Everything you need to know about the operation, applications, and benefits of pneumatic brakes.
What are the main advantages of pneumatic brakes in industrial applications?
Pneumatic brakes provide a robust and reliable braking solution with simple construction and maintenance. They allow for fast response times, good heat dissipation, and are often economical when a compressed air supply is already available. Their versatility makes them ideal for numerous industries such as mechanical engineering and packaging.
How does ATEK Drive Solutions assist in selecting the right pneumatic brake for specific requirements?
ATEK Drive Solutions offers comprehensive technical consulting and uses a modular assembly system, enabling millions of configurations. This allows the pneumatic brake to be optimally tailored to your specific application to ensure maximum efficiency and fast delivery times .
What role does the fail-safe principle play in pneumatic brakes, and when is it particularly important?
Fail-safe pneumatic brakes automatically enter the safe brake state in case of a pressure loss. This is crucial for safety applications, for example, in hoisting devices, vertical axes, or in systems where an uncontrolled stop could lead to damage or danger. They reliably protect both people and machines.
Can pneumatic brakes from ATEK be adapted to existing systems or custom-developed?
Yes, ATEK Drive Solutions specializes in the development of customized special solutions, even in small series. Thanks to the modular assembly system and high engineering expertise, pneumatic brakes can be flexibly adapted to existing systems and individual requirements. They can be.
What are the essential aspects of installing and maintaining pneumatic brakes to maximize their lifespan?
A correct installation and alignment are fundamental. It is also crucial to use clean, dry compressed air at the specified operating pressure. Regular inspections of the brake pads, seals, and adherence to maintenance recommendations, such as the use of maintenance equipment, can extend the lifespan by up to 25%.
For which industries and applications are ATEK’s pneumatic brakes particularly well suited?
ATEK’s pneumatic brakes are suitable for a wide range of industries, including machinery and plant engineering, packaging industry, machine tool construction, printing industry, conveyor technology, and robotics. They are ideal for applications that require precise stopping processes, high cycle counts, and reliability. How do innovations such as optimized cooling or modular designs contribute to the performance enhancement of pneumatic brakes?
Wie tragen Innovationen wie optimierte Kühlung oder modulare Bauweisen zur Leistungssteigerung pneumatischer Bremsen bei?
Optimized cooling concepts, e.g., through special air channels, significantly improve heat dissipation, which can double the lifespan of the brake pads. Modular designs allow for an exact adaptation of the braking force to the respective requirement, thus providing an more efficient and often more cost-effective solution..
What influence does the quality of compressed air have on the function and reliability of a pneumatic brake?
The quality of compressed air is crucial for the reliable function and longevity of a pneumatic brake. Contaminants such as water, oil, or particles can lead to premature wear, malfunctions, and corrosion. Therefore, the use of filtered and ideally dried compressed air is essential.
Pneumatic brakes are robust and versatile solutions for industrial applications, with a correct selection and design potentially increasing the system efficiency by up to 5% and reducing the maintenance time by up to 15% .
The choice of the right pneumatic brake, supported by modular assembly systems and technical consulting as provided by ATEK, allows for millions of configurations und and fast delivery times, which is particularly crucial for custom requirements.
Innovations such as fail-safe mechanisms, improved cooling concepts, and smart technologies not only enhance the safety and reliability, but can also double the lifespan of brake pads und and reduce operating costs by up to 5%..Explore the world of pneumatic brakes: From the basics to the latest innovations for industrial applications. Learn how to select the right brake for your specific requirements.
Pneumatic brakes have become indispensable in many industrial applications. They provide a reliable and efficient way to control movements and safely stop machines. Need a custom solution? Contact us at ATEK Drive Solutions for personal consulting.
Do you need assistance in selecting the optimal pneumatic brake for your application?
Request individual consulting now!
Understand: Master the basics of pneumatic brakes
Pneumatic brakes are robust and versatile solutions for numerous industrial applications. This article explains their selection, function, and benefits to ensure the optimal use of these compressed air brakes .
Basics and significance
The versatility of compressed air-operated brakes is often underestimated; they offer much more than just simple stopping functions. For instance, packaging systems utilize the fast response of a pneumatic brake for significantly increased cycle rates (up to 10%). A thorough understanding, as outlined in Understanding industrial brakes , optimizes their use.
Why use compressed air as the drive medium?
The often already available supply of compressed air in companies (e.g., at a machinery manufacturer with over 200 compressed air tools) makes pneumatic systems and thus the pneumatic brake often the most economical solution for braking applications up to a certain torque. A constant air quality for the reliable operation of the compressed air brake is critical..
