Expert knowledge for machine builders: Functionality, applications, and the benefits of the passive lever brake from ATEK Drive Solutions.
What exactly is a passive lever brake and how does it work at its core?
A passive lever brake is a safety brake that generates its braking force through spring force and thus is safely closed in a power-failure state (e.g., during a power outage). Releasing the brake requires energy – either pneumatic, hydraulic, or electric. This fail-safe principle ensures that the brake reliably holds in emergencies.
For which industrial applications are ATEK passive lever brakes particularly suitable?
ATEK passive lever brakes are excellent for safety-critical holding and emergency stop applications in various industries. These include crane systems, elevators, conveyor technology, machine tools, wind turbines and the stage technology, where safely holding loads during a power failure is crucial.
What advantages does ATEK’s modular construction system provide for passive lever brakes?
ATEK’s modular construction system allows for a high variety of variants and quick delivery times. Customers can configure an optimized brake for their application from standard components , leading to customized solutions, often with delivery times of just a few weeks, even for specific torque requirements such as 5,000 Nm., was zu maßgeschneiderten Lösungen führt, oft mit Lieferzeiten von nur wenigen Wochen, selbst für spezifische Drehmomentanforderungen wie 5.000 Nm.
How do I choose the right release mechanism (pneumatic, hydraulic, electric) for my passive lever brake?
The choice of release mechanism depends on the existing infrastructure and control requirements. ab. Pneumatic systems (ATEK RH series) are often cost-effective when compressed air is available. Hydraulic systems are suitable for high forces. Electric systems (ATEK EMS series) are suited for high-dynamic applications and easy integration into digital controls.
What does “fail-safe principle” mean in connection with passive lever brakes?
Das fail-safe principle means that the brake is designed to automatically transition to a safe state in the event of a power failure or system fault – that is, it brakes. In passive lever brakes, this is achieved through the spring force that closes the brake when the energy to release is removed. How do the RH and EMS types of passive lever brakes from ATEK differ?
Wie unterscheiden sich die RH- und EMS-Typen der passiven Hebelbremsen von ATEK?
Both RH and EMS types are spring-actuated safety brakes. The main difference lies in the release mechanism: RH types can be released pneumatically or hydraulically. EMS types, such as the EMS 170, are specifically designed for electric release , which allows for precise control and fast response times in automated systems.
What braking forces do ATEK passive lever brakes cover?
ATEK offers passive lever brakes for a wide range of applications with clamping forces typically ranging from 2,600 N to 33,000 N . This allows for the selection of the appropriate brake for various holding and safety tasks, from smaller machines to larger industrial plants.
What should be particularly considered when maintaining passive lever brakes?
For lasting functional reliability, regular inspections of the brake pads, mechanics, and the release mechanism are important. Main wear parts such as der Bremsbeläge, der Mechanik und des Lösemechanismus wichtig. Hauptverschleißteile wie brake pads must be replaced in time . A complete documentation and the carrying out of maintenance by trained personnel, including the correct adjustment of the clearance according to the manufacturer’s specifications, are crucial.
Passive lever brakes are essential safety components, which securely protect machines and plants even during power failures and thus increase operational safety. fail-safe principle (federbetätigt schließend) Maschinen und Anlagen auch bei Energieausfall zuverlässig sichern und so die Betriebssicherheit erhöhen.
ATEK offers tailored solutions with its modular passive lever brakes (RH & EMS series) that can save up to 20% space and enable reaction times of under 50ms (EMS type) for increased plant safety.
The correct design based on braking force (ATEK: 2,600 N – 33,000 N), release mechanism, and environmental conditions, as well as regular maintenance are crucial for the long-term reliability and protection of the investment.Learn everything about passive lever brakes: from different designs to applications and the advantages that ATEK Drive Solutions offers you. Secure your systems with reliable braking technology!
Passive lever brakes are essential for safety in many industrial applications. Are you looking for a reliable solution for your drive technology? ATEK Drive Solutions offers you a wide range of passive lever brakes that meet the highest safety standards. Contact us at /contact for personalized advice.
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Introduction to passive lever brakes
Passive lever brakes: Safety for drive technology – Selection criteria
Passive lever brakes ensure the reliable standstill of machines, even in emergencies. This article deals with selection criteria for optimizing safety and efficiency and presents the passive braking technology .
What do we understand by passive lever brakes?
In case of power failure, passive lever brakes secure moving loads without external power supply. They hold, for example, suspended loads in crane systems until power is restored or controlled lowering occurs. This ensures fail-safety. Learn more about brakes here.
The basic operating principle
“Passive”: braking force spring-actuated, brake closed without energy. Releasing requires an active process (pneumatic, hydraulic, electric). Fail-safe principle relevant for safety applications, e.g., emergency stop packaging machines (>100 cycles/min.). Learn more about various. Lösen erfordert aktiven Vorgang (pneumatisch, hydraulisch, elektrisch). Fail-Safe-Prinzip relevant für Sicherheitsanwendungen, z.B. Not-Aus Verpackungsmaschinen (>100 Zyklen/Min.). Erfahren Sie mehr über verschiedene brake types.
distinction from active systems.
Unlike active brakes (energy to brake), passive systems work without external energy – ideal for holding/emergency stops. In case of power failure, active brakes lose effect; passivelever brakes secure, for example, heavy loads.Functionality and application areas of passive lever brakes
Spring force as the core of the braking effect
Spring package generates braking force: tensioned springs press brake pads onto disc/drum.. ATEK RH brakes, for example, use spring packages for braking torques up to 33,000 N. Force is immediately available. Discover the variety of our industrial brakes..
