How ATEK Drive Solutions masters the challenges of the offshore industry with robust and customizable braking solutions.
Why are special floating caliper brakes necessary for offshore applications?
Offshore environments are characterized by extreme conditions such as saltwater, high humidity, and storms. Special floating caliper brakes are necessary to withstand corrosion, functioning reliably at low temperatures (down to -40°C) und to meet high safety standards. Which materials make ATEK’s floating caliper brakes particularly resistant for offshore use?
Welche Materialien machen Schwimmsattelbremsen von ATEK für den Offshore-Einsatz besonders widerstandsfähig?
ATEK uses LT spheroidal graphite cast iron for the brake caliper, which withstands extreme low temperatures. This is complemented by special coatings (e.g. KTL) und stainless steel components (A4), to ensure high corrosion resistance, confirmed by salt spray tests for over 1440 hours.
How is the maintainability of floating caliper brakes ensured in hard-to-reach offshore areas?
The design focuses on easy maintenance. This includes a brake pad replacement that can be performed by one person, and designs where seals are accessible without needing to disassemble the entire brake. This can reduce maintenance time by up to 30%. Wartungszeit um bis zu 30% verkürzen.
What advantages does a monoblock design offer for floating caliper brakes in offshore applications?
A monoblock design made of LT spheroidal graphite cast iron eliminates bare contact surfaces, significantly increasing the corrosion resistance.Moreover, extended pin guides and double guide bushings improve the floating function, leading to a more even power transmission und resulting in less wear and can extend the lifespan of the guides by up to 50%.
Which actuation – hydraulic or electromechanical – is better suited for floating caliper brakes in offshore use?
The choice depends on the application. Electromechanical brakes (EMB-STOP) offer a simple ‘plug & play’ installation. Hydraulic systems (KTR-STOP®) often provide higher clamping forces (e.g. up to 16.5 kN active). ATEK advises on the selection of the optimal solution for specific holding or operating brake functions.
What brake pads are recommended for floating caliper brakes in offshore environments?
For offshore applications, sintered metal brake pads are often recommended. They often show about empfohlen. Sie zeigen oft eine um 25% better performance in wet and dirty environments and higher resistance to thermal stresses, such as those occurring during emergency stops of winches.
How do floating caliper brakes contribute to safety in offshore facilities?
Floating caliper brakes serve as reliable operating and holding brakes.Fail-safe features, often spring-loaded and hydraulically vented, are standard. Redundant safety switches and monitoring systems for brake status and wear increase operational safety..
Can ATEK’s floating caliper brakes be customized for specific offshore equipment such as winches or azimuth drives?
Yes, ATEK Drive Solutions specializes in custom drive solutions.Floating caliper brakes can be tailored for specific requirements in offshore wind turbines (rotor and azimuth brakes), cranes, winches and other specialized applications, including the integration of SBT devices (Stop-Block-Turn).
Specialized floating caliper brakes are essential for offshore use, as materials like LT spheroidal graphite cast iron withstand temperatures down to -40°C and special coatings pass salt spray tests for over 1440 hours, ensuring maximum corrosion resistance. bestehen, was maximale Korrosionsbeständigkeit gewährleistet.
Innovative design features such as the monoblock design and optimized guides can extend the lifespan of components by up to 50%., while maintenance-friendly designs reduce maintenance times by up to 30%. Floating caliper brakes offer.
Schwimmsattelbremsen bieten versatile applications in offshore facilities, from wind turbines, where they are designed for over 20 years of operational life, to cranes and winches with fail-safe functions for maximum safety. Discover how floating caliper brakes from ATEK Drive Solutions have been specially developed for the demanding conditions in offshore applications. Learn more about material selection, design features, and testing procedures that ensure the highest reliability.
