Discover the advantages, functionalities, and areas of application of electric brakes for your industrial applications.
What are the main advantages of electric brakes for industrial applications?
Electric brakes offer increased safety through redundancy and integration with systems such as ESP/ABS, more precise control for demanding processes, reduced maintenance effort compared to hydraulic/mechanical systems and the potential for energy recovery (regeneration).
How do electric brakes contribute to energy efficiency in industrial machines?
Primarily through regeneration: Electromotive brakes can convert kinetic energy during braking into electrical energy and feed it back or store it. This can significantly reduce the overall energy consumption of a facility, as examples from rail transport (up to 8% energy recovery) show.
Are electric brakes suitable for harsh industrial environments?
Yes, there are electric brakes specifically designed for industry, which are robust and designed for demanding conditions. Encapsulated actuators protect against environmental influences. ATEK Drive Solutions, for example, offers electric industrial brakes tailored to specific requirements.
What role does ATEK Drive Solutions play in implementing electric brake solutions?
ATEK Drive Solutions is a system provider for the entire industrial drive train. We combine decades of experience with new expertise to develop and integrate customized electric brake solutions , often as part of a comprehensive drive concept with gear boxes and motors.
Can electric brakes be integrated into existing industrial control systems?
Yes, a key advantage of electric brakes is their good integrability into digital control systems via standard interfaces. This allows for precise control and the realization of complex automated braking processes in robotics, automation, and mechanical engineering.
What is the difference between an electric parking brake (EFB) from the automotive sector and industrial electric brakes?
Die EFB in passenger cars primarily serves to hold the vehicle. Industrial electric brakes are often designed for dynamic braking operations, holding functions under load, and a higher cycle strength in production processes. They must meet specific industrial standards and can apply significantly higher braking torques .
What is the maintenance effort of industrial electric brakes compared to traditional systems?
Electric brakes tend to have a lower maintenance effort. Components such as hydraulic fluids or cables that wear out or need maintenance are eliminated. In Brake-by-Wire systems, even the brake fluid change is completely eliminated, which reduces downtime and costs..
What are the core advantages of “Brake-by-Wire” systems for industry?
Brake-by-Wire systems completely replace hydraulic components with electric actuators. This leads to shorter reaction times, potentially shorter stopping distances (in the automotive sector up to 9 meters from 100 km/h), reduced weight and maintenance effort (no brake fluid) and a simplified system architecture.
Electric brakes revolutionize industrial applications through superior precision, faster response times and the possibility of energy recovery (regeneration), which can increase energy efficiency in rail transport by up to 8%. The integration
Die Integration of electric brake systems with safety features like ABS/ESP and the development towards Brake-by-Wire technologies promise significant safety improvements, such as up to 9 meters shorter stopping distances, and a reduced maintenance effort.
For manufacturing companies, electric brakes offer , especially customized solutions from system providers like ATEK Drive Solutions,optimized drive trains. This leads tohigher productivity through more precise control lower operating costs und thanks to dank reduced wear and maintenance effort..Learn all about electric brakes: from the various designs to their integration into modern drive systems to the advantages for your company.
Electric brakes are a crucial factor for efficiency and safety in modern drive systems. Do you want to know how you can benefit from this technology? Contact us at ATEK Drive Solutions for a personalized consultation!
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Introduction to the world of electric brakes.
Electric brake systems: Potentials for industrial drive trains
Electric brake systems optimize industrial applications. This article explains technology, advantages, and potentials.
Die electric brake, once a niche technology, is now standard, such as the millions of installed electric parking brakes in vehicles. Its potential is increasingly affecting industrial sectors, from the automotive industry to heavy industrial brakes and drive technology. Electric systems replace or complement mechanical/hydraulic components for deceleration/holding, in response to demands for safety, efficiency, and automation. ESP integration improves vehicle control and reduces accident rates. The precision of electric control opens new possibilities beyond traditional systems in the field of braking technology.
Die electric brake is established in automobiles to trains; functionality, benefits, and challenges are highlighted.
Progressive digitalization and electrification drive the proliferation. The easy integration into overarching control systems is an advantage, which enables precise braking operations in robotics and automation.Functionality and types of electric brakes
Electromotors (actuators), often with gear boxes, replace cables/hydraulic pressure and press brake pads precisely against the brake disc (full force in about 150ms). Speed/precision are crucial for safety functions. Relevant: energy-efficient electromagnetic disc brake (servo drives).
- Actuators (electric motors with gear boxes) replace traditional braking mechanisms such as cables or hydraulics.
- They enable precise and rapid control of the brake pads (full force in about 150ms).
- Electromotive brakes in trains and electric vehicles use the traction motor in generator operation for regeneration.
- Regeneration converts kinetic energy into electrical energy and increases energy efficiency.
- Important types include the electric parking brake (EFB), regenerative brakes, and friction brakes.
- Challenges in developing actuators include miniaturization while simultaneously developing high force.
Die electromotive brake (trains, electric vehicles) switches traction motors to generator operation (regeneration). Deutsche Bahn gained 820 GWh (about 8% of its electricity demand) this way in 2009. Regeneration increases energy efficiency. The friction brake (heat dissipation) serves as a backup. Electric motor with brake for special applications.
