Mechanical, hydraulic, pneumatic, spring-operated – ATEK offers the right solution for every requirement.
What are the main types of lever brakes and where are they typically used?
There are mechanical, hydraulic, pneumatic, and spring-operated lever brakes. Mechanical ones are suitable for simple holding tasks, hydraulic ones for heavy-duty applications with high force, pneumatic ones for fast, automated cycles, and spring-operated ones as safety brakes that engage reliably during power failure.
When is a spring-operated lever brake the right choice?
A spring-operated lever brake is ideal when highest safety and a fail-safe function are required. It brakes automatically during power failure and is therefore often used as an emergency stop or holding brake in critical applications such as elevators or cranes, where it can safely hold loads of up to 1,600 kg.
What advantages does the modular system from ATEK offer in lever brakes?
The modular system from ATEK allows for millions of configurations for lever brakes. This means a tailored solution for your specific application, often with short delivery times, as ATEK has a large stock of approximately 500,000 individual parts.
Can ATEK supply lever brakes for special environmental conditions or high cycle rates?
Yes, ATEK develops customized lever brakes, designed for demanding environments (e.g. temperature resistance up to 80°C, stainless steel versions for the food industry) and high cycle rates (e.g. 150 cycles/min). Our RH and EMS series offer various options here.
What range of braking forces do ATEK lever brakes cover?
ATEK offers lever brakes for a very wide range of braking forces, from 330 N to 40,000 N. Thus, we can provide solutions for a variety of industrial applications, from light positioning tasks to heavy holding functions.
How does ATEK support the selection and integration of the appropriate lever brake?
ATEK offers comprehensive technical advice from experts. We assist you in designing, sizing, and optimizing your drive solution to ensure that the chosen lever brake perfectly fits your application and achieves a long lifespan of over 2 million cycles .
What does the “lack of servo effect” mean in ATEK lever brakes?
The absence of a servo effect is a deliberate design feature of many ATEK lever brakes. This ensures a consistent braking performance in both rotation directions, which is particularly important for applications that require reliable bidirectional braking.
Are ATEK lever brakes suitable for applications with high precision requirements or fast response times?
Yes, ATEK lever brakes, such as the RH series, are characterized by fast response times . Pneumatic variants allow stop times of less than 100 ms. For the highest precision, e.g. in tool spindles with ±0.01 mm accuracy, we offer optimally coordinated system solutions.
ATEK Drive Solutions offers a wide range of lever brakes (mechanical, hydraulic, pneumatic, spring-operated), which are characterized by modular design and high adaptability , thus simplifying integration into complete drive systems, which can increase overall performance by up to 15% .
ATEK delivers tailored lever brake solutions through customized design and a modular system that covers braking forces from 330 N to 40,000 N and enables fast delivery times.
ATEK lever brakes, especially spring-operated variants as safety brakes and models with fast response times (e.g. <100ms), ensure high operational safety and process stability, which can reduce scrap in packaging lines by up to 5%. Ausschuss in Verpackungslinien um bis zu 5% senken .Discover the diverse applications and advantages of lever brakes in industrial drive technology. From precise control to reliable emergency braking – we show you what matters.
Lever brakes are essential components in numerous industrial applications. Are you looking for the optimal solution for your specific requirements? Our experts are happy to advise you! Contact us now Contact .
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Introduction to lever brakes
What exactly do lever brakes achieve?
Lever brakes secure stopping, holding and positioning in industrial machines, even for heavy loads such as cranes (>10 tons).
Why are they indispensable in industry?
Their robustness and reliability minimize failure risks. They are core components where ATEK components ensure, for example, 99.8% availability.
The ATEK approach: More than individual parts
ATEK as a system provider delivers complete drive systems, simplifying integration (e.g. in packaging lines) and can increase performance by up to 15%. Understanding active lever brakes.
Such braking devices with lever action are important components for various industrial applications, from securing to dynamic deceleration. In conveyor technology, they ensure continuous material flow, for example. A correct design of these brake systems is crucial for safety and efficiency; ATEK Drive Solutions ensures a precise adjustment.
