ATEK solutions for the highest demands in steel mills – robust, reliable, efficient.
What are the primary safety aspects of heavy-duty industrial brakes for rolling mill drives?
In rolling mills, there are fail-safe braking functions and adherence to the highest safety standards such as SIL 3 and PL e is crucial. ATEK relies on redundant systems and robust components to optimally protect personnel and equipment, as brake failure can have serious consequences.
How does ATEK ensure the precision of its heavy-duty brakes in critical rolling mill applications?
ATEK achieves the highest precision through precise design of the brakes, the use of high-quality components und finely adjustable braking systems, such as our hydraulic brakes. For rolling mills, we achieve positioning accuracies in the micrometer range, often with deviations of less than 0.1 mm, which is crucial for product quality, especially for specialty sheets.
Our rolling mill operates under harsh environmental conditions (dust, heat). Are ATEK brakes designed for this?
Yes, ATEK heavy-duty industrial brakes are specifically designed for extreme environmental conditions in rolling mills. We use special materials, high-strength steels und optimized sealing systems (often IP67 protection), to ensure reliable operation even in dust, heat up to 80°C, and aggressive media .
What types of heavy-duty industrial brakes does ATEK offer for rolling mill applications?
ATEK offers a wide range of industrial brakes, including hydraulic brakes for maximum braking forces (up to 72,000 Nm), pneumatic brakes for robust and economical solutions, as well as rapid-switching electromagnetic brakes. In addition, we develop custom special solutions and offer designs such as disc, caliper, and band brakes to meet the specific requirements of rolling mill drives.
How does ATEK assist in selecting the correct brake and calculating the braking torque?
ATEK offers comprehensive technical advice and support in the design phase. Our experts assist in the precise calculation of braking torque for all load cases, as this is fundamental for safety and longevity. We leverage our decades of experience and specialized software tools, to find the optimal braking solution for your application.
What innovations does ATEK integrate into its braking systems to enhance performance and reduce downtime?
ATEK relies on advanced technologies wie electrified brakes for more precise control and diagnostics, as well as intelligent braking systems with sensors for condition monitoring and predictive maintenance. This can significantly reduce unplanned downtimes (example customer: -8%) and enables opportunities such as remote maintenance.
We have limited installation space available for brakes. Does ATEK offer compact solutions?
Yes, ATEK is known for its ability to develop customized and compact braking solutions. Thanks to our modular system and our expertise in special development we can also realize suitable heavy-duty brakes for very tight installation spaces. An example is a brake developed for a customer with 20% reduced axial length.
What is the typical lifespan and maintenance effort for ATEK heavy-duty brakes in rolling mills?
ATEK brakes are designed for durability and low maintenance effort . Many of our systems are designed for over 2 million load cycles before major maintenance . Furthermore, we focus on maintenance-friendly designs, so that, for example, a brake pad replacement can often be completed in less than 60 minutes , minimizing downtime.
Choosing the right heavy-duty industrial brake is crucial for safety and precision in rolling mills; ATEK systems meet standards such as SIL 3 and enable positioning accuracies of <0.1 mm.
ATEK offers robust brakes designed for extreme conditions (dust, heat up to 80°C, IP67) and develops custom solutions even for the tightest installation spaces, such as a 20% axially shortened brake for a customer.
Innovative technologies such as intelligent braking systems with sensors und electrified brakes increase efficiency, enable predictive maintenance and can reduce unplanned downtimes by up to 8% as well as improve the brake reaction time by 15%..Learn how ATEK heavy-duty industrial brakes optimize the efficiency and safety of your rolling mill drives. Discover the advantages of customized solutions and cutting-edge technology.
Rolling mills place the highest demands on their components. ATEK offers you heavy-duty industrial brakes that meet these challenges. Are you looking for the optimal brake for your rolling mill? Contact us now Contact us!
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Introduction to heavy-duty industrial brakes for rolling mill drives
Understand the critical role of braking systems in rolling mills
Significant forces act in rolling mills; the brake is more than just a stopper. The precision and reliability of a heavy-duty industrial brake are crucial for product quality and plant safety. Unplanned downtimes can lead to production losses of over 10,000 euros per hour.
Industrial brakes in detail
Basics and functioning in the heavy-duty sector
Brakes for ton-heavy rolls must position precisely. Their function: controlled conversion of motion energy into heat, even under extreme conditions. Our systems are designed for over 2 million load cycles before major maintenance.
Fundamentals of brake technology
ATEK expertise: your partner for demanding braking solutions
Specific challenges of rolling mill drives require competent partners. We combine experience with technology for tailored braking solutions. The brake reaction time for a steel customer was improved by 15%.Requirements for heavy-duty industrial brakes in rolling mills
Safety aspects: essential for human and machine
Brake failure during full production has serious consequences. Redundant systems and fail-safe components are therefore essential and standard. Our brakes meet safety standards such as SIL 3 and PL e. Fixed caliper brakes for heavy-duty
Precision requirements for the highest product quality
A brake must hold ton-heavy rolls precisely. Holding accuracy in the µm range is often crucial for quality, e.g., for specialty sheets. We realize positioning accuracies with <0.1 mm deviation.