How does a electric brake?
Actuators (motor, gear box) convert rotation into linear motion. Challenge: Miniaturization/power development (ZF Friedrichshafen AG is developing).
Electromechanical actuators
Precise dosage, rapid response. Fundamental for assistance systems (automatic emergency braking). Lifespan >300,000 cycles.
Electromotive brake
Standard in electric/hybrid vehicles (regeneration, range +17%). Also cranes, elevators.
Types of electric brakes
EFB, regenerative, friction brakes. Specific application fields. EFB: Comfort. Selection depending on application in the electronic brake system.
electric parking brake (EFB)
Constant force, automatic management. Prevents rolling away, creates space. Standard.
Regenerative brake (regeneration)
Converts kinetic energy into electrical energy. Reduces consumption/wear. Challenge: Storage/grid.
Friction brake
Energy to heat; backup. Indispensable in case of non-absorbent grid. Waste heat utilization.Advantages and disadvantages of electric brakes
Advantages: Safety (redundancy, ABS/ESP integration). Shorter stopping distances (ZF: up to 9m from 100km/h). Automatic wear leveling ensures performance. Fewer mechanical parts reduce maintenance/susceptibility. Auto-Hold increases comfort.
Disadvantages: Disconnected feeling. Soft release depends on software. Unsprung mass can affect handling. Retrofitting is complex/expensive. Aspects for safety brakes.
Advantages
Less wear/brake dust. Less material/waste. Regeneration saves energy.
Redundancy and safety
Double systems. Backup function in case of failure.
Automatic wear leveling
Constant pedal travel. No manual adjustment needed.
Integration with ESP and ABS
Quick adjustments. Improves stability. Audi was a pioneer.
Environmental friendliness
Elimination of brake fluid (in Brake-by-Wire). No disposal/leakages.
Comfort
Auto-Hold. Reduces driver load.
Disadvantages
Costs decrease. TCO often positive. Initial investment factor.
Loss of direct control
Adaptation. Systems simulate feeling.
Dependence on programming
Software errors possible. Tests/redundancy standard.
Increased unsprung mass
factor. Lightweight construction/placement is important. Brembo is researching lightweight actuators.
Complexity and costs
Retrofitting: CAN integration, calibration.Application areas and innovations
Automotive industry: EFB, recuperation (E-/Hybrid). Rail transport: recuperation, resistance brakes. They also use niches (Gyro drive) for brake motors.
- Wide application in the automotive industry, especially Electric parking brakes (EFB) and recuperation in electric vehicles.
- Used in rail transport, primarily for recuperation and as resistance brakes.
- Forward-looking innovation: Brake-by-Wire systems, which are intended to replace hydraulic components.
- Brake-by-Wire promises shorter stopping distances, reduced maintenance, and higher system efficiency.
- The advancing digitalization opens up new possibilities for brake design and function.
- Further application fields are emerging in wind power, medical technology, and robotics.
- Die electric brake is developing into the intelligent actuator, integrated into autonomous driving functions.
Innovation: Brake-by-Wire (ZF: ready for series production by 2027) replaces hydraulics. Shorter stopping distances, less maintenance, higher efficiency. Digitalization opens up possibilities. Insights for brake design.
Application areas
Many systems can be electrified. Challenge: specific requirements (mining). ATEK Drive Solutions focuses on brake solutions.
automotive industry
Next step: Brake-by-Wire. Advantages, simplified architecture. Continental, Bosch, ZF are players.
Rail transport
Recuperation (mass/energy). Affects costs/environment. Network must absorb energy.
Further applications
wind power, medical technology, robotics. Diversity is growing.
innovations
Brake-by-Wire: fail-safe (redundancy). Safety is a priority. ABS/ESP remain.
Brake-by-Wire systems
Hybrid systems coexist. Ultimately fully electric.
Future perspectives
BbW, integration with autonomous functions. The brake as an intelligent actuator (ZF: series production starting in the 2030s).
Electric brake compared to traditional systems
Electric systems (EFB, Brake-by-Wire) are less susceptible (no freezing cables), BbW eliminates brake fluid change, reduces maintenance/costs. Lifespan of electronic components is often higher.
Purchase costs are converging. TCO can be lower due to reduced maintenance. The EFB emergency braking function is a safety plus.
Maintenance and reliability
lower maintenance; fewer wear parts. Diagnostics report problems.
Less prone to failure
Prevents corrosion/damage. Encapsulated actuators protected.
Reduced maintenance effort
Fewer workshop visits. Pads are more durable in recuperation.
Costs
Will become standard; Economies of scale make them affordable.
Convergence of costs
Trend through fewer components/assembly time (BbW).
Safety
The EFB emergency braking function is safe; pulsating braking maintains steering capability.
Emergency brake function
Longer pressing of the EFB switch; Details in the manual.Conclusion and outlook
Electric brakes offer advantages in safety, comfort, environmental friendliness (recuperation). Brake-by-Wire simplifies vehicle architecture. Challenges (braking feel, complexity) are being addressed. Digitalization and networking favor their use as key components for mobility and industrial solutions. The future of brake technology is electric, intelligent.
