Discover the versatile applications and advantages of ATEK Elephant Brakes for your drive technology.
What are the main advantages of ATEK Elephant Brakes as industrial lever brakes?
ATEK Elephant Brakes offer maximum braking performance as industrial lever brakes with minimal axial installation space (e.g., only 100 mm for up to 2000 Nm). They are characterized by a modular system with over 1 million configuration options, various actuation types and a design without servo effect for consistent, direction-independent braking performance .
For which industrial applications are ATEK’s lever brakes particularly suitable?
ATEK’s lever brakes are ideal for conveyor systems, lifting devices, cranes, wind turbines, and special machines.Thanks to their robustness and flexibility, they are also suitable for demanding areas like robotics and packaging machines, where precise and reliable braking operations are required.
What distinguishes active (service) from passive (safety) lever brakes and when is which used?
Active lever brakes (service brakes) are actuated to actively brake or stop a process and are open in a resting state. Passive lever brakes (safety brakes), such as the spring-actuated EMS 170, are closed in a resting state and open when powered. They are used to safely protect machines and personnel in the event of a power failure .for example, in lifting devices or wind turbines.
What braking forces does the RH series of ATEK lever brakes cover, and for which disc diameters are they suitable?
The RH series of ATEK lever brakes offers a wide range of braking forces, from 330 N to 40,000 N.These brakes are designed for brake discs with diameters ranging from Ø120 mm to over Ø600 mm , allowing flexible adaptation to a wide variety of industrial requirements.
Why is the design without servo effect advantageous in industrial lever brakes?
The design without servo effect ensures a consistent and direction-independent braking performance.This is particularly important in applications with reverse operation, such as in lifting devices or positioning systems, as the braking effect is always reliably consistent, regardless of the direction of drive rotation.
How does ATEK assist customers in selecting the right lever brake?
ATEK offers comprehensive technical advice from specialists to design the optimal lever brake for specific requirements. In addition, selection tools with over 50 parameters and an online product configurator assist in the selection. ATEK also develops und ein Online-Produktkonfigurator bei der Auswahl. ATEK entwickelt auch customized special solutions..
What role do electrified lever brakes play in modern automation?
Electrified lever brakes, such as the ATEK EMS 170, enable a very fine dosage of braking effect and fast response times (e.g., <150 ms). This increases the process reliability in automated systems with short cycle times and is crucial for applications that require precise stopping processes.
What does the modular system of ATEK mean for the configuration of lever brakes?
The modular system of ATEK enables an extremely high variety of variants with over 1 million possible configurations for lever brakes. Customers can flexibly choose the actuation type, number of brake calipers, and disc diameter to obtain a tailored braking solution for their specific application , often with quick delivery times.
Lever brakes are versatile brake components for various industrial applications, while modern systems like ATEK Elephant Brakes combine proven principles with the latest technology and, through a modular system enable over 1 million configurations. ermöglichen.
Industrial lever brakes from ATEK are characterized by with minimal axial installation space (e.g., only 100 mm for up to 2000 Nm) and provide consistent, direction-independent braking performance thanks to the design without servo effect, which increases operational safety in demanding applications.The future of lever brake technology lies in
Die Zukunft der Hebelbremstechnologie liegt in intelligent systems with sensors for condition monitoring, which ATEK is promoting through combination with servo motor controllers to enable predictive maintenance und to minimize downtime at over 2 million cycles per year. Learn everything about the different designs, areas of application, and advantages of lever brakes in modern industry. From compact solutions to customized special designs – we show you how to find the optimal lever brake for your requirements.
Are you looking for a reliable and space-saving braking solution for your industrial application? Lever brakes, especially our ATEK Elephant Brakes, offer a variety of advantages. Contact us at
Erfahren Sie alles über die verschiedenen Bauarten, Anwendungsbereiche und Vorteile von Hebelbremsen in der modernen Industrie. Von kompakten Lösungen bis hin zu maßgeschneiderten Sonderanfertigungen – wir zeigen Ihnen, wie Sie die optimale Hebelbremse für Ihre Anforderungen finden.