Distinction from other brake types
Pneumatic brakes often provide simpler integration and maintenance compared to hydraulic brakes (which achieve higher forces) or electromagnetic variants, which is particularly advantageous in critical applications without the risk of oil leaks. For example, a food manufacturer was able to reduce its maintenance time by 15% by using ATEK.. Ein Lebensmittelhersteller konnte beispielsweise durch den Einsatz von ATEK Pneumatic brakes Learn more about different types of brakes.Analyze: Understanding the functions and types of pneumatic brakes
The core principle: Compressed air generates friction
Pneumatic brakes converting supplied air pressure (typically 5-7 bar) directly into braking force: A piston presses the brake pads against a brake disc or drum. This precise power transmission is crucial for repeatable stopping processes, as required for yarn tension control in textile machines. ATEK offers detailed pneumatic solutions , which clarify the operating principle of the, die das Funktionsprinzip der pneumatic brake .
Variety of designs: From disc to fail-safe
In addition to classic disc and drum brakes, fail-safe brakes,Pneumatic brakeswhich securely close in case of a pressure drop, are of great importance. This inherent safety feature, which is often legally required in hoisting devices and for vertical axes, reliably prevents failures and protects both people and machines.. Mayr® fail-safe brakes, for example, exhibit reliability of over 99.9%. Special spring brakes with pneumatic release also exist for specific requirements, a variant of the, eine Variante der pneumatic brake.
Special case: Electropneumatic brakes (EP brakes)
EP brakes represent an interesting development as they combine the robust power of pneumatics with precise electronics control. This enables highly synchronized braking maneuvers, for example, across multiple axes or in trains, significantly improving overall system dynamics.In rail transport, using such electropneumatic braking systems can shorten stopping distances by up to 15% compared to purely pneumatic braking systems. Apply: Make optimal use of pneumatic brakes in applications
Anwenden: Einsatzgebiete pneumatischer Bremsen optimal nutzen
Core industrial applications
Pneumatic brakes are well-suited for packaging machines that can reach up to 120 cycles per minute, as well as for machine tools that require precise positioning. Their robustness and attractive price-performance ratio often make the pneumatic brake the first choice.ATEK supplies these, compressed air brakes for example, for unwinders, where they ensure consistent web tension. Pneumatically operated disc brakes are often used in conveyor systems. Ideal for packaging machines and machine tools due to their robustness and the good price-performance ratio that many
- Ideal für Verpackungsmaschinen und Werkzeugmaschinen dank ihrer Robustheit und dem guten Preis-Leistungs-Verhältnis, das viele pneumatic brakes are characterized by.
- Use in unwinders to ensure constant web tension, a core competence of the pneumatic brake..
- Proven in heavy commercial vehicles, where pneumatic brake systems provide reliable and strong braking performance.
- EP brakes, as advanced pneumatic brake, increase safety in rail transport.
- Indispensable in stage technology for safely holding heavy loads, often implemented with redundant Pneumatic brakes.
- as rotor hold brakes in wind turbines, frequently used pneumatic brake for maintenance work and under high wind loads.
Application in vehicle technology
Heavy commercial vehicles widely rely on pneumatic brakes due to their reliability and ability to provide large, sustained braking forces. An example is the Knorr-Bremse SYNACT®, which allows for a weight reduction of up to 4 kg per brake ( Pneumatic brakes. Ein Beispiel ist die Knorr-Bremse SYNACT®, die eine Gewichtsreduktion von bis zu 4 kg pro Bremse ermöglicht (Knorr-Bremse SYNACT®: Weight -4 kg/brake), which in turn enhances fuel efficiency. More information on various actuation types, including the pneumatic type, is available.
Special areas: From rail to stage
In particularly critical fields, specific designs play a crucial role. pneumatic brake a role: EP brakes significantly contribute to safety in rail transport. In the stage technology, the secure holding of heavy backdrops is often ensured by redundantly designed pneumatic braking systems, which is essential. Wind turbines also use pneumatic brakes as rotor holding brakes, both for maintenance work and to secure against extreme wind loads (up to 200 km/h).Select: Identify the appropriate pneumatic brake and manufacturer
The right questions before selection
Before selecting a pneumatic brake certain key parameters must be clarified: These include the required braking torque (e.g., 500 Nm), the available operating pressure (e.g., 6 bar), and the environmental conditions (temperature, dust load). In particular, the permitted heat dissipation of the pneumatic brake is a crucial factor for its lifespan with frequent braking cycles. For explosive areas, there are special explosion-proof pneumatic brakes.
