Everything you need to know about the function, advantages, and applications of mechanical brakes.
What are the main advantages of mechanical brakes for industrial applications?
Mechanical brakes offer a simple construction, are often more cost-effective (system costs can be up to 25% lower than those of hydraulic solutions) and operate independently of energy, making them ideal for emergency systems or mobile devices.
When is a mechanical brake the better choice over hydraulic or pneumatic systems?
A mechanical brake is preferred when simplicity, lower acquisition costs, independence from external energy (power, compressed air) or a direct, well-perceptible actuation are crucial. They are also excellent as fail-safe backup systems.
How maintenance-intensive are mechanical brakes, and what should typically be considered?
The maintenance effort is often lower than for more complex systems but requires regular inspections and adjustments, such as the readjustment of cable pulls (if necessary after 1,000-2,000 cycles depending on the application) and the check for wear of the brake pads and mechanical components.
Can mechanical brakes be integrated into modern connected industrial systems?
Yes, modern mechanical brakes can be integrated through sensor integration for wear monitoring and connection to control systems in Industry 4.0 concepts. This allows for predictive maintenance and can reduce downtime by up to 15%.
What performance data is typical for industrial mechanical brakes from ATEK?
Industrial mechanical brakes from ATEK can be designed for high holding forces (e.g., for positioning loads over 500 kg) and dynamic braking torques of up to 3808 Nm (like certain Tolomatic models, which ATEK considers a reference for energy-independent solutions). In emergency stop systems, reaction times of under 0.5 seconds are achievable.
Which industries are mechanical brakes particularly suitable for?
They are ideal for hoisting devices, conveyor systems (e.g., stop accuracy +/- 5 cm), general mechanical engineering, wind turbines (as safety brakes for rotor stop in 30-60s), agricultural machinery, construction machinery and stage technology. Does ATEK Drive Solutions also offer customized mechanical brakes?.
Bietet ATEK Drive Solutions auch kundenspezifische mechanische Bremsen an?
Yes, ATEK Drive Solutions specializes in the development of customized special solutions for mechanical brakes, also in small series. Through a modular system and comprehensive consulting, brakes are optimally tailored to the respective industrial drive task.
Mechanical brakes offer reliable and cost-effective solutions for various industrial applications, with system costs potentially being up to 25% lower than hydraulic alternatives.
Their energy independence and simple construction make them ideal for critical safety functions and applications without external power supply, with modern designs reaction times of under 0.5 seconds achieving this in emergency stop systems.
Innovations such as advanced lining materials (e.g., sintered metal for +30% service life) und sensor integration for Industry 4.0 enhance performance and enable predictive maintenance that can reduce downtime by up to 15%. Learn when mechanical brakes are the optimal solution for your drive technology and how you can benefit from their reliability and cost-effectiveness.
Mechanical brakes are proven components in drive technology. They provide a reliable and cost-effective solution for numerous applications. Discover the advantages and applications of this technology and find out if it is suitable for your requirements. Do you have questions? Feel free to contact us at
Erfahren Sie, wann mechanische Bremsen die optimale Lösung für Ihre Antriebstechnik sind und wie Sie von ihrer Zuverlässigkeit und Wirtschaftlichkeit profitieren können.
Mechanische Bremsen sind bewährte Komponenten in der Antriebstechnik. Sie bieten eine zuverlässige und kostengünstige Lösung für zahlreiche Anwendungen. Entdecken Sie die Vorteile und Einsatzbereiche dieser Technologie und finden Sie heraus, ob sie auch für Ihre Anforderungen geeignet ist. Sie haben Fragen? Kontaktieren Sie uns gerne unter ATEK Drive Solutions.
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Understand: Master the fundamentals and principles of mechanical brakes
Mechanical brakes are based on direct force transmission using levers or cable pulls to precisely stop movements. Emergency stop systems in packaging machinery use these brake devices for reaction times under 0.5 seconds. Their strength lies in simplicity and direct force transmission. ATEK Drive Solutions confirms this proven brake technology.
Their core principle is targeted friction: surfaces are pressed against each other to safely stop machines. This controlled friction, optimized at ATEK for friction values over 0.4 µ, is critical to the function of these brake systems.. The conversion of motion energy into heat through friction is characteristic.
In drive technology, mechanically operated brakes serve safety in fail-safety. Holding brakes in robot joints precisely position loads over 500 kg. Robustness and low complexity make such friction brakes suitable for critical applications. Information on the selection of the brake type is available.Recognize: Distinguish the functions and types of mechanical brakes
Mechanically acting brakes often work through cable pulls or levers. The direct mechanical coupling allows for intuitive and robust handling. Manual parking brakes in machine tools, for example, secure with a hand force of 200 Newtons. Immediate force transmission ensures a direct response of these brake systems.
- Mechanical brakes typically use cable pulls or levers for force transmission.
- Their direct mechanical coupling leads to robust handling and intuitive operation.
- A main feature is the immediate force transmission, ensuring a direct response.
- The most common designs include drum and disc brakes.
- Drum brakes are often encapsulated and dirt-resistant, ideal for harsh environments like construction machinery.
- Industrial disc brakes are distinguished by better heat dissipation, making them predestined for applications with high braking performance.
- Special types like band and shoe brakes serve specific niche applications in heavy industry or winches.
- The selection of the right brake type depends on the environmental conditions and thermal requirements of the application.