Sie suchen nach einer zuverlässigen und platzsparenden Bremslösung für Ihre industrielle Anwendung? Hebelbremsen, insbesondere unsere ATEK Elephant Brakes, bieten eine Vielzahl von Vorteilen. Kontaktieren Sie uns unter /contact for personalized advice!
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Introduction to lever brakes
This article covers applications, advantages, and designs of lever brakes (e.g., ATEK Elephant Brakes) for industrial drive technology and explains selection criteria for these important brake components.
What is a lever brake?
A lever brake utilizes the lever force amplification effect, a well-known principle, to safely stop heavy loads. The Exter brake (around 1870), a weight brake for tender locomotives, was an early industrial example of this type of brake; however, its hard-to-regulate braking force limited the spread of such lever brakes.
Historical and modern applications
Historical systems like the Exter brake were primarily mechanical. Today’s technology offers a variety of actuation types for a lever brake. Modern industrial lever brakes use pneumatic, hydraulic, or electrical systems for precise control and high braking forces. Electrified variants of these brakes finely dose the braking effect in automated systems, increasing process reliability in lines with short cycle times (<2s), a core feature of powerful lever brakes.Lever brakes in industrial applications: ATEK Drive Solutions
ATEK Elephant Brakes: Compact braking solutions
Maximum braking power in minimal installation space is often required. ATEK Elephant Brakes provide excellent solutions for this. These lever brakes are characterized by high axial space efficiency, advantageous for compact machines. Some of our lever brake-models require only 100 mm axial installation space at braking torques up to 2000 Nm, ideal for robotics.
- ATEK Elephant Brakes provide maximum braking power with minimal installation space. lever brakes High axial space efficiency is a key feature of these brakes, beneficial for compact machines.
- Some models of these
- Einige Modelle dieser lever brake require only 100 mm axial installation space at braking torques up to 2000 Nm, ideal for robotics.
- Thanks to a modular system, ATEK offers a variety of actuation types for every lever brake, from manual to electric.
- The range includes both active service brakes and passive safety brakes, both variants of the lever brake.
- The EMS 170 is a spring-actuated, electrically released safety brakelever brake, which safely closes in the event of a power failure with a response time of <150 ms.
- The design without servo effect ensures a consistent and direction-independent braking performance of the lever brake.
- The RH series offers braking forces of 330 N to 40,000 N for discs with diameters of Ø120 mm to >600 mm, suitable for various lever brakes.
Different actuation types
Power source and safety philosophy determine the actuation type of each lever brake. The modular system of Elephant Brakes is diverse. ATEK offers various actuation types for their lever brakes, from manual to electric, for active service and passive safety brakes. The spring-actuated/electrically released EMS 170, a special safety brake,lever brake, safely closes in the event of a power failure (response time <150 ms), protecting personnel/machines.
Technical details and configuration options
The design without servo effect of the Elephant Brakes, an advanced lever brake, ensures adaptability. This ensures consistent, direction-independent braking performance, important in reverse operations (lifting devices, positioning systems). The RH series of these lever brakes offers braking forces of 330 N to 40,000 N for discs (Ø120 mm to >600 mm).Lever brakes in comparison: bicycle brakes vs. industrial brakes
Functionality of bicycle lever brakes
In bicycle brakes, a simple form of lever brake, the brake lever tightens a cable. The mechanism presses brake pads against the rim or brake disc to decelerate. A typical bicycle rim brake generates about 500 N of braking force, sufficient for about 100 kg of total weight.
- In bicycle brakes, which can be considered simple lever brakes a cable mechanism presses brake pads against the rim or brake disc.
- A typical bicycle rim brake generates around 500 N of braking force, suitable for around 100 kg of total weight.