Overview of leading providers
Leading suppliers of Pneumatic brakes include companies such as ATEK Drive Solutions (wide range of compressed air brakes), mayr® (specialist for safety brakes), and VULKAN (proportional braking solutions). The choice of manufacturer should ideally also offer the possibility of custom adaptations of the pneumatic brake. Globe Airmotors, for example, offers compact brakes specifically designed for air motors.
Finding the optimal solution
The optimal adaptation of a pneumatic brake to the specific application is facilitated by online configurators and knowledgeable technical advice. ATEK’s modular system, for example, allows millions of configurations for gear brake units, supporting a quick delivery of the suitable pneumatic brake. . A careful design of the compressed air brake is critical. can increase system efficiency by up to 5%.Ensure: Optimize installation, maintenance, and safety
Correct installation as a basis
An incorrect alignment or improper fastening during the installation of a pneumatic brake inevitably leads to increased wear and potential malfunctions. For optimal performance and a long lifespan of the compressed air brake is critical. , it is also essential to have clean, dry compressed air with the specified operating pressure (e.g., 5.5 bar). The use of a maintenance device (consisting of filter, regulator, and possibly oiler) is strongly recommended and can extend the lifespan of the pneumatic brake by up to 25%.
- Proper alignment and fastening during installation are fundamental to avoiding wear on any pneumatic brake.
- Clean, dry compressed air with the specific, predetermined pressure is crucial for their performance and longevity. compressed air brake is critical. The use of a maintenance device (filter, regulator, if necessary, oiler) for the compressed air supply can extend the lifespan of the
- Der Einsatz eines Wartungsgeräts (Filter, Regler, ggf. Öler) für die Druckluftversorgung kann die Lebensdauer der pneumatic brake. by up to 25%.
- Regular checks of brake pad thickness and the tightness of air connections are part of the proactive maintenance of pneumatic braking systems.
- A carefully documented maintenance history of the pneumatic brake helps predict failures and reduce unplanned downtimes (one customer reported a reduction of 40%).
- The friction surfaces of the pneumatic brake must always be kept free of oil and grease to prevent impairment of braking effectiveness.
- Compliance with maximum speed and braking torque, as well as the use of protective covers, are important safety measures when operating Pneumatic brakes.
Proactive maintenance for longevity
A regular check of brake pad thickness (some manufacturers like the Double E Group provide wear indicators for this) and the tightness of air connections is essential for the longevity of Pneumatic brakes . As previously mentioned, documented maintenance helps predict potential failures of the pneumatic brake at an early stage. One customer was able to reduce their downtimes by an impressive 40%.
Safety aspects in operation
When operating pneumatic brakes , the use of protective covers as well as strict adherence to the maximum permitted speed and braking torque is required. Particularly important: the friction surfaces of the pneumatic brake must always be kept free of oil and grease, as contaminants can significantly reduce braking effectiveness. For KTR-STOP® brakes, for example, it is noted to keep the environment of the compressed air brake is critical. free from aggressive media to ensure corrosion protection.Benefit: From innovations and future developments in pneumatic brakes
Intelligent brake technology
Digital technologies are also making their way into the pneumatic brake Systems like the Active Caliper Release (ACR) from Knorr-Bremse, for example, reduce the residual drag torque. This not only reduces energy consumption and wear on the pneumatic brake but also operating costs (by up to 5%). Future sensors in Pneumatic brakes will provide even more condition data for predictive maintenance.
Efficiency increase through design
Innovative cooling concepts, such as integrated fan wheels or special air channels (e.g., in brakes from the Double E Group), significantly improve heat dissipation at Pneumatic brakes . A mere 10°C lower operating temperature can already double the lifespan of the brake pads of a pneumatic brake. Modular designs also allow an exact adaptation of the braking force of the compressed air brake is critical. to the specific requirement.
Outlook: Sustainability and networking
The future development of pneumatic brakes will be heavily influenced by topics such as energy efficiency, the reduction of brake dust, and integration into Industry 4.0 concepts. Material innovations, especially in brake pads, promise longer service intervals and a lower environmental impact from the pneumatic brake. ATEK is continuously working on developing advanced solutions in the field of pneumatic brake., such as the compact pneumatic drum brake for conveyor rollers shows.
Pneumatic brakes are and remain powerful and highly adaptable components in modern drive technology. A careful selection and conscientious maintenance of each pneumatic brake secure long-term efficiency and reliability in operation. ATEK Drive Solutions is your competent partner to advise you in optimizing your application with the optimal compressed air brake is critical. .