Modern industrial plants demand high performance. ATEK braking solutions, including advanced Lever brakes, help machine engineering customers reduce cycle times and increase process safety (productivity increase >10%). ATEK provides solutions based on many years of experience and the latest technology. More about mechanical braking options.Types of lever brakes and their functioning
Mechanical lever brakes: The solid foundation
Mechanical lever brakes are straightforward and cost-effective, ideal for manual positioning tasks (e.g., holding loads up to 500 kg).
Hydraulic lever brakes: Power and precision
Hydraulic lever brakes offer high and precise braking force required for heavy-duty applications (e.g. presses >2,000 kN). Discover hydraulic brakes.
Pneumatic lever brakes: Fast and flexible
Pneumatic lever brakes use compressed air for quick reaction in automated systems (e.g. 150 cycles/min). Info: pneumatic braking systems.
Spring-operated lever brakes: Safety first
Spring-operated lever brakes serve as fail-safe systems in case of power failure and are thus essential for emergency stop functions (e.g. in elevators securing loads of 1,600 kg).
The choice of the appropriate type of lever braking system depends on the specific application. Mechanically operated brakes are suitable for simple machines (e.g. a hand lever brake for 250 kg load). Their simplicity lowers costs and makes them ideal for applications like securing flaps.
Hydraulic or pneumatic lever brakes provide higher forces and better control options. Pneumatically ventilated brakes, such as ATEK’s stainless steel spring brakes (often a combination of spring-operated und pneumatic released), are ideal for fast cycles (<100ms stop time). Hydraulic braking systems dominate in heavy-duty applications (>50,000 Nm). The choice of actuation type takes into account factors such as required force, reaction speed, costs, and existing infrastructure.Applications of lever brakes in the industry
Machine and plant engineering: Precision matters
Hier sichern Lever brakes kritische Bewegungen und ermöglichen eine exakte Positionierung (z.B. einer Werkzeugspindel mit einer Genauigkeit von ±0,01 mm).
- Machine and plant engineering: Ensuring precise movements and exact positioning through the use of Lever brakes (e.g. tool spindle accuracy of ±0.01 mm).
- Packaging industry: Millimeter-accurate stopping to optimize material flow and reduce scrap by up to 5% with the help of precise braking mechanisms with levers.
- Special applications: Reliable use of Lever brakes in demanding areas such as wind power (rotor locking at >100 km/h) and food production.
- Conveyor technology: Securing material transport and preventing load backflow, for example, on incline conveyors through robust holding devices with levers.
- Process stability: Correctly designed Lever brakes, such as ATEK’s spring brake systems (a type of spring-operated lever brake), secure axes (e.g. Z-axis of a milling machine) even in the event of a power failure.
- ATEK solutions: A wide range of Lever brakes from 330 N to 40,000 N for various industrial applications.
Packaging industry: Efficiency through precise stopping
In the packaging industry, they optimize Lever brakes material flow through millimeter-accurate stopping (of films or cartons), which can reduce scrap by up to 5%.
Special applications: From wind power to food technology
ATEK lever braking systems prove themselves under extreme conditions: whether in wind power for rotor locking at wind speeds of over 100 km/h or in food production, where there are specific requirements for materials and hygiene. See passive lever brakes.
In mechanical engineering, such braking mechanisms with levers provide, for example, axis securing. An ATEK spring-operated brake, a special form of lever brake, reliably secures the Z-axis of a milling machine during power outages. The right brake significantly increases process stability. ATEK offers solutions ranging from 330 N to 40,000 N.
In logistics and conveyor technology, Lever brakes they ensure safe material transport and prevent unwanted load backflow on incline conveyors. ATEK’s RH series, for example, can be modularly adapted to different holding forces (suitable for belt inclines up to 30°). See fail-safe brakes for cranes.Selection criteria for lever brakes
Braking torque: More than just force
The correct braking torque for a lever brake takes into account not only the load to be held but also mass inertia and required stopping time. A miscalculation, for example in applications with 15 stops per minute, can be problematic.