Offshore applications impose extreme requirements on drive technology. ATEK Drive Solutions offers you floating caliper brakes that are up to the challenges. Are you looking for a reliable and durable braking solution? Contact
Entdecken Sie, wie Schwimmsattelbremsen von ATEK Drive Solutions speziell für die anspruchsvollen Bedingungen in Offshore-Anwendungen entwickelt wurden. Erfahren Sie mehr über Materialauswahl, Designmerkmale und Testverfahren, die höchste Zuverlässigkeit gewährleisten.
Offshore-Anwendungen stellen extreme Anforderungen an Antriebstechnik. ATEK Drive Solutions bietet Ihnen Schwimmsattelbremsen, die diesen Herausforderungen gewachsen sind. Sie suchen eine zuverlässige und langlebige Bremslösung? Nehmen Sie jetzt us now!
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Challenges and requirements in the offshore sector
Offshore facilities impose high demands on components. Specialized floating caliper brakes from ATEK Drive Solutions are designed to meet these challenges in the offshore sector . This article describes solutions for demanding offshore projects, particularly in the context of floating caliper brakes for offshore applications..
Die Offshore industry places high demands on components. Saltwater and storms exert significant forces on brakes, making the development of robust floating caliper brakes solutions for offshore use essential. Careful material selection is therefore crucial for the longevity of the equipment. For instance, LT spheroidal graphite cast iron is used, which withstands temperatures of up to -40°C. Special coatings such as KTL and stainless steel components (e.g. A4 screws) complement the protection to effectively combat corrosion. These materials pass salt spray tests according to DIN ISO 9227 for over 1440 hours. unerlässlich macht. Eine sorgfältige Materialauswahl ist daher entscheidend für die Langlebigkeit der Anlage. Zum Einsatz kommt beispielsweise LT-Sphäroguss, der Temperaturen bis -40°C standhält. Spezielle Beschichtungen wie KTL und Edelstahlkomponenten (z.B. A4-Schrauben) ergänzen den Schutz, um Korrosion effektiv zu begegnen. Diese Materialien bestehen Salzsprühtests nach DIN ISO 9227 über 1440 Stunden. Corrosion-resistant brake units are required for such offshore applications. Accessibility of remote
offshore platforms impacts operational costs. Maintainability, such as an easy brake pad replacement by one person, reduces downtime and costs in durch Wartungsteams beeinflusst die Betriebskosten. Wartungsfreundlichkeit, beispielsweise ein einfacher Bremsbelagwechsel durch eine Person, reduziert Ausfallzeiten und Kosten bei floating caliper brakes in offshore applications.ATEK’s designs often allow access to seals without needing to disassemble the entire brake, which can reduce maintenance time by up to 30%. The installation of ship braking systems is designed for longevity. Safety systems, such as redundant limit switches for condition monitoring (open/closed, wear), are standard in solutions for floating caliper brakes for offshore applications..
Materials withstand the elements.
Material failure at arctic temperatures would have serious consequences. LT spheroidal graphite and high-strength steels for pistons and pins ensure function even at -40°C. ATEK uses special alloys that retain their mechanical properties under extreme cold exposure, verified by tests in a cryogenic chamber. This material integrity is crucial for the reliability of floating caliper brakes in harsh offshore environments..
Accessibility minimizes downtime.
A lengthy brake pad replacement requiring special tools increases downtimes. ATEK’s brakes, especially those designed for floating caliper brakes , are designed so that one person can often perform the replacement in under 60 minutes. For example, the design of the KTR XS series allows quick access to the pads, optimizing maintenance intervals and reducing operational costs. offshore applications., sind so konzipiert, dass eine einzelne Person den Wechsel oft in unter 60 Minuten durchführen kann. Das Design der KTR XS-Baureihe beispielsweise erlaubt einen schnellen Zugang zu den Belägen, was die Wartungsintervalle optimiert und die Betriebskosten senkt.Design and functionality of floating caliper brakes
A thoughtful design is critical for the longevity of floating caliper brakes in offshore use.Every joint of a brake can be a potential attack point for corrosion. The monoblock design of the ATEK floating caliper brakes made of LT spheroidal graphite eliminates such bare contact surfaces and increases corrosion resistance, a key factor for offshore applications.. Enhanced pin guides and double guide bushings improve the floating function, leading to even power transmission and reduced wear. This can extend the lifespan of the guides by up to 50%. For special requirements, underwater brakes are also available. Monoblock design made of LT spheroidal graphite eliminates bare contact surfaces and increases corrosion resistance.
