Innovative solutions for reliable locking functions in industrial applications – from heavy industry to robotics.
What distinguishes a locking unit from a standard service brake?
A locking unit primarily serves the safe holding of static loads and locking, often shape-locking and fail-safe, to prevent load drop during power failure. Standard service brakes, on the other hand, are designed for the dynamic deceleration of movements and usually work friction-locking.
What types of locking units are there and where are they typically used?
There are spring-actuated, hydraulic, and electric locking units. Spring-actuated systems (e.g. RINGSPANN KEFH) are ideal for fail-safe applications in mechanical engineering and stage technology. Hydraulic systems offer high holding forces for heavy-duty applications, while electric systems enable precise control in robotics and machine tools.
What does “fail-safe” mean in spring-actuated locking units?
“Fail-safe” means that the locking unit automatically transitions to a safe, locked state during a power or control failure. This is usually achieved through preloaded springs that generate braking force without external power supply, thus ensuring maximum system safety. .
Can locking units be customized to specific industrial requirements?
Ja, Locking units can be highly customized. ATEK Drive Solutions specializes in the development of custom solutions that are tailored to holding forces, sizes, environmental conditions, and connections of your application, even for small series.
What advantages does a system supplier like ATEK offer for braking systems with locking units?
As a system supplier, ATEK provides complete drive trains (gear boxes, brake with locking unit, motor) from a single source. This reduces your interface complexity, shortens engineering times, and ensures an optimally coordinated overall solution based on decades of experience.
How do I choose the right locking unit for my application?
The selection depends on factors such as load requirements, environmental conditions, required holding accuracy, and integration into your control system. A precise analysis of these parameters is crucial. ATEK provides comprehensive technical consulting, to find the optimal solution for your specific needs.
Are locking units maintenance-intensive?
Many modern locking units, especially closed systems like some RST units or well-designed spring-actuated brakes, are low-maintenance or even maintenance-free designed. This contributes to the reduction of total operating costs (TCO). However, maintenance requirements depend on the type and operating conditions.
In which industries are braking systems with locking units particularly important?
They are indispensable in numerous sectors, including mechanical and plant engineering, robotics and automation, packaging industry, conveyor technology, medical technology, renewable energies (e.g. wind turbines) and vehicle technology, where precise positioning and the safe holding of loads are critical.
Braking systems with locking units are crucial for system safety and process accuracy in the industry, as they reliably hold loads in static positions and prevent unwanted movements even during power failure..
ATEK Drive Solutions offers integrated drive solutions including locking units. Through modular systems and custom development, engineering times can be shortened by up to können Engineering-Zeiten um bis zu 20% and the system performance increased by 10-15% .
The correct selection of a locking unit, based on load, environment, and integration, ensures optimal safety and efficiency. This can extend the system lifespan to over 25,000 operating hours and significantly reduce the total operating costs (TCO)..Discover the world of braking systems with locking units: operation, application areas, and the benefits of ATEK solutions for your individual requirements.
Braking systems with locking units are essential for safety and precision in numerous applications. Are you looking for a reliable solution for your specific requirements? Contact us at ATEK Drive Solutions for personalized advice.
Do you need a customized locking unit for your application?
Request a custom solution now!
Understanding the basics: What are braking systems with locking units?
Define and clarify the core function
Braking systems with locking units secure loads, e.g. on lifting devices, during power failure. Unlike primarily decelerating service brakes, they reliably secure static positions. In vertical drives, these locking systems prevent load drop, require highest holding accuracy and increase system safety.
Clarify the distinction to standard brakes
In contrast to standard industrial brakes (often friction-locking), locking units usually work shape-locking or with high holding forces through spring reserves. This guarantees firm locking without slip, for example, with rotor positions in wind turbines, where minimal movements can cause damage. Our safety brakes offer solutions.
Highlight the importance in the industry
In industrial applications, precision and safety are crucial. Exact positioning is a prerequisite for process steps in robotics or machine tools (e.g. ABB, repeat accuracy up to 0.01 mm). This optimizes cycle times, ensures quality, and reduces scrap, thereby increasing availability. Such holding brakes with blocking function are essential here.Decipher the functionalities: Technologies behind the locking
Spring-actuated locking units analyze
Spring-actuated locking units units (e.g., RINGSPANN KEFH) use preloaded springs. In case of power failure or control signal, springs act directly on the mechanism for immediate, safe locking (fail-safe principle). This is required, for example, in stage technology (loads >500 kg), where reliable holding brakes are needed.