Environment and actuation: Decisive factors
Environmental conditions (temperature, dust development) and the available energy source determine the optimal actuation type (e.g., mechanical, hydraulic, pneumatic) and the material of the lever brake (e.g., stainless steel for the food industry, temperature-resistant materials up to 80°C).
ATEK’s modular system: Millions of possibilities
ATEK’s modular system for Lever brakes enables over a million configurations and ensures fast delivery (inventory: about 500,000 parts). Specifically designed brakes are often available within a few days.
The selection of the suitable lever brake requires a precise analysis of braking torque, switching duration, and environmental conditions. A brake for use in a foundry, for example, requires higher heat resistance. ATEK supports customers in defining all relevant parameters to avoid misinvestments and ensure a long service life (>2 million cycles for some models).
The system integration of the chosen lever brake is an important aspect that includes size, weight, and interfaces. ATEK’s EMS series, for example, is particularly compact and suitable for tight installation spaces. The modular system and the opportunity for custom adaptations also meet complex requirements, including the choice of brake disc size and material.ATEK Drive Solutions and lever brakes
ATEK as a system provider: Your advantage
ATEK supplies matched gear boxes, Lever brakes and other types of brakes, as well as motors. This reduces interfaces and ensures the overall performance of the system (e.g., for a textile machine, efficiency could be increased by +12%).
- System competence: ATEK offers completely coordinated drive trains as a system provider, including gear boxes, various brakes (including lever brakes – mechanical, hydraulic, pneumatic, spring-operated) and motors.
- Performance improvement: Through optimized system integration, efficiency increases (e.g., +12% in textile machines) can be achieved, where lever braking systems can play a key role.
- Innovative trends: Focus on electrification and smart braking solutions with levers and other types with sensors for predictive maintenance and condition monitoring.
- Fast E-brakes: ATEK’s electric brakes (which can also be executed as Lever brakes ) offer response times under 20 ms and proactively report wear.
- Customized solutions: Development of Lever brakes and other brake types for specific customer requirements, even in small series (e.g., a brake with exactly 127 Nm torque or a specific size of 80 mm). See
- Digitale Zukunft: Investition in vernetzte Bremssysteme mit intelligenter Überwachung zur Reduzierung von Stillständen (bis zu 30%), auch bei Lever brakes.
- Expertenberatung: ATEK-Spezialisten unterstützen bei der Auswahl und Auslegung der optimalen Bremslösung, einschließlich der passenden lever brake.
Trends: Elektrifizierung und smarte Bremsen
Elektrifizierung und der Einsatz von Sensorik machen Bremsvorrichtungen, einschließlich Lever brakes, intelligent und ermöglichen Funktionen wie vorausschauende Wartung. ATEKs E-Bremsen (<20ms Reaktionszeit) melden beispielsweise proaktiv Verschleißzustände.
Kundenspezifische Lösungen: Ihr Bedarf im Fokus
ATEK entwickelt Lever brakes und andere Bremslösungen für spezielle Anforderungen und Kleinserien (z.B. eine Bremse mit exakt 127 Nm Drehmoment oder einer spezifischen Baugröße von 80 mm). Siehe solutions for servomotors, which often use spring-operated holding brakes .
ATEK Drive Solutions is your partner and system provider for complete solutions that often include various types of lever brakes (mechanical, hydraulic, pneumatic, spring-operated) . For example, an optimized combination of servo bevel gear boxes and a holding brake improved the measurement accuracy of an E-motor test stand by 5%. The strength of ATEK lies in the combination of experience and product innovation.
The future belongs to digital and connected brake systems, including smart lever braking systems. ATEK continuously invests in electrified systems and intelligent monitoring solutions. Integrated sensors monitor the condition of brake pads, signal maintenance needs, and help reduce unplanned downtimes by up to 30%. ATEK thus provides future-proof systems. Benefit from our expertise in combined brake systems.
The selection of the right lever brake – whether it is mechanical, hydraulic, pneumatic or spring-operated – is crucial for the performance and safety of your facility. ATEK’s comprehensive system competence and expertise help you find the optimal solution for your specific requirements. ATEK’s experts are happy to advise you.
