Maximum safety and reliability underground – ATEK Drive Solutions offers innovative brake solutions for mining.
What makes a mechanical disc brake “explosion-proof” for mining?
A explosion-proof mechanical disc brake for mining machinery prevents ignition sources through specific design features such as low-sparking material selection (e.g., bronze brake carriers), a robust encapsulation (IP6X) against dust and moisture, as well as an intelligent temperature management, to keep surface temperatures safely below the ignition thresholds of methane or coal dust.
What ATEX categories are relevant for brakes in mining machinery and how does ATEK ensure compliance?
For mining, the ATEX equipment group I with the categories M1 (very high safety) and M2 (high safety) is crucial. ATEK ensures compliance through strict adherence to the ATEX product directive 2014/34/EU and relevant standards such as EN ISO 80079-36/-37, which is evidenced by certifications from notified bodies such as DMT GmbH & Co. KG.
How does ATEK address the risk of sparking and high temperatures in its explosion-proof disc brakes?
ATEK minimizes sparking through the careful selection of material pairs, e.g., sintered metal linings with specially treated steel alloys that can reduce sparking by up to 90%. High temperatures are prevented by design measures for heat dissipation such as cooling fins and optionally through PT100 sensors for temperature monitoring to always stay below the ignition temperature.
Can ATEK develop custom explosion-proof mechanical disc brakes for specific mining machines?
Yes, ATEK specializes in the development of custom special solutions for explosion-proof mechanical disc brakes, even in small series. Based on a thorough analysis of specific requirements (braking force, environment, installation) we develop tailored brakes, such as versions for low temperatures or with integrated remote maintenance.
What advantages does ATEK’s modular system offer for explosion-proof brakes for mining?
ATEK’s modular system allows for a high variety of variants and short delivery times for explosion-proof mechanical disc brakes. Standardized, certified Ex-components can be flexibly combined to meet individual requirements quickly, for example, a special disc brake for corrosive environments within a few weeks.
What are the typical maintenance requirements and how does ATEK support operational safety?
ATEK brakes are designed for long maintenance intervals (>20,000 operating hours) . Regular inspections (e.g., visual inspection every 500, detailed inspection every 2000 operating hours) and predictive maintenance strategies are important. ATEK supports this through robust constructions, detailed technical documentation and is working on intelligent brakes with condition monitoring to further optimize maintenance.
Explosion-proof mechanical disc brakes are indispensable for mining machinery , to ensure maximum safety according to, um höchste Sicherheit gemäß ATEX regulations (equipment group I, M1/M2) and relevant standards such as EN ISO 80079-36/-37 to proactively avoid ignition risks in explosive atmospheres.
ATEK Drive Solutions achieves superior safety through careful material selection (e.g., spark reduction of up to 90%), robust IP6X encapsulation und intelligent temperature management (e.g., compliance with T4), which increases reliability and can significantly reduce unplanned downtime.
As a system provider, ATEK not only delivers brakes but also comprehensive, customized drive solutions for mining, where the modular system provides flexibility and fast delivery times (e.g., special solutions in 4 weeks) and through extensive technical consulting can extend maintenance intervals by up to 25% can.Learn how ATEK Drive Solutions’ explosion-proof mechanical disc brakes increase safety in mining while ensuring maximum performance. Discover the benefits of our robust and reliable brake solutions for mining machinery.
In the demanding environment of mining, safety is paramount. Explosion-proof mechanical disc brakes play a crucial role. ATEK Drive Solutions offers you innovative solutions designed specifically for the needs of mining. Contact us at ATEK Drive Solutions, to learn more.
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Introduction: Why explosion-proof mechanical disc brakes for mining machinery are indispensable
Extreme conditions underground – dust, moisture, explosive atmospheres (methane, coal dust) – require special brake solutions, particularly explosion-proof mechanical disc brakes for mining machinery. They must exhibit the highest reliability and must not present an ignition source, which is crucial with heavy loads. The right brake technology is a strategic safety decision. Standard solutions are far from sufficient; full braking performance even in the event of a power failure is essential, as with our proven safety brakes..
