Precise brake solutions for mechanical engineering, automation, and more – ATEK Drive Solutions explains the technology and applications
What exactly is meant by a controllable brake and how does it differ from standard brakes?
A controllable brake, often referred to as an adjustable brake , allows the precise and dynamic adjustment of the braking force to specific process requirements. Unlike standard brakes, which usually only provide an on/off function, controllable brakes can vary the braking torque continuously or in fine steps. This is crucial for applications that require constant web tension, gentle deceleration, or exact positioning, such as in unwinding applications, where web tensions of only 0.5 Nm must be maintained constantly, to avoid material tears.
What types of controllable brakes does ATEK Drive Solutions offer and what principles do they operate on?
ATEK Drive Solutions offers a wide range of controllable brakes, including mechanical, pneumatic, hydraulic, and electrical industrial brakes. Special forms such as hysteresis and magnetic powder brakes allow for particularly fine and often wear-free control. The adjustment of the braking torque is carried out depending on the type by mechanical adjustment, variable air pressure (e.g., FNC brake with 45 to 1,100 Nm), or by controlling electromagnetic fields..
In which industrial applications are controllable brakes particularly advantageous?
Controllable brakes are indispensable in numerous industries. In the mechanical and plant engineering , they improve positioning accuracy, which can shorten the cycle time by up to 12% in CNC applications. In the packaging and textile industry , they ensure constant web tension for materials such as films or yarns, significantly reducing the scrap rate (e.g., by 8% at a film manufacturer).. Other areas of application include test benches, stage technology, and robotics.
What criteria should a controllable brake be selected for a specific application?
Selecting the appropriate controllable brake requires a precise definition of the needed torque range (e.g., 0.5 Nm to over 1,000 Nm) and the maximum speed range (e.g., up to 8,000 rpm or higher).. Important are also the actuation type (manual, pneumatic, electric), the environmental conditions (temperature, protection class) , and the need for heat dissipation, especially in heavy-duty applications or high cycle counts. ATEK supports you in this careful analysis.
Can ATEK Drive Solutions also develop custom controllable brakes? Yes, a core competence of ATEK Drive Solutions is the
Ja, eine Kernkompetenz von ATEK Drive Solutions ist die development of custom special solutions, even for controllable brakes. Based on decades of experience and a modular system, we can also implement tailored drive solutions for complex requirements and in small series , which are precisely tailored to your application. How do
Wie tragen controllable brakes contribute to the realization of Industry 4.0 concepts?
Modern controllable brakes are transformed into intelligent components in terms of Industry 4.0 through integrated sensors and digital interfaces (e.g., Profinet). They can collect operating data, proactively report wear, and thereby enable a predictive maintenance . This can increase plant availability by up to 10% and reduce maintenance costs.
What advantages do controllable brakes offer in terms of energy efficiency and sustainability?
The precise control by controllable brakes avoids unnecessary energy consumption due to overshooting or inefficient process flows. Future developments will increasingly focus on energy recovery , in which braking energy is partially fed back into the system. This can reduce the overall energy consumption of a plant by 3-7% Gesamtenergieverbrauch einer Anlage um 3-7 % senken and thus contributes to sustainability.
Controllable brakes enable a precise control of the braking torque, leading to a significant increase in quality and efficiency in industrial processes, such as by reducing the scrap rate by up to 8%..
With their diverse actuation types (mechanical, pneumatic, electromagnetic) and designs like hysteresis or magnetic powder brakes, adjustable brakes are extremely versatile and can shorten cycle times in machines by up to 12%. Zykluszeiten in Maschinen um bis zu 12 % verkürzen.
ATEK Drive Solutions offers not only standard solutions but also highly customized controllable brakes, supported by comprehensive consulting and a modular system to ensure optimal performance and fast delivery times .Discover the world of controllable brakes: From the basics to the latest innovations. Learn how to optimize your plant performance and enhance safety.
Controllable brakes are essential for precise and safe drive systems. They allow for sensitive control and adjustment of the braking force to various requirements. Do you need a custom solution? Contact us at ATEK Drive Solutions, your expert in drive technology.
Do you need a controllable brake tailored exactly to your requirements?
Request a custom solution now!
Introduction to controllable brakes
Precise brake solutions are important for mechanical engineering, automation, and other areas. ATEK Drive Solutions explains the technology and various applications of controllable brakes. These enable optimization of plant performance and enhancement of safety. We are available for individual consulting.
What are controllable brakes actually?
Understanding basic functional principles
The difference from standard brakes
Controllable brakes allows for the exact control of dynamic processes. For example, they maintain web tensions of 0.5 Nm constant in unwinding applications, preventing material tears and ensuring quality. This precision enhances product quality. For more information on the basics here.
