materials and design details
Stable caliper design, even pressure for durability. Materials, manufacturing for reliability. Electromechanical floating caliper brakes: housing alloys for 380 kN.
Custom adaptations even for small series
ATEK: tailored active lever brakes, small series (design, force, integration). Analysis, construction of optimal solutions. Example: RH 200 theater (assembly, quiet pneumatics).
Active lever brakes in comparison to other brake systems
Active versus passive brakes: application scenarios decide
Purpose decides: The active lever brake as an operating brake (external energy). Passive (spring pressure) as safety brakes. Function: operation (active) vs. emergency (passive). Elevators: passive emergency brake, active control.
Distinction from pneumatic and hydraulic systems
Actively actuated brakes: often pneumatically (KTR, up to 31 kN), hydraulically (ATEK EB, up to 340,000 N). Also manually, electromechanically. Choice: force, environment, energy. various actuation types of lever brakes.
The space alongside electrodynamic brakes
Electrodynamic brakes: energy recovery, often without holding function. Active lever brakes provide redundancy and a safe holding function here. Trams: complement for emergency braking force (HYA, up to 56 kN).Maintenance and servicing of Active lever brakes
The importance of regular inspections
Regular inspections for functionality. Check wear of pads, pneumatic/hydraulic components. Visual inspection: Leakages/Damages. Thickness of pads (min. 2 mm).
- Regular inspections are essential to ensure the long-term function of these brake systems with lever action ; in this context, wear of pads (minimum thickness 2 mm) and pneumatic/hydraulic components must be checked.
- Conduct visual inspections for leakages and damages to identify potential problems early.
- The Active Caliper Reset (ABR) system, which supports the retraction of the pads with springs and minimizes residual drag, requires special attention.
- Replace the ABR springs at every pad change, as used springs can impair performance and cause noise.
- Ensure correct component positioning, particularly of the ABR pad ears, as incorrect assembly can affect the reset function.
- Strictly follow the manufacturer’s specifications for assembly and adjustment, including torque settings, to avoid uneven fastening and increased wear.
Special case: Active Caliper Reset (ABR)
ABR: Springs for pad retraction, minimizes residual drag. Critical: Replace ABR springs when changing pads. Used springs are unsuitable (wear, noise). Important for performance.
Correct assembly and adjustment
Correct component positioning (ABR pad ears) is crucial. Incorrect assembly: reset function impaired. Manufacturer specifications/Torque settings. Uneven fastening: wear. ATEK: instructions Brake manufacturers.Future developments and trends in active lever brakes
The advance of electromechanical systems
Trend: electromechanical brakes (controllability, integration). Goal: efficiency, less energy (actuators). Expected: forces >400 kN.
Intelligent integration and material innovation
Sensor integration, control for dynamic performance. Material: Lightweight construction (composite, aluminum) reduces mass. Wear-resistant parts: durability, less maintenance, costs -10%.
Focus on sustainability and energy efficiency
Focus: minimize energy, maximize lifespan. ABR: less residual drag, saves energy. Energy recovery. Optimized cycles: energy -5%.