“Explosion-proof” means proactive avoidance of ignition sources through construction (material selection, encapsulation). Such mechanical disc brakes, specially designed for use in mining machinery, provide significant braking moments while maintaining a compact design. Sparking and high surface temperatures must be strictly avoided. Temperatures must remain safely below the ignition thresholds of methane (approx. 595°C) or coal dust (approx. 200-500°C), a central aspect of our ATEX brakes, such as our explosion-proof mechanical disc brakes.Durability, long maintenance intervals (>20,000 operating hours) and seamless system integration with components like explosion-proof gear boxes are of great importance.Legal foundations and standards: The framework for explosion protection for mechanical disc brakes for mining machinery
ATEX regulations as a foundation
The ATEX product directive 2014/34/EU is binding for equipment in explosive areas of the EU. For mining, equipment group I with categories M1/M2 is decisive. Our explosion-proof mechanical disc brakes for mining machinery, for example, for underground chain conveyors, meet these strict requirements, certified by recognized bodies such as DMT GmbH & Co. KG.
- The ATEX product directive 2014/34/EU forms the legal basis for equipment used in explosive areas within the EU.
- For the mining sector, the equipment group I with categories M1 (very high safety) and M2 (high safety) is crucial.
- Certifications, for example, by independent testing bodies like DMT GmbH & Co. KG, demonstrate the compliance of the explosion-proof brakes..
- Important standards such as EN ISO 80079-36 (non-electrical equipment for explosive areas – fundamentals and requirements) and EN ISO 80079-37 (non-electrical equipment for explosive areas – protection by constructive safety ‘c’, protection by ignition source monitoring ‘b’, protection by liquid-tight encapsulation ‘k’) create a consistent safety foundation.
- These standards define detailed requirements for the ignition risk assessment and the measures to avoid them at explosion-proof mechanical disc brakes..
- The selection of the correct ignition protection type, such as constructive safety (Ex h c), is fundamental for mechanical brakes, especially for explosion-proof mechanical disc brakes, is of fundamental importance.
- ‘Ex h c’ prevents potential ignition sources through specific constructive measures, such as the use of low-sparking material pairs.
Important IEC/EN standards in detail
Standards such as EN ISO 80079-36 (regarding non-electrical equipment) and EN ISO 80079-37 (focusing on ignition protection type ‘c’ – constructive safety) create a uniform and reliable safety basis. They precisely define the procedures for ignition risk assessment and avoidance. In particular, EN ISO 80079-36 requires a systematic and documented ignition risk assessment, an indispensable guide for the development of our mechanical brakes, especially for explosion-proof disc brakes..
Understanding ignition protection types for mechanical brakes
The correct ignition protection type, such as constructive safety (Ex h c), is of central importance for the safety of explosion-proof mechanical disc brakes for mining machinery. ‘Ex h c’ eliminates ignition risks through thoughtful design, for example, by using low-sparking materials (like bronze brake carriers versus steel brake discs), a principle that is also taken into account in our fixed caliper brakes for heavy-duty industry which often serve as a basis for explosion-proof mechanical disc brakes for mining machinery .Constructive excellence: Design of explosion-proof mechanical disc brakes for mining machinery
Material selection as the first line of defense
Careful material selection is crucial to reducing sparking and excessive heat generation in explosion-proof mechanical disc brakes for mining machinery. Special brake linings ensure a constant coefficient of friction and no harmful wear. Sintered metal linings combined with specially treated steel alloys can reduce sparking by up to 90%, a technology that is suitable for heavy-duty brakes for underground chain conveyors,a typical application for our explosion-proof mechanical disc brakes., is used.
- Careful and tested material selection to minimize potential spark formation and excessive heat development, critical for any explosion-proof mechanical caliper brake.
- Use of specialized brake linings that ensure stable friction values over a wide temperature range and non-hazardous, non-flammable wear (e.g., sintered metal linings).
- Robust and fully encapsulated housings (at least protection class IP6X) to protect internal components from dust and moisture and prevent the escape of ignition sources from the caliper brake.
- Verification and validation of maximum surface temperatures (e.g., adherence to temperature class T4, corresponding to 135°C) through finite element analyses (FEA) and extensive test bench tests.
- Intelligent temperature management to ensure that the surface temperatures of the explosion-proof brake always remain below the ignition threshold temperatures of the surrounding hazardous atmosphere.
- Constructive measures for optimized heat dissipation (e.g., integrated cooling fins on the housing) and optional monitoring of brake temperature by PT100 sensors for critical applications.
- Specific constructive adjustments for explosion protection of explosion-proof caliper brakes, such as effective encapsulation of the brake linings and measures to prevent dust accumulation in the braking area.
Robust housings and effective encapsulation
A robust, effectively encapsulated housing (protection class IP6X) shields the internal components and prevents the escape of potential ignition sources from the explosion-proof mechanical caliper brake. The maximum surface temperatures (e.g., below T4, 135°C) are confirmed by FEA simulations and real tests.