Common types of this brake devices are drum and disc brakes. Encapsulated, dirt-resistant drum brakes are suitable for construction machinery. Industrial disc brakes provide better heat dissipation, which is important for high-speed spindles with up to 10 kW braking performance. The choice of design depends on the environment and thermal requirements.
Band and shoe brakes address niches. Band brakes secure loads up to 10 tons in winches; shoe brakes are used in rail vehicles or heavy industry. Special forms of these mechanical brake systems expand the range of applications. The portfolio includes various lever brakes..Weighing: Assessing the strengths and weaknesses of mechanical brakes
Mechanical brakes are attractive due to their uncomplicated construction and lower costs; system costs can be up to 25% lower than those of hydraulic solutions. Economy and simplicity are clear strengths of this brake technology. Main advantages:
- Simple, robust construction
- Often lower acquisition costs
- independence from external energy
- Direct, well-perceptible actuation
Their energy independence (functioning without electricity or compressed air) makes mechanically operated brakes them ideal for mobile devices or emergency systems. Tolomatic brakes for such environments reach up to 3808 Nm. Energy independence ensures the function of these brake devices under adverse conditions. See Fundamentals of brake technology.
However, such brake systems. adjustments (e.g., cable stretch after 1000-2000 cycles) are required, and their braking force is often lower than that of hydraulic systems. A conscious approach to maintenance and performance limits is important.Safety brakes, often classified as mechanical brakes are relevant for maximum reliability.Applying: Identifying optimal application fields for mechanical brakes
Mechanical brakes are widely used in industrial everyday life: in hoisting devices for precise control of ton loads, in conveyor systems of logistics centers with stop accuracies of +/- 5 cm, and as band brakes in harbor cranes that secure containers of up to 40 tons. Their versatility makes these brake systems a part of many industrial brake-systems.
- Hoisting devices benefit from mechanical braking devices for precise control of heavy loads.
- In conveyor systems of logistics centers, they ensure high stop accuracies.
- Harbor cranes utilize them as band brakes to secure heavy containers.
- Als Safety brakes In wind turbines, they reliably stop rotors under extreme conditions or maintenance.
- Agricultural machines use mechanically acting brakes for precise processes in the cultivation process.
- Stage technology relies on them for the safe movement of backdrops and loads.
- Their versatility allows for use in numerous industrial brake-systems.
In modern wind turbines, such brake mechanisms play a critical role as safety brakes that reliably stop the rotor during extreme wind or maintenance. The rotor must often come to a stop within 30-60 seconds to avoid damage. This reliability underscores their importance as an effective safety brake..
Other application fields include agricultural machines for precise cultivation processes and stage technology for safe backdrop movements with loads of up to 2 tons. The adaptability of these mechanical brake systems to diverse industry requirements is an advantage. The choice of the right brake type is crucial.Compare: Positioning mechanical brakes against alternatives
Compared to hydraulic systems, which often offer more power and finer controllability (pressures over 200 bar), mechanical brakes score with simplicity and up to 50% lower system costs. Weighing performance, complexity, and costs is central when choosing the brake system.
Pneumatic brakes are superior for fast switching times (cycles under 1 second in production lines) and high forces, provided compressed air is available. Mechanically acting brakes are often more compact and energy-independent. Auxiliary energy availability and cycle times influence the choice of the appropriate brake technology.
Compared to electric brakes, which enable energy recovery and are less wear-intensive, serve mechanically operated brakes often as a fail-safe backup or holding brake. In electric vehicles, these brake devices can take over up to 100% of the braking power in case of system failure. The combination of different types of brakes is often optimal. Consultation by an experienced brake manufacturer is recommended.Benefit: Utilize future trends in mechanical brakes
The development of mechanical brake systems is progressing. New lining materials and optimized designs improve lifespan and performance. Sintered metal linings, for example, can increase the service life of these brake devices by up to 30% under harsh conditions compared to organic linings. Material innovations continuously enhance efficiency.
- Continuous improvement through material innovations such as sintered metal linings that increase lifespan.
- Optimized designs enhance performance and efficiency. of mechanical brake systems.
- Integration of sensors for wear monitoring enables connection to Industry 4.0 concepts.
- Smart features such as predictive maintenance reduce downtime and operating costs.
- Even in the age of electrification, mechanically operated brakes remain relevant as robust safety and holding elements.
- They are often combined with electric systems, for example, as parking brakes in electric vehicles.
- ATEK Drive Solutions offers modular and customized solutions that address these trends.
Mechanical brakes integrate into Industry 4.0 through sensors for wear monitoring and control connection. This enables predictive maintenance that reduces downtime by up to 15%. Smart features increase availability and lower operating costs in mechanical brake systems..
With increasing electrification, the mechanical brakes remains a robust, reliable component, often combined with electric systems. As a parking brake in electric forklifts, this type of brake holds vehicles on slopes up to 15%. It complements modern drives as a safety and holding element. ATEK Drive Solutions integrates these proven brake technologies..
ATEK Drive Solutions combines experience with expertise in servomotors. The modular system allows for various configurations, fast delivery times, and customized special solutions, even in small series, to provide optimal solutions for industrial brakes. are often a suitable choice for reliable, economical, and energy-independent solutions in drive technology. For customized brake solutions based on the
Mechanically acting brakes sind oft eine geeignete Wahl für zuverlässige, wirtschaftliche und energieunabhängige Lösungen in der Antriebstechnik. Für maßgeschneiderte Bremslösungen, die auf der mechanical brake ATEK is available.