- Monoblock-Design aus LT-Sphäroguss eliminiert blanke Kontaktflächen und erhöht Korrosionsbeständigkeit.
- Enhanced pin guides improve the floating function.
- Double guide bushings optimize the floating function.
- Result: More even power transmission and less wear.
- Lifespan of the guides can be extended by up to 50%.
- Special available. for special requirements in offshore sector Monoblock design made of LT spheroidal graphite eliminates bare contact surfaces and increases corrosion resistance.
The choice between active or passive brake systems depends on the specific offshore application. Electromechanical brakes (EMB-STOP) allow for a ‘plug & play’ installation, while hydraulic systems (KTR-STOP®) often provide higher clamping forces, for example, up to 16.5 kN active. ATEK supports in choosing the optimal solution for specific requirements for floating caliper brakes, whether for holding or operating brake functions in offshore sector. The choice of brake pads, whether organic or sintered metal, is also important. Sintered metal pads often show about 25% better performance in wet and dirty environments, as are typically found in offshore sector offshore applications.
Robust construction for continuous operation.
A reliable braking force even after years in salt mist is ensured by the use of LT spheroidal graphite and the elimination of contact corrosion points through the monoblock design of floating caliper brakes , which is critical for offshore applications. . The optimized guide of the KTR XS series, for instance, ensures consistent braking performance over the entire lifespan of the pads.
Suitable actuators and linings
For demands of the highest precision, standard solutions are often insufficient. ATEK offers both hydraulic and electromechanical actuators and precisely adapts brake linings (organic or sintered metal) to the operating conditions of the floating caliper brakes in offshore applications. Sintered metal linings, for example, provide up to 30% higher durability under high thermal loads, such as those occurring during emergency stops of winches.Applications and examples in the offshore sector
floating caliper brakes of ATEK are used in a variety of offshore applications. applications, from wind turbines to heavy lifting equipment. These specialized floating caliper brakes for offshore applications. are designed for extreme conditions. In offshore wind turbines they serve as reliable rotor and azimuth brakes that withstand wind loads of over 200 km/h. The KTR XS series, for example, is designed for such dynamic and static holding tasks. The shipbuilding industry benefits from this expertise in the field of floating caliper brakes.
For cranes and winches on impacts operational costs. Maintainability, such as an easy brake pad replacement by one person, reduces downtime and costs in or ships, safely holding loads in the ton range is crucial. floating caliper brakes of ATEK provide high clamping forces and fail-safe properties, often spring-loaded and hydraulically released, ideal for the offshore sector. An example is their use in anchor winches, where braking forces of over 500 kN may be required. The SBT device (Stop-Block-Turn) also enables precise stopping, blocking, and turning, which is advantageous for azimuth drives of ships or positioning systems of platforms. These systems are often certified according to standards such as those for WBA shaft brake systems according to DNV GL , emphasizing the quality of the floating caliper brakes for offshore applications. .
Offshore wind energy
Standard brakes often cannot withstand the dynamic loads of a 15-MW wind turbine. Specialized rotor and azimuth brakes, often designed as floating caliper brakes , with clamping forces up to 150 kN per saddle are required here. ATEK solutions for floating caliper brakes in offshore applications. are designed for over 20 years of operational lifespan under these conditions.
Safe lifting and holding
In the event of hydraulic failure of a heavy-duty crane, spring-actuated floating caliper brakes ensure that the load, such as a 50-ton module, is held immediately. This fail-safe function is a core component of ATEK’s brake philosophy for offshore cranes and winches, where floating caliper brakes play a key role.Cooling and overload protection
The enormous heat generation during emergency braking of floating caliper brakes in offshore applications. requires effective cooling measures. Integrated oil/air coolers (OPC) and cooling pump systems with seawater-resistant coatings ensure heat dissipation, even at ambient temperatures of 45°C. These systems can be designed for specific voltages, e.g., 690V, and include protective measures such as stone impact protection grids. Insufficient cooling can reduce the lifespan of brake linings by up to 50%.