- Spring-actuated units: Use preloaded springs and work according to the fail-safe principle, important for example in stage technology.
- Hydraulic systems: Known for generating very high holding forces, used for example in excavator arms.
- Electric systems: Stand out for precise control options and easy digital integration, relevant for machine tools.
- Innovative selective mechanisms: Allow locking only in precisely defined positions, minimizing friction and wear.
- Innovative bistable systems: Hold locking or unlocking states without a continuous power supply, thus improving energy efficiency, e.g. in electric car parking brakes.
Compare hydraulic and electric systems
Hydraulic systems (e.g. for excavator arms) generate high holding forces. Electric units offer precise control and simple digital integration. Machine tools use electric brakes with locking function for split-second, position-precise spindle locking. These positioning brakes are crucial for accuracy. Learn more about industrial brakes.
Innovative approaches: Showcasing selective and bistable mechanisms
Innovative concepts enable non-permanent locking. Selective mechanisms (e.g. aviation patents) lock only in defined positions, minimizing friction/wear. Bistable systems hold states (locked/unlocked) without continuous power, improving energy efficiency of electric car parking brakes by up to 15%. Such advanced locking mechanisms are forward-looking.Analyze application areas: Where locking units are indispensable
Mechanical engineering and automation shape
In mechanical engineering/automation, locking units they secure exact positioning of robotic arms, prevent collisions/production errors. Packaging machines precisely stop films, shortening cycle times (up to 10%). Integration into electronic braking systems is often standard, where the Braking systems with locking units play a key role.
Secure vehicle and conveyor technology
In vehicle technology (e.g. forklifts on inclines), integrated units in gearboxes/parking brakes prevent rollback. In conveyor technology (e.g. belt systems), these safety brakes prevent belt runback, protecting materials/systems.
Special applications: Mastering energy and aviation
In energy generation/aviation (fixing wind turbine gondolas, locking aircraft landing gear), highly reliable and often redundant locking systems are crucial. They withstand extreme conditions/loads. Propeller shaft locking systems (shipping) absorb torques of several kNm. ATEK offers sophisticated braking systems.Define selection criteria: Finding the right locking unit
Evaluate load, environment, and integration
Requirements vary (food production: hygienic design, IP69K vs. steel mill). An analysis of load profile, environment, and integration into control technology is essential for selecting the right locking unit. ATEK considers this for system lifetimes of often >25,000 operating hours.
- Evaluate load, environment, and integration: Analyze load profile, environmental conditions (e.g., hygienic design, IP69K), and integration into control technology.
- Consideration of system lifespan: Planning for long operating times, often over 25,000 hours.
- Prioritization of safety aspects: Use of fail-safe mechanisms in the event of a power or control failure in brake systems with locking function.
- Optimization of maintenance effort: Selecting low-maintenance or maintenance-free designs to reduce total operating costs (TCO).
- Utilization of expert consulting: Seeking expertise to select the most suitable and economical solution in complex drive trains.
Optimize safety aspects and maintenance
Fail-safe mechanisms (e.g. spring-actuated, without external power) are often required for locking systems during power/control line failure. Additionally, low-maintenance/maintenance-free designs (e.g. RST ML locking units for bicycle suspension forks as closed cartridges) help reduce TCO.
The human factor: Utilize consulting and expertise
Technical complexity in the drive train often requires expert advice. Informed consulting by specialists is key to finding the optimal, economical solution, especially when selecting braking systems with locking units.ATEK offers this with experience in gearbox construction/drive technology, e.g. for locking systems for propeller shafts..Find the right system solution for locking tasks with ATEK.
Understanding the ATEK system approach
Complete drive systems (gear boxes, brake with locking unit, motor) from a single source reduce user complexity. ATEK Drive Solutions GmbH provides integrated solutions as a system provider, shortens engineering times (by up to 20%) and accelerates commissioning. These holding brakes are an integral part.
Exploiting modularity and customer specifications
ATEK’s modular systems and development expertise meet specific requirements (holding force, size, interface) for Braking systems with locking units. Custom systems are thus created, including for small series. Flexibility enables tailored solutions (from robotics to heavy industry) with performance enhancement (10-15% vs. standard).
Ensuring quality and cost-effectiveness
Optimized manufacturing, large inventory (~0.5 million parts) and technical expertise ensure quality/cost-effectiveness of our holding brakes with blocking function. This enables fast delivery and good value for money. Customers benefit from reliable components and lower total operating costs.
