Minimize downtime and optimize your maintenance processes with the innovative braking system from ATEK Drive Solutions.
What are the main advantages of modular brake systems with quick-change pad carriers?
The main advantages are a drastic reduction in maintenance times – often from hours to minutes – and thus a significant reduction in operating costs. This leads to a higher equipment availability and efficiency, as costly downtimes are minimized. One example is a time saving of up to 70% per brake intervention.
How does the quick-change mechanism work in these brake systems?
The mechanism is often based on a special holding device or cage, which secures the brake pads as a unit. This pad carrier can then be released and exchanged without tools or with minimal effort. Patented designs and spring-loaded systems further facilitate this process and ensure a quick and safe handling.
Which industries are particularly suited for these brake systems?
These systems are ideal for industries with high production throughput and low tolerances for downtime.These include the machine and plant engineering, food packaging industry, conveyor technology (especially automated guided vehicles – AGVs), robotics, logistics, and the food industry, where quick maintenance is also important for hygiene reasons.
Do modular brake systems with quick-change pad carriers contribute to sustainability?
Yes, because many quick-change pad carriers are designed to be reconditioned. Instead of discarding the entire carrier, only the worn brake pads are renewed. This werden können. Anstatt den gesamten Träger zu entsorgen, werden nur die verschlissenen Bremsbeläge erneuert. Dies reduces material waste and saves resources, which can lead to material cost savings of up to 60% compared to a new part.
What role does intelligent brake control play in these systems?
Intelligent brake controls optimize performance and lifespan. They can reduce energy consumption by up to 80%, by lowering the voltage after the brake is engaged. Additionally, monitoring systems like the ROBA®-brake-checker enable a predictive maintenance, providing data on wear, temperature, and switching times.
Can these brake systems meet specific safety requirements, e.g., for AGVs?
Yes, especially fail-safe brakes, which are often part of modular systems, are essential for safety-critical applications like AGVs. They ensure that the brake securely engages in case of power failure or emergency stop. In combination with redundant systems, requirements can be met up to Performance Level ‘d’ (PL ‘d’) according to DIN EN ISO 13849 .
How do these systems simplify maintenance and what does that mean for the personnel?
The systems significantly simplify maintenance, as the pad exchange can be done quickly, often without tools and without extensive specialist knowledge. This reduces the training effort for maintenance personnel – a packaging machine manufacturer was able to halve this, for example – and increases the flexibility within the team.
Are there concrete figures for time savings when changing brake pads?
Yes, the time savings are significant. Users report a reduction in downtime of up to 70% per brake intervention.In the steel industry, maintenance time per use was reduced from much longer periods to about 45 minutes, and with ATEK designs, a change is often possible in under five minutes. Modular brake systems with quick-change pad carriers
Modulare Bremssysteme mit Schnellwechsel-Belagträgern drastically minimize downtimes, shortening brake pad changes from hours to minutes. This can lead to a time saving of up to 70% per maintenance intervention.
Through the simple handling and often tool-free exchange, not only is the equipment availability significantly increased, but also the training effort for personnel is reduced by up to 50% and operating costs are lowered by using reconditionable pad carriers (up to 60% material cost savings).
The integration of intelligent control and monitoring systems enables an optimization of energy consumption by up to 80% and supports predictive maintenance concepts, which further enhances the overall efficiency and reliability of these advanced brake systems.Discover how the modular brake system with quick-change pad carriers revolutionizes your maintenance and reduces operating costs.
Downtimes are expensive. ATEK Drive Solutions presents an innovative solution: a modular brake system with quick-change pad carriers. Learn how to optimize your maintenance processes and minimize downtimes. Need a custom solution? Contact us at ATEK Drive Solutions.
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Understand: Modular brake systems with quick-change pad carriers
A brake pad change can cause production lines to be down for hours. Modulare Bremssysteme mit Schnellwechsel-Belagträgern These systems shorten downtime to minutes. Users in logistics report up to 70% time savings per brake intervention through the use of such systems. Minimizing costly downtimes lowers operating costs and promotes efficient maintenance.
The systems, especially modular brake systems with quick-change pad carriers, are well thought out: The quick-change pad carriers allow for exchange without special tools. A packaging machine manufacturer was able to halve the training time for maintenance personnel working with these advanced braking systems. Easy handling increases team flexibility and productivity. Modular system explained.
The brake pad as a easily replaceable unit, a core feature of a modular brake system with quick-change pad carriers, enhances efficiency, especially with high throughput such as in the food industry (hygiene, quick maintenance). Rapid interchangeability ensures continuous production and compliance with standards. Learn more about industrial brakes.Optimize: Utilize the functionality and advantages of modular brake systems with quick-change pad carriers
Functionality of a modular brake system with quick-change pad carriers
Central to a modular brake system with quick-change pad carriers is often a holding device for the tool-free change of the pad carrier; patented ATEK designs allow this in under five minutes. Spring-loaded systems retract the pad carriers after release, prevent collisions, and speed up maintenance. Well-thought-out designs ensure reliability and quick maintenance of these advanced brake systems. Everything about brake pads.