- The braking force is primarily generated by a strong spring package.
- Tensioned springs reliably press brake pads onto a brake disc or drum.
- Releasing the brake requires active energy input, whether pneumatic, hydraulic, or electric.
- The choice of the release mechanism depends on the existing infrastructure and the specific application requirements.
- Spring force brakes are ideally suited for safety-critical applications such as cranes and elevators.
- They are also used in conveyor belts, machine tools, and wind turbines.
- They also play an important role in stage technology to securely hold heavy backdrops.
Diverse release mechanisms: Pneumatic, Hydraulic, Electric
Releasing occurs through energy input against spring force.. ATEK: pneumatic, hydraulic, electric actuations (e.g., EMS types). Electric EMS 170 in PLC systems used for rapid control (ms). Choice according to infrastructure/requirements.
Typical application fields in industry
Application in safety-critical areas: Passive lever brakes secure cranes, elevators, conveyor belts, machine tools, wind turbines.. Example stage technology: holding heavy backdrops during drive failure. The reliability of these passive lever brakes is crucial.Advantages and design features of ATEK passive lever brakes
Flexibility through modular construction system.
Modular construction systems allow for customization: Numerous configurations are created from standard components.. For 5,000 Nm torque, for example, a combination of suitable springs, release mechanisms, flanges; delivery time often just a few weeks. This flexibility is offered by brake manufacturer..
Compact design for tight spaces.
Space-saving construction is advantageous in limited installation space. Passive ATEK lever brakes are compact. The RH050-RH360 series, for example, often reduces axial space by up to 20% compared to alternatives – relevant during upgrades.
Fast response times and no servo effect
Fast response times are important in emergencies. These safety brakes are optimized for this and have no servo effect: Braking force proportional to control, controllable, without self-amplification. ATEK EMS brakes: response times <50ms, relevant for safety in high-speed machines. A reliable lever brake is important here.Comparison with active brake systems
Fundamental difference: energy to brake vs. energy to release.
Main difference: Passive brake systems use spring energy for braking (energy for releasing), active brakes use energy for braking. Example: Active brake on a machine tool spindle is powered; during power failure, no effect. A passive lever brake holds securely. Information on the active lever brake.
application differences and typical use scenarios.
The application determines the brake type: Active brakes for dynamic processes, passive braking devices for holding/emergency stop functions.. E-vehicle: active regenerative brakes (dynamics), passive parking brake (stand). Industry: spring-applied brakes secure vertical axes in case of power loss, active for precise positioning.
Considering system complexity and costs
Costs: consider the entire system. One passive brake is often simpler, but the actuation for release may require additional components (e.g. compressed air supply for pneumatic release). Initial costs may be lower, TCO (e.g. over 10 years) should be assessed individually.Selection criteria and configuration of passive lever brakes
Determining the required braking force range
Selection is based on the calculation of holding moment/holding force. ATEK: passive lever brakes from 2,600 N to 33,000 N clamping force. Crane (5t load): choose an appropriate brake with a reserve considering safety factors/lever arms. Expert support is helpful.
- Precisely determine the required holding moment or holding force for your application.
- Choose the appropriate release mechanism – pneumatic, hydraulic or electrical – based on your infrastructure.
- Tailor the mechanism to the specific control requirements of your system.
- Consider all relevant environmental conditions such as temperature, humidity, and dust exposure.
- Adjust material selection and sealing systems for aggressive media or special hygiene requirements.
- Check the necessity of additional features, such as manual release for maintenance operations.
- Consider a gap monitoring system for wear indication and optimization of maintenance intervals.
Selection of the optimal release mechanism
Choose the release mechanism (pneumatic, hydraulic, electrical) according to infrastructure/control requirements. Compressed air available: pneumatic solution (ATEK RH series) is often cost-effective. High-dynamic applications (robotics): electrically vented brakes (ATEK EMS series), integration into digital controls (bus) is possible. The brake technology offers options.
Considering environmental conditions and additional features
Environmental influences (temperature, humidity, dust, aggressive media) affect material choice/sealing. Food industry: Hygienic Design/stainless steel brakes. Additional features: manual release (maintenance), gap monitoring (wear indication, optimized maintenance intervals) increase system availability.Maintenance and servicing for lasting safety
Importance of regular inspections
Regular inspections are necessary for the functional safety/lifetime of passive lever brakes. Recommended: annually or after switching cycles (e.g. 500,000) visual/function check (pads, mechanics, release mechanism).
Replacement of wear parts and lifetime planning
Main wear part: brake pads. Timely replacement prevents damage, ensures braking performance. Lifetime depends on usage/load (holding brake: years; cycle brake: 1-2 million cycles). ATEK provides specifications.
Importance of documentation and trained personnel
Comprehensive maintenance documentation and trained personnel are important. Manufacturers often provide detailed manuals/training. Correct adjustment of the clearance (after pad replacement, according to instructions) is crucial for function/error prevention.
Passive lever brakes contribute significantly to the safety and reliability of industrial drive technology through their fail-safe principle. Correct selection and application-specific configuration of these fail-safe brakes is crucial. ATEK Drive Solutions supports with expertise and modular systems in finding solutions. Contact us for personalized advice on optimal plant safety.
