Safe, precise, and efficient: The key component for modern material flow systems
What exactly are dynamic holding brakes and why are they so important for material flow systems?
Dynamic holding brakes are designed to stop moving loads precisely and hold them safely in position. In material flow systems, they are crucial for process safety, exact positioning (e.g., <0.5 mm deviation), and the efficiency of automated processes, as optimized by ATEK Drive Solutions for your applications.
What are the main types of dynamic holding brakes and where are they typically used?
The main types include electromagnetic brakes (permanent magnet and spring-applied brakes), pneumatic and hydraulic brakes. Electromagnetic brakes are suitable for precise applications such as robotics and servomotors, while pneumatic and hydraulic brakes are often used in heavy-duty areas such as conveyor systems and cranes .
How does electronic control improve the performance of dynamic holding brakes?
Electronic control allows for precise adjustment of braking force, significantly optimizing response times (e.g., by up to 50% through overexcitation) and can reduce energy consumption by features such as voltage reduction during holding operation . This increases the overall efficiency of the system.. Dies steigert die Gesamteffizienz des Systems.
For which specific applications in material flow are dynamic holding brakes especially critical?
They are especially critical for Autonomous Mobile Robots (AMRs) for exact positioning, in conveyor technology (e.g., electric overhead conveyors) for safe stops, in automated warehouse and picking systems for high throughput and in explosion-proof areas, where special brakes are required.
What are the main criteria for selecting the right dynamic holding brake?
Important criteria include the specific load cases (maximum/minimum load), required operating modes (holding, lifting, accelerating), the required braking torque, environmental conditions, and safety requirements. Accurate design, as provided by ATEK, is crucial for optimal performance and durability.
How do you deal with challenges like torque peaks and dead times in dynamic holding brakes?
Torque peaks can be reduced by minimizing play in the drive train and gradually applying the braking torque . Dead times are minimized by fast-switching brakes and optimized electronic controls (e.g., with overexcitation), improving responsiveness., was die Reaktionsschnelligkeit verbessert.
Can dynamic holding brakes contribute to the energy efficiency of material flow systems?
Yes, modern dynamic holding brakes, especially when combined with intelligent controls, can contribute to energy efficiency. For example, through voltage reduction during holding operation or through regenerative systems, which can recover braking energy and thus reduce the overall energy consumption by up to 20%. Why is redundancy often necessary in dynamic holding brakes in automated material flow systems?
Warum ist Redundanz bei dynamischen Haltebremsen in automatisierten Materialflusssystemen oft notwendig?
Redundancy, e.g., through the use of two independent brake systems per axis or fail-safe mechanisms, is crucial in highly automated systems for failure safety and the protection of personnel and materials. It ensures that loads can be held safely even in the event of a component failure.
Dynamic holding brakes are essential for precision and safety in material flow systems. They enable exact positioning of loads with deviations often under 0.5 mm and can improve positioning accuracy in assembly lines by up to 15%. Positioniergenauigkeit in Montagelinien um bis zu 15% verbessern.
Die Correct selection and integration of the brake, tailored to load cases and operating modes, is crucial. Modern electronic controls optimize response times by up to 50% and increase the efficiency of the dynamic holding brakes..
Challenges such as torque peaks and dead times can be minimized through constructive measures and intelligent control . Additionally, energy-efficient brakes and regenerative systems can reduce the energy consumption by up to 20%, which reduces operational costs. Learn how dynamic holding brakes optimize your material flow processes and increase safety. Discover the latest technologies and application areas!
In the dynamic world of material flow systems, precision and safety are crucial. Dynamic holding brakes play a key role here. Want to optimize your processes? Contact us at.
Erfahren Sie, wie dynamische Haltebremsen Ihre Materialflussprozesse optimieren und die Sicherheit erhöhen. Entdecken Sie die neuesten Technologien und Anwendungsbereiche!
In der dynamischen Welt der Materialflusssysteme sind Präzision und Sicherheit entscheidend. Dynamische Haltebremsen spielen hier eine Schlüsselrolle. Sie möchten Ihre Prozesse optimieren? Kontaktieren Sie uns unter our experts for personalized consulting.
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Introduction to dynamic holding brakes for material flow systems
Dynamic holding brakes in material flow
Modern material flow systems require precision and safety. Dynamic holding brakes are key components for process optimization and increasing plant safety, which is highlighted here.
Dynamic holding brakes stop conveyors with millimeter precision, even under full load, and serve precise process control. They stop and hold loads in a controlled and exact manner, which is crucial in automated environments with robots and AGVs. This can improve positioning accuracy in assembly lines by 15%. Correct design of these brakes for material flow systems is system-relevant. See safety brakes..
