The ultimate guide to correctly adjusting brake motors for maximum efficiency and safety in your industrial applications.
Why is precise adjustment of the brake on the brake motor so important?
A properly adjusted brake ensures maximum safety and efficiency of the drive system. It prevents premature wear, overheating of the motor, and ensures the reliable function of the machine, which is especially critical for precise positioning tasks, as enabled by ATEK servo motors.
What signs indicate that my brake motor brake needs to be readjusted? Typical signs include
squeaking or grinding noises , anoticeable decrease in braking force overheating of the motor, or the brake as well as vibrations. Even if the motor does not stop immediately after switching off, checking and possibly. Auch wenn der Motor nach dem Abschalten nicht sofort stoppt, ist eine Überprüfung und ggf. das readjusting the brake is necessary.
How is the air gap of a spring pressure brake correctly adjusted?
The air gap, usually between 0.2 mm and 0.5 mm, is adjusted when the brake is de-energized and cooled. To do this, mounting or adjustment screws are loosened, the gap is measured with a feeler gauge at several points and the screws are then evenly and often tightened with a defined torque to ensure the correct distance between the anchor disk and the magnetic housing.
Can I adjust the braking force of a brake motor myself?
Yes, for many spring pressure brakes, the braking torque can be adjusted by the number and arrangement of the brake springs. The manufacturer’s specifications (e.g. in the manual section 9) provide information about possible configurations and the resulting torques. A symmetrical spring arrangement is crucial.
What are the consequences of a too large air gap on the brake motor?
An excessively large air gap prevents the electromagnet from fully attracting the anchor disc. The brake does not release properly, drags continuously, leading to increased wear of the linings, overheating of the brake and motor up to damaging the motor insulation and causes reduced braking performance. What tools do I typically need for
Welche Werkzeuge benötige ich typischerweise zum adjusting a brake motor brake??
By default, you will need a set of hex keys, a precise feeler gauge e.g. 0.05 mm to 1 mm, a torque wrench for properly tightening the screws, possibly screw locking agents (e.g. Loctite), and cleaning materials. The exact tools depend on the specific type of brake.
How often should the brake of a brake motor be checked and adjusted?
Inspection intervals depend significantly on the application and the frequency of switching . For critical applications or high switching frequencies (e.g. >100 cycles/hour), monthly checks of the air gap and lining thickness are recommended. Otherwise, checks every 500 operating hours or according to manufacturer’s specifications are often sufficient.
What is meant by over-excitation in brakes and when is it useful?
Over-excitation, often realized by special rectifiers (e.g. Kendrion MSG series), serves to reduce the response time (release time) of the brake.A higher voltage (e.g. double the rated voltage) is temporarily applied to the magnetic coil. This is useful in the case of medium to large brakes or very high switching frequencies, to improve the dynamics of the system.
A precise air gap adjustment e.g. to 0.2-0.5 mm depending on the model, is crucial to ensuring the optimal braking performance, preventing overheating and significantly extending the lifespan of the brake motor, reducing downtime by up to 15%. Regular inspection and proper maintenance, including the correct adjustment of the brake, not only ensure the kann.
Regelmäßige Inspektion und fachgerechte Wartung, inklusive der korrekten Justierung der Bremse, sichern nicht nur die operational safety and reliability, but can also improve energy efficiency by up to 5% and minimize the need for premature readjustment of the motor brake. Understanding the specific adjustment procedures for different types of brakes, such as spring pressure or DC brakes, and adhering to minimieren.
Das Verständnis der spezifischen Einstellverfahren für verschiedene Bremsentypen, wie Federdruck- oder DC-Bremsen, und die Beachtung von manufacturer specifications for torques and spring configurations enable a tailored adjustment and ensure that the brake motor brake is correctly adjusted to achieve maximum performance and safety.Learn how to correctly adjust your brake motors to minimize downtime, extend lifetime, and optimize performance. Avoid costly repairs and increase the efficiency of your plants!