Fine adjustment is often made through electromagnetic fields or pneumatics, which continuously adjust the torque. For example, an FNC brake varies its torque with air pressure from 45 to 1,100 Nm to adapt. They adapt dynamically. Discover our electronic braking system.Types and operating principles of controllable brakes
Mechanical, pneumatic, and electrical regulation
Specialists in detail: Hysteresis and magnetic powder brakes
The distinction in adjustable brakes is made according to actuation: mechanical, pneumatic, hydraulic, electromagnetic. For example, pneumatic brakes offer proportional torque control up to 1,100 Nm for variable loads. The actuation depends on the application. See our torque-adjustable spring brake.
Hysteresis or magnetic powder brakes, as special forms, often operate wear-free and are therefore low maintenance. For example, the PMB-2 hysteresis brake delivers 0-2 Nm, independent of speed, for precise tasks. of controllable brakes, arbeiten oft verschleißfrei und sind daher wartungsarm. Beispielsweise liefert die PMB-2 Hysteresebremse 0-2 Nm, drehzahlunabhängig, für präzise Aufgaben. They are suitable for precision regulations. For smallest applications, there is the micro-adjustable brake.Applications of controllable brakes in the industry
Mechanical engineering: Precision and repeat accuracy
Packaging industry: Ensuring constant web tension
Further areas of application: From the stage to the test bench
In mechanical engineering, controllable brakes they improve positioning accuracy. For example, an electromagnetic brake reduced the cycle time by 12% in CNC applications with ±0.01 mm accuracy. This increases efficiency. Discover solutions for Disc brake adjustment.
- Improvement of positioning accuracy in mechanical engineering applications.
- Potential to reduce cycle times, e.g., by 12% in CNC machines.
- Achieving high accuracy, for example of ±0.01 mm.
- Increasing production efficiency through precise braking actions.
- Optimization of CNC applications through the use of of controllable brakes.
- Ensuring high repeat accuracy in dynamic processes.
Adjustable brake solutions are also important in packaging or the textile industry, as they maintain constant web tensions, e.g., for films. This reduced the scrap rate by 8% at a film manufacturer. They protect materials and optimize processes. For tension control, the Sie schützen Materialien und optimieren Prozesse. Für Spannsteuerungen eignet sich die hydraulically controlled torque brake.Selection criteria for controllable brakes
Define torque range and speed range
Consider actuation type and environmental conditions
Don’t forget heat dissipation
Define the torque range, e.g., 10-100 Nm, and the maximum speed for your application when selecting a controllable brake . For example, a test application with 8,000 rpm requires a specific brake. This base data is crucial. Learn more about digitally controlled brakes.
- Define the required torque range (e.g., 10-100 Nm).
- Determine the maximum speed of your application.
- Consider specific requirements, such as high speeds (e.g., 8,000 rpm for test applications).
- Recognize this base data as crucial for the correct selection of a controllable brake..
- Ensure that the brake is designed for the specific requirements profile.
- A precise definition of these parameters prevents misjudgments and optimizes performance.
Consider actuation, environment, and heat dissipation when selecting your variable brake. Consider manual adjustment or Profinet connection. For example, air-cooled brakes are suitable for heavy-duty applications, which can increase the lifespan by 30%. Careful analysis ensures functionality. For continuous operation, the maintenance-free brake.Advantages and disadvantages of controllable brakes
The advantages at a glance
Possible challenges and solutions
Controllable brakes enable precise adjustment of braking force to variable process requirements. A customer reduced downtime by 20% through their use. This increases quality and efficiency. Discover our controllable braking solutions.
Higher initial costs and more complex controls are potential challenges with brakes with control. The integration of a digitally controlled brake, for example, requires effort. ATEK supports you for long-term benefits. More about electronic braking systems.Future perspectives and technological developments
Integration into Industry 4.0
Further development of control technology and energy efficiency
Sensors and digital interfaces make controllable brakes intelligent Industry 4.0 components. Such a brake proactively reports wear, which can increase availability by 10%. Predictive maintenance is becoming standard. Die digitally controlled brake shows this.
Future adjustable brakes will be more economical and utilize energy recovery for increased efficiency. Brake energy can be fed back, reducing total consumption by 3-7%. Sustainability is the focus. Discover maintenance-free options.
Controllable brakes are precision instruments for process optimization. ATEK Drive Solutions provides corresponding, also customized solutions as a system provider. For efficiency enhancement, you can configure your brake or contact us for consultation.