- In contrast, industrial lever brakes are designed for ton-heavy loads and harsh environmental conditions.
- ATEK Elephant Brakes are examples of industrial lever brakes, delivering high braking forces.
- The pads of industrial lever brakes withstand temperatures of >300°C.
- For industrial applications, correct sizing of the lever brake is critical for safety and function.
Differences from industrial lever brakes
Bicycle brakes are not suitable for ton-heavy industrial machines where a robust lever brake is required. Industrial lever brakes, like our ATEK Elephant Brakes, are designed for high loads and harsh environments, with higher braking forces. Their pads withstand >300°C, unlike bicycle brake pads. Correct sizing of each lever brake is critical for safety/function.Selection criteria and areas of application for lever brakes
Important selection criteria.
A precise requirements analysis is necessary for the selection and sizing of the suitable lever brake. Fundamentally, brake torque calculation and thermal load of the lever brake. Design tools (>50 parameters) assist in choosing the right lever brake. Criteria:
- Required braking force/brake torque for the lever brake
- actuation type of the lever brake (manual, pneumatic, etc.)
- Available installation space for the lever brake
- Environmental conditions (temperature, dirt) to which the lever brake is exposed
- Safety requirements (e.g. an active vs. passive brake als lever brake-type)
Actuation type
Energy sources and plant safety philosophy influence the actuation type of the lever brake. Passive brakes (often spring-loaded lever brakes, closing in case of power failure) are suitable for safety-critical applications. In wind turbines, such lever brakes keep the rotor safe in case of power failure, even with wind speeds >100 km/h.
Space requirement
Limited installation space requires compact solutions for a lever brake. The clamping design of our lever brakes allows for low axial space requirements. In packaging machines, for example, these lever brakes are integrated in spaces <80mm wide (braking force up to 1500N).Kränzle lever brake: An example from pressure cleaning technology
Kränzle lever brake KRA44804
lever brakes are also used outside of heavy industry, differently sized for smaller devices. The Kränzle lever brake KRA44804 is an original replacement part for high-pressure cleaners. This specific lever brake secures the device at rest (manual, holding force approx. 200 N, device weight approx. 30 kg).
- lever brakes are also used in smaller devices, such as high-pressure cleaners, with the design of the lever brake adjusted.
- The Kränzle lever brake KRA44804 is a specific original replacement part for such devices, a proven lever brake.
- It serves as a manual lever brake for securing the device at rest and provides approx. 200 N holding force for devices weighing about 30 kg.
- The quality label “Made in Germany” is important for manufacturers of lever brakes like Kränzle and ATEK.
- This quality philosophy in the manufacturing of lever brakes encompasses in-house development and high manufacturing standards.
- It results in durable products, such as Kränzle machines with >10 years lifespan, also thanks to robust lever brakes.
Kränzle: Quality Made in Germany
“Made in Germany” with lever brakes often means in-house development and high manufacturing standards (the principle of Kränzle/ATEK for every lever brake). This quality philosophy leads to durable products (Kränzle devices >10 years lifespan). Quality focus is typical for German machine builders, especially in the area of lever brake.Conclusion and outlook
Summary
lever brakes are versatile brake components, ranging from delicate mechanisms to robust industrial plants for heavy loads. Adaptability is an essential characteristic of every lever brake. Modern lever brakes (e.g., ATEK Elephant Brakes) combine proven principles with current technology for high performance. Our modular system for lever brakes allows for >1 million configurations.
Future prospects
Smarter systems are shaping the future of lever brake and the entire brake technology. Sensors for condition monitoring and networking with controls are becoming increasingly important for lever brakes. ATEK promotes this development, e.g., by combining our lever brakes with servo motor controllers for predictive maintenance and minimized downtimes (>2 million cycles/year).
Modern lever brakes are versatile and adaptable for complex industrial applications. Modular systems for lever brakes (e.g., from ATEK) often offer high power density. Experts assist with specific requirements for each lever brake.