Intelligent temperature management
A sophisticated temperature management system ensures that the surface temperature of the explosion-proof caliper brake remains safely below the ignition temperature of the surrounding atmosphere. Measures for heat dissipation (such as cooling fins) and optional PT100 sensors (for continuous monitoring and possible emergency shutdown) ensure this, for example, when dynamically braking a 10-ton load with a mining machine.
Specifications of explosion-proof caliper brakes
Even explosion-proof mechanical caliper brakes for mining machines require specific adaptations of their fundamentally open design for explosion protection, despite their high braking moments and compactness, such as effective lining encapsulation and measures to prevent dust.ATEK Drive Solutions: Your expertise for safe explosion-proof mechanical disc brakes for mining machinery
ATEK as a system provider: More than just brakes
ATEK combines expertise in brake, Gear Boxes, and servo motor technology as a system provider to deliver comprehensive solutions for mining. Our explosion-proof mechanical disc brakes. solutions are optimally tuned to other drive components such as explosion-proof Gear Boxes which minimizes the number of interfaces and enhances overall performance (e.g., up to 15% better energy efficiency in the system combination).
Modular system for flexibility in explosion protection
Our modular system allows for a variety of configurations and short delivery times for explosion-proof brakes, especially mechanical caliper brakes for mining machines. Standardized, tested components are flexibly combined to meet individual requirements, for example, a special explosion-proof caliper brake for use in environments with corrosive salts, delivered within just 4 weeks.
Custom special solutions for extreme requirements
We design tailor-made special solutions, even in small series, for the most demanding conditions in mining. After a thorough analysis of your specific needs (required braking force, environmental conditions, installation situation), we develop and manufacture tailor-made explosion-proof mechanical disc brakes, such as a variant for low temperatures down to -40°C with integrated remote maintenance option.
Comprehensive consulting and close customer connection
We offer detailed technical consulting to realize optimal and operationally safe braking concepts, such as our explosion-proof mechanical caliper brakes for mining machines. Our experts accompany you from the first inquiry to commissioning and maintenance. One customer was able to extend the maintenance intervals of their systems by 25%. Discover our wide portfolio of industrial brakes.Security in operation: certification, maintenance, and future perspectives for explosion-proof disc brakes.
The path to ATEX certification
The ATEX certification by a notified body certifies the compliance of an explosion-proof mechanical caliper brake for mining machines with the relevant directives after thorough examination of design, materials, and manufacturing processes. For devices of group I, category M1, it must be demonstrated, for example, that even with two independent faults, no active ignition source is present. Our ATEX-certified gear motor, which are often used together with our explosion-proof mechanical disc brakes for mining machinery products, are subject to comparable certification processes.
Regular inspection and proactive maintenance
Regular inspections and a proactive maintenance strategy ensure the durable functionality and explosion protection of explosion-proof mechanical caliper brakes. Proposed intervals (e.g., visual inspection every 500 operating hours, detailed inspection every 2000 operating hours) and the use of digital maintenance plans can increase operational safety by up to 15%.
Seamless documentation and correct labeling
Seamless documentation and the correct labeling of each explosion-proof brake (including information on manufacturer, type, explosion protection class, device group, temperature class, certificate number according to EN ISO 80079-36) are essential. Each of our explosion-proof mechanical disc brakes for mining machinery products receives a nameplate with all relevant information as well as comprehensive technical documentation.
Future music: intelligent explosion-proof brakes
Intelligent explosion-proof brakes equipped with advanced sensors for continuous condition monitoring and predictive maintenance represent the next stage of development. We are intensively working on the development of systems for real-time capture of parameters such as wear, temperature, and vibrations. A explosion-proof caliper brake, which independently signals the optimal time for a lining change, can minimize unplanned downtime by up to 20% – that’s our vision for the future of brake technology in the explosion protection sector.Conclusion: Safety and efficiency through specialized brake technology in mining
The demanding and hazardous conditions in mining require uncompromising safety solutions. Explosion-proof mechanical caliper brakes for mining machines are not just a component but a fundamental pillar for the protection of people and machines. Adhering to strict standards like ATEX, combined with thoughtful design, high-quality material selection, and intelligent temperature management, ensures the necessary reliability underground.
ATEK Drive Solutions stands by you as a competent partner to meet the specific requirements of your mining operation with tailor-made and certified explosion-proof caliper brakes solutions. From consulting and development to maintenance, we offer you a comprehensive service package. Contact us to learn more about how our mechanical disc brakes for mining machinery solutions can sustainably improve the safety and productivity of your mining machines.