A properly adjusted brake motor is crucial for the safety and efficiency of your plants. But what should you pay attention to? We show you how to avoid typical mistakes and optimally adjust your brake motors. Do you need individual advice? Contact now Contact our experts!
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Understand: The basics of brake motor adjustment
An incorrectly adjusted air gap in brake motors reduces braking performance and can cause motor damage. The correct adjustment of the brake on the brake motor reduces downtime by up to 15%.
Understand how brake motors work
Brake motors, such as those from ATEK for electric motors with brakes, often use spring-based safety brakes that close in case of voltage drop. Wear can lead to continuous braking and overheating. Servo motors stop within milliseconds for precise positioning.
Identify typical brakes in brake motors
Spring pressure brakes slow down mechanically and release electromagnetically; their air gap is critical (often only 0.2 mm). Pneumatic/hydraulic brakes serve special applications with high forces (e.g. >10,000 Nm).
Recognize common problems and their causes
Squeaking or motor overheating are alarm signals. An air gap that is too large (e.g. >0.5 mm) prevents proper release, leading to dragging brakes, lining wear, thermal overload, and significantly reducing lifespan. In such cases, it is often necessary to readjust the brake motor brake.. See also our information on the brake motor.Master: Functionality and types of brake motors
A minimally faulty air gap can cause motor overheating. A correct adjustment of the brake motor brake improves function, energy efficiency (up to 5% savings) and lifespan. Choosing suitable industrial brakes is crucial.
- Fail-safe function: Spring pressure brakes close automatically by spring force in case of power failure.
- Electromagnetic solution: The brake is released by an electromagnet that attracts the anchor disc and frees the rotor (release times often < 50 ms).
- Pneumatic brakes: Ideal for high moments in compact design (e.g. presses >200 kN).
- Hydraulic brakes: Used for the highest braking forces, such as in wind turbines.
- Electric brakes: Suitable for dynamic stops, often as DC short-circuit brakes with braking resistance.
- Problem cause air gap: Lining wear leads to an increase in the air gap, which impairs braking performance and requires a readjustment of the motor brake. Consequences of an incorrect air gap: A dragging brake, heat generation, vibrations, damage to motor insulation, and premature failures can result.
- The functionality of brake motors in detail
Spring pressure brakes, such as those from ATEK Drive Solutions, are fail-safe: closed when de-energized by spring force. An electromagnet releases them by attracting the anchor disc, which frees the brake rotor. Release times are often below 50 ms.
Federdruckbremsen, wie bei ATEK Drive Solutions, sind Fail-Safe: stromlos geschlossen durch Federkraft. Ein Elektromagnet löst sie durch Anziehen der Ankerscheibe, was den Bremsrotor freigibt. Lüftzeiten liegen oft unter 50 ms.
Different types of brakes and their application fields
Pneumatic brakes provide high moments compactly (presses >200 kN). Hydraulic brakes deliver the highest forces (wind power). Electric brakes (DC short-circuit) are suitable for dynamic stops, often with braking resistance. The type selection influences maintenance and performance.
Recognize common problems in brake motors early
Lining wear increases the air gap (e.g. 0.8 mm instead of 0.3 mm). If it is too large, the brake drags, generates heat, vibrations, damages motor insulation, and leads to premature failures. Proper expertise is essential here. A good adjustment of the brake on the brake motor brake design Bremsenauslegung prevents this.Apply: Precisely adjust the brake motor brake – step by step
Minimal deviations in the brake air gap (e.g. 0.15 mm) can cause thermal problems, which is why it is so important to properly adjust the brake motor brake.Exact tolerances (millimeter fractions) are crucial. ATEK Drive Solutions motors require this. Orientation: Product configurator for brakes.
Preparation and essential safety measures
Beforehand: Disconnect and secure the motor from the mains. Allow the brake/motor to cool below 40°C. Insulated tools, protective gloves, and cleanliness are required.
Precisely adjust the air gap in spring pressure brakes: A core aspect of the adjustment of the brake motor brake.