Their core function is the control of moving masses by converting kinetic energy. Unlike service brakes, they reliably hold positions. In the packaging industry, they position products with <0.5 mm deviation, ensuring quality and throughput. The design, e.g., for modular brake-gearing units, is application-specific for each dynamic holding brake in the material flow system..Functionality and types of dynamic holding brakes
What is a dynamic brake?
Dynamic brakes convert kinetic energy (mostly into heat) to slow down or stop movements and hold loads safely. They enable defined stopping and holding. A servomotor with such a brake positions loads of >500 kg precisely. Kollmorgen Webhelp describes this as energy conversion. These dynamic brake systems for material flow are therefore fundamental.
Types of dynamic holding brakes
Electromagnetic brakes (permanent magnet, spring-applied) offer precise action for fast cycles (robotics, servomotors). Pneumatic brakes are robust for heavy-duty; hydraulic brakes provide high performance for cranes. The selection of the respective dynamic holding brake, e.g., industrial disc brake, is crucial for the requirements in the material flow system..
The role of electronic control
Electronic controls are essential for the full potential. They adjust braking force and optimize response times (e.g., -50% through overexcitation). Voltage reduction during holding operation saves energy. A well-thought-out electronic brake system increases the efficiency of the holding brakes in material flow systems..Application areas in material flow systems
AMR integration (Autonomous Mobile Robots)
For AMRs, dynamic holding brakes are key elements for safety and precision. They enable exact stopping/positioning (e.g., electronic components <1 mm tolerance), minimize losses, and ensure delivery (4R principle). A space-saving saddle brake is often a suitable dynamic holding brake for such material flow systems..
- Ensuring precision and safety in Autonomous Mobile Robots (AMR).
- Enabling exact positioning (<1 mm) in AMR navigation.
- Ensuring reliable material flow in conveyor technology.
- Preventing uncontrolled movements, even in power failures.
- Optimizing throughput in automated warehouse and picking systems.
- Ensuring timely and accurate material supply.
Conveyor technology
In conveyor technology (electric overhead conveyors, belt conveyors), they ensure reliable material flow. They enable precise stopping at transfer points and prevent uncontrolled movements, even in power failure. Stacking devices equipped with appropriate precision brakes for conveyor systems, position tons loads with centimeter precision.
Warehouse and picking systems
Dynamic holding brakes for material flow systems optimize material flow in automated warehouses. Materials are available on time and with precise positioning. In automated small part warehouses, they enable >200 in/out operations/hour/aisle through precise positioning of shuttles/stacking devices, which increases throughput and reduces errors.Selection criteria and system integration
Load cases and operating modes
The selection of a dynamic holding brake for material flow systems depends on load cases (maximum/minimum load) and operating modes. Holding, lifting, lowering, accelerating, decelerating require different braking performances/thermal behaviors. A crane (10t load) needs different brakes compared to when unloaded. See holding brake for shaft..
Torque considerations
The braking torque consists of the static load torque and torques to decelerate rotating/translational masses. These components vary depending on the load case. In an emergency stop (conveyor, 500kg), the dynamic holding brake must hold the load and absorb kinetic energy.
Safety aspects and redundancy
Fail-safe is central in highly automated systems. Redundant brake systems (e.g., two independent brakes/axis) and fail-safe mechanisms are often essential, especially for dynamic holding brakes in demanding material flow systems. Ein redundant brake system secures loads in the event of component failure (e.g., SIL 3 in stage technology).Challenges and solutions
Minimizing dead times
Dead times impair braking performance and safety, especially in dynamic holding brakes for material handling systems. Short reaction times and optimized control are important. Quick-switch rectifiers/excitation modules reduce response times (>30%), saving milliseconds. An optimized electric motor with brake is crucial.
- Optimization of control to minimize dead times and improve response speed.
- Implementation of techniques to reduce harmful torque spikes during emergency braking.
- Application of measures such as play minimization and gradual torque application.
- Integration of energy recovery systems to enhance overall efficiency.
- Use of servo amplifiers that feed generated energy back into the grid.
Reduction of torque spikes
Torque spikes during emergency stops (2.5-7x static load torque) jeopardize the lifespan of the gear boxes. Measures: play minimization, gradual torque application (DIN EN 13001-2), and increased damping are important for the longevity of the dynamic holding brake.
Consideration of energy recovery
Energy recovery improves system efficiency. Servo amplifiers/frequency converters feed generated energy back into the grid (instead of dissipating as heat). This reduces energy consumption (up to 20%). An energy-efficient electromagnetic disc brake is an example of such holding brakes in modern material handling systems.Conclusion and outlook
Dynamic holding brakes are essential for high-performance, safe material flow systems. Correct selection and integration increase efficiency and flexibility. They enable the precision of modern automation. Future developments in the area of dynamic holding brakes for material handling systems aim for smarter brakes (sensors, AI maintenance). ATEK Drive Solutions advises on tailored solutions.