- Effective cooling measures are essential during emergency braking, especially in the case of floating caliper brakes in offshore use..
- Integrated oil/air coolers (OPC) and cooling pump systems ensure heat dissipation.
- Systems are equipped with seawater-resistant coatings.
- Functionality even at ambient temperatures of 45°C.
- Design for specific voltages (e.g., 690V) possible.
- Protective measures such as stone impact protection grids are integrated.
- Insufficient cooling can shorten the lifespan of the brake linings by up to 50%.
Expensive drive trains in offshore facilities must be protected from overload, an important consideration when designing systems with floating caliper brakes. KTR-SI overload systems, such as the KTR-SI Compact or the release KTR-SI FRE, disconnect the drive during torque peaks that exceed, for example, 150% of the rated torque. These systems prevent costly damage and failures, e.g., to gear boxes of drilling rigs. Integration with a corrosion-resistant gear unit forms a robust overall system for the offshore sector.
Thermal management for continuous performance
Passive cooling is often not sufficient during continuous operation under full load. Active cooling circuits with OPC coolers can lower the operating temperature of the brake by up to 40°C. This is particularly important for offshore applications. such as dynamic positioning systems, where floating caliper brakes are frequently activated.
Protection against costly damage
A delayed reacting overload system can cause significant damage. ATEK’s KTR-SI systems react within milliseconds and can be designed for torques up to 500,000 Nm. This protects, for example, the main drives of supply ships from offshore sector damage caused by blocked propellers.Outlook and future developments
The development of powerful brake systems, especially floating caliper brakes, for the Offshore industry is continuously progressing. The focus is on smart materials, predictive maintenance through integrated sensors, and energy-efficient designs for floating caliper brakes in offshore applications.. Brake linings, for example, could digitally report their wear level and proactively trigger maintenance before a failure occurs. Condition monitoring can reduce unplanned downtime by up to 20%.
Additive manufacturing processes open up new possibilities for producing complex component geometries for floating caliper brakes, optimally tailored to specific offshore requirements. Lighter and simultaneously more robust components, for example made through 3D printing from special metal alloys, can further increase efficiency and safety. Prototypes already show a weight reduction of up to 15% at equal or higher strength. The development of a complete ship shaft brake system benefits from these innovations. Continuous research at the ATEK competence center for brake systems, including tests on universal brake test benches and shake tables, drives these developments for floating caliper brakes in offshore use. .
Smart brakes for predictive maintenance
Failures can be predicted through the integration of sensors that monitor wear, temperature, and vibrations in real time and send data to a control system. ATEK is developing systems that enable a precise remaining service life forecast for brake components from floating caliper brakes and thus optimize maintenance planning for offshore applications. .
Innovative manufacturing for optimized designs
Traditional manufacturing is not always the optimal solution for complex requirements. Additive manufacturing allows for creating components with optimized internal structures that are lighter and more stable than conventionally manufactured parts. For example, cooling channels can be directly integrated into the brake caliper of floating caliper brakes , improving heat dissipation by up to 25% and increasing suitability for demanding offshore applications. .Conclusion: Reliable floating caliper brakes for demanding offshore applications
In summary, choosing the right brake systems, especially specialized floating caliper brakes, is crucial for the success and safety of offshore applications. . The extreme conditions in the offshore sector require solutions that are not only robust and durable, but also maintenance-friendly and intelligent.
For demanding floating caliper brakes in offshore applications. ATEK Drive Solutions offers advanced technologies and tailored solutions. The comprehensive expertise of the company, from material selection to design and integration of monitoring and cooling systems, supports the performance and reliability of your offshore projects. Trust ATEK as your partner for innovative braking technology in the demanding offshore sector.