The air gap (typ. 0.2-0.5 mm) is critical. Too large (e.g. 0.7 mm instead of 0.4 mm) reduces magnetic force/release. Measure at least three points with a feeler gauge. Tighten adjustment screws evenly for parallelism, secure locknuts with torque (e.g. 5 Nm). This precision when Adjusting the brake motor brake is essential for optimal function.
Specific adjustment procedures for different brake types
The exact adjustment of the brake on the brake motor depends on the specific type. Procedures vary: Type ‘AC’/’K’: Loosen the fastening nuts, set the gap (e.g. 0.20 mm) with a feeler gauge/adjustment screws, tighten the nuts. ‘S’ brakes: Adjustment is often central. Observe manufacturer specifications (0.1 mm deviation critical).
Adjust braking force through spring equipment
Brake torque is often variable through the number of springs. Symmetrical arrangement is important. Technical documentation (e.g. section 9) shows torques (e.g. 6 springs/10 Nm). Incorrect equipment reduces effectiveness or overloads.Ensure: Effective maintenance and troubleshooting
Uneven lining wear can cause vibrations (e.g. after 2000 h). Regular inspection and maintenance, including correct adjustment of the brake on the brake motor, prevent failures and extend lifespan. Visual inspections and air gap measurements (e.g. every 500 h) are often sufficient. Knowledge of brake technology is useful.
- Adjust inspection intervals: With high switching frequencies (>100 cycles/h) monthly air gap and lining checks should be performed.
- Document measurement values: Collect data such as air gap increase (>0.1 mm) for trend analysis and early detection of wear.
- Fault diagnosis “brake releases poorly”: Check power supply (e.g. correct DC voltage of 24V) and the mechanical freedom of the brake.
- Causes for “brake drags permanently”: Common reasons are a too large air gap requiring a readjustment of the brake motor brake , or fatigued brake springs.
- Identify defective rectifier diode: Symptoms in DC brakes can be buzzing of the magnetic coil or a noticeable loss of braking force.
- Replacement of worn parts: Replace brake pads when minimum thickness is reached (e.g. <2 mm) and use only original spare parts.
- Correct assembly: When replacing components such as brake discs or pads, tighten all screws to the torque specified by the manufacturer (e.g. 25 Nm for M6/8.8).
Regular inspection: The key to reliability
Intervals depend on the application. Critical applications/high switching frequencies (>100 cycles/h): monthly air gap/lining checks. Document measurement values for trend analyses (e.g. gap increase >0.1 mm).
Common errors and their effective resolution
Brake releases poorly: Check voltage (e.g. 20V instead of 24V DC) or mechanism. Drags permanently: Often the air gap is too large, and one must readjust the brake motor brake, or the springs are fatigued. A defective rectifier diode (DC brakes) often causes buzzing/power loss. Check manual release.
Replacement of brake pads and brake discs: When and How
Replace at minimum thickness (e.g. lining <2 mm). Use only original parts. Check coupling (stroke) when replacing rotor. Tighten screws with torque (e.g. 25 Nm for M6/8.8). See Adjusting disc brakes.Optimize: Special cases and advanced brake technologies
For extremely short braking response times (e.g. stage technology), over-excitation is an option that goes beyond mere adjusting the brake motor brake . Such techniques improve performance but require understanding. ATEK Drive Solutions offers expertise and components.
Over-excitation for significant reduction of response time
For medium/large brakes or high switching frequencies (>200 cycles/min), over-excitation (e.g. MSG rectifier) can reduce response time by up to 70%. A short (100-200 ms) double the rated voltage is applied, then reduced to holding voltage.
Professional handling of inductive voltage peaks
Switching off magnetic coils generates high voltage peaks (hundreds of volts) that can damage contacts/electronics. Use DC contactors with suppression devices (varistors, flyback diodes) or AC contactors (AC-3, EN 60947-4-1). Flyback diode limits to approx. 0.7V.
Use MSG rectifier and current measurement optimally
Intelligent rectifiers (e.g. Kendrion MSG 2.480I) use current measurement for optimization. Correctly route motor supply cables through a loop. For low currents (<0.6 A), lead cables multiple times if necessary. Pay attention to rectifier design for motor size.