- Quick, tool-free change of pad carriers, often in less than five minutes.
- Spring-loaded mechanisms to avoid collisions and accelerate maintenance.
- Designs that ensure reliability and prompt maintenance.
- Significant reduction in maintenance time, which lowers operating costs.
- Increased equipment availability due to minimized downtimes.
- Use of reconditionable pad carriers to reduce material costs and promote sustainability.
Advantages of modular brake systems with quick-change pad carriers
The main advantage offered by a modular brake system with quick-change pad carriers is the time savings (e.g., in the steel industry: 45 minutes per use), which lowers operating costs and increases equipment availability. Reconditionable pad carriers (up to 60% material cost savings compared to a new part) combine sustainability with cost-effectiveness. Cost reduction and resource conservation are central advantages of these systems. Appropriate brake accessories and recycling options are relevant.Apply: Successfully unlock the application areas of modular brake systems with quick-change pad carriers
Industrial applications
In conveyor technology (e.g., AGVs), reliability is crucial; ATEK fail-safe brakes, often part of a modular brake system with quick-change pad carriers, meet PL ‘d’ (DIN EN ISO 13849). In robotics, the rapid maintenance enabled by such systems reduces arm downtimes from several hours to under one hour. Safety, efficiency, and minimized downtimes are key factors in intralogistics and automation. Conveyor solutions and knowledge about various types of brakes are important.
- Ensuring high reliability in conveyor technology, e.g., for AGVs through fail-safe brakes up to PL ‘d’.
- Drastic reduction of downtimes in robotics, for example from several hours to under one hour.
- Focus on safety, efficiency, and minimizing downtimes in intralogistics and automation.
- Increase in machine availability in mobile applications such as special vehicles under extreme conditions.
- Reduction of workshop times and improvement of cost-effectiveness in commercial vehicles.
- Need for robust and maintenance-friendly brake designs for easy handling.
Mobile applications
Even in mobile applications like special vehicles (mining, agriculture) under harsh conditions, the availability increases. modular brake systems with quick-change pad carriers Electrically actuated lever brakes in commercial vehicles designed as modular systems benefit from shorter workshop times, improving cost-effectiveness. Robust, maintenance-friendly brakes with easy handling are crucial and lower personnel requirements.Design: Optimize technical aspects and design of modular brake systems with quick-change pad carriers
Material selection and construction
Wear-resistant friction materials and corrosion-resistant metals (e.g., special alloys for industrial disc brakes with >10 years of lifespan) are standard in developing a modular brake system with quick-change pad carriers. Compact construction with high power density is important in limited installation space (medical technology, robotic joints) to achieve high braking torques. Material quality and optimized design are crucial for reliability and power density of these brake systems.
- Use of wear-resistant friction materials and corrosion-resistant metals for maximum lifespan.
- Standardization of materials that allow a lifespan of over 10 years.
- Development of compact constructions that ensure high power density in limited installation space.
- Focus on achieving high braking torques, even in compact designs for applications such as medical technology.
- Implementation of modern brake controls to significantly reduce energy consumption.
- Use of monitoring systems to collect data for predictive maintenance.
- Optimization of overall efficiency, extending service life, and adjusting maintenance intervals through intelligent systems.
Integration and control
Modern brake controls (e.g., from ATEK) reduce energy consumption (up to 80%) with a modular brake system with quick-change pad carriers by reducing voltage after engagement, which protects the brake and power source (batteries in AGVs). Monitoring systems (e.g., ROBA®-brake-checker) provide data for the predictive maintenance of such systems. Intelligent control and predictive maintenance optimize efficiency, service life, and maintenance intervals.Further developing: Overcoming challenges for modular brake systems with quick-change shoe carriers and shaping future trends
Challenges
Higher initial costs for a modular brake system with quick-change pad carriers can be mitigated by considering total cost of ownership (e.g., 15% annual savings in maintenance costs). The integration of these systems into existing systems requires planning and expertise, as retrofit solutions demonstrate. Long-term savings and feasible integration are important aspects. Support is provided by a product configurator.
Future developments
Research aims at lighter materials (e.g., carbon fiber) for weight reduction and performance increase, even with a modular brake system with quick-change pad carriers (robotics). Intelligent sensors that report wear and request replacement of shoe carriers simplify maintenance and enhance safety. Lightweight construction, sensors, and networking shape the future of modern brake technology, especially for systems with quick-change shoe carriers in the context of Industry 4.0.Benefit: Secure the advantages of modular brake systems with quick-change shoe carriers for your company
Modulare Bremssysteme mit Schnellwechsel-Belagträgern optimize maintenance through serviceability, efficiency, and cost reduction, lowering total operating costs and increasing competitiveness. Continuous developments (materials, sensors) in these brake systems enable more precise maintenance forecasts and minimize failures. Such modular brake systems are a building block for optimized production processes and future-proof investments. The switch to a modular brake system with quick-change pad carriers pays off quickly through reduced downtimes and ease of handling.