Resistance to extreme environmental conditions
Brakes must withstand dust, heat (up to 80°C), and aggressive media. Special materials (e.g., high-strength steels) and optimized seals ensure longevity under extreme conditions. Our rolling mill brakes often have IP67 protection.
Hydraulic braking systems
Managing high dynamic loads in the rolling process
Heavy-duty industrial brakes must withstand high dynamic forces. Our brakes safely absorb repeated shock loads (up to 2.5x nominal torque). Relevant when reversing in the rolling mill.Design types of heavy-duty industrial brakes for rolling mills
Hydraulic brakes: powerful and precise controllable
Hydraulic brakes are often the first choice. High power density and fine controllability make them suitable for maximum braking forces and precise control (e.g., main drives for hot rolling mills). We offer hydraulic brakes up to 72,000 Nm. Shaft brake systems with high torque
- Hydraulic brakes: Provide high power density and precise controllability, ideal for main drives (up to 72,000 Nm).
- Pneumatic brakes: Characterized by robustness, low maintenance, and cost-effectiveness, often used for auxiliary drives.
- Electromagnetic brakes: Enable very fast switching times (<50 ms) and are suitable for dynamic safety and holding functions.
- Band brakes: Suitable for applications requiring high braking torques, typically on drums.
- Industrial disc brakes: Offer compact designs and precise control options.
- Caliper brakes: A solution when space is limited and high holding forces are required.
Pneumatic brakes: Robust and low maintenance
Pneumatic brakes are often reliable and economical for auxiliary drives. Simple design and low maintenance costs (e.g., transport rolls, winders) are advantageous. Typical maintenance interval: >1.5 million switching cycles.
Electromagnetic brakes: Fast and dynamic
Fast switching times are sometimes critical. Electromagnetic brakes (often spring-applied brakes) offer very short reaction times; good for safety/holding brakes (ms reaction). Our E-magnetic brakes: Switching times <50 ms.
Special designs: Band, caliper, and disc brakes in focus
For many rolling mill applications, suitable brake designs exist. The spectrum: band brakes (high torques, drums) to compact industrial disc brakes (precise control). Caliper brakes are suitable for limited space and high holding forces.Selection criteria for the optimal heavy-duty industrial brake
Braking torque calculation: The basis for safety and efficiency
The required braking torque is determined exactly. Precise calculation of all load cases (emergency stop to gentle deceleration) is fundamental; we support with expertise/software. Underestimating the braking torque by 10% can halve the lifespan.
Space and integration: Tailored solutions
For non-standard needs: Modular kits and custom development enable suitable brakes even for the tightest spaces. For a customer: brake with 20% reduced axial installation length.
Heat management: Avoid overheating, maximize lifespan
Against overheating: Effective heat dissipation (ventilated discs, external cooling) is crucial for performance/durability under frequent cycles. Our brakes: Continuous braking power up to 50 kW.
More about brake discs
Controllability and ease of maintenance as key factors
Important: fine control, minimal downtime. Modern systems offer good controllability; we focus on maintenance-friendly designs for efficient service operations. Brake pad replacement often <60 mins.Innovative solutions and future trends in heavy-duty brakes
Electrification and intelligent braking systems
Digitalization is changing brake technology in rolling mills. Electrified brakes: more precise control/diagnosis; intelligent systems monitor condition, predict maintenance. Customer reduced unplanned downtimes by 8% with sensor brakes. Integration of drive systems
- Progressive electrification enables more precise control and improved diagnostic capabilities.
- Use of intelligent braking systems for continuous condition monitoring and forecasting maintenance needs.
- Exploiting the potential of remote maintenance through modern interfaces for diagnosis and parameterization.
- Implementation of predictive maintenance strategies to increase efficiency and minimize downtime.
- Active material research for the development of more powerful components, e.g., high-temperature resistant friction materials.
- Focus on new alloys to increase the wear resistance and overall performance of the brakes.
- Achieving significant lifespan extensions through innovative materials such as ceramic composites.
Potential of remote maintenance and predictive maintenance
Remote monitoring of the brake condition is possible. Modern interfaces: remote access for diagnosis/parameterization, minimizes downtime, increases maintenance efficiency (up to 25%). An aspect of future braking systems.
Material research for even more powerful components
New materials are relevant for future brakes. We are researching friction materials/alloys for higher temperature resistance, wear resistance, and overall performance. Ceramic composite tests: +30% lifespan (extreme conditions).Conclusion: The right heavy-duty industrial brake for your rolling mill
The suitable heavy-duty industrial brake is crucial for safe, efficient rolling mill operations. ATEK Drive Solutions offers products and comprehensive solutions. We are ready for individual consultation on plant optimization.
