Maximum safety and reliability: Everything about hydraulically released, spring-loaded safety brakes in elevator systems.
What is a hydraulically released, spring-loaded safety brake and how does it work in elevators?
A hydraulically released, spring-loaded safety brake for elevator systems uses the force of pre-tensioned springs, to create a braking effect. Hydraulic pressure is used to overcome this spring force and release the brake. If the hydraulic pressure fails, e.g., during a power outage or a leak, the springs automatically push the brake pads against the brake disc and bring the elevator to a safe stop.
Why is the “Fail-Safe” mechanism in these elevator brakes so important?
The “Fail-Safe” mechanism is crucial as it ensures the fundamental safety of the elevator. The brake is designed to gewährleistet. Die Bremse ist so konstruiert, dass sie brake actively without a power supply (unpowered). Any failure of the hydraulic system or power supply automatically triggers the safe engagement of the brake through spring force. This significantly minimizes the risk in an emergency. considerably.
What role does redundancy according to EN 81 play in hydraulically released safety brakes?
The EN 81 standard often requires redundant brake systems, meaning at least two independent brake units. For hydraulically released, spring-loaded safety brakes, this often means that two such brakes or two independent hydraulic circuits are used. If one system fails, the other can take over the braking function, which significantly increases the overall safety of the elevator system..
What are the main advantages of these brakes compared to purely electromagnetic systems for elevators?
Hydraulically released, spring-loaded brakes offer the advantage that the braking force is mechanically stored by springs and thus operates independently of an external power supply. Hydraulics allow for a sensitive and simultaneously very powerful actuation.They can often provide higher and more consistent braking moments over a longer period, which is particularly advantageous with heavy loads and in emergency situations.
How does the selection of hydraulic components contribute to the performance of the safety brake?
The selection of hydraulic components such as pumps, valves, and accumulators is critical. Fast switching valves minimize the response time of the brake (<150 ms is possible). Hydraulic accumulators can compensate for pressure fluctuations and ensure consistent performance. The correct sizing affects not only the operational reliability but also the energy efficiency of the brake system, with optimized units saving up to 30% energy. What noise reduction measures are common in hydraulically released spring force brakes in elevators?
For noise reduction,
quiet hydraulic pumps, damped valves, and flow-optimized lines are used. The goal is often to achieve a noise level of eingesetzt. Ziel ist es oft, einen Geräuschpegel von below 55 dB(A) . Additional measures such as special housings and soundproofing materials can further reduce sound emissions, which significantly improves comfort in passenger elevators.
How do regular maintenance and inspection ensure the safety and reliability of these brake systems?
Regular maintenance, typically annually, includes the inspection of the hydraulic oil, hoses, seals, and brake pads.. Testing procedures according to EN 81-20/50, often conducted by independent agencies such as TÜV, confirm compliance with safety standards through dynamic overload tests and emergency stop simulations. This ensures the long-term functionality and safety of the brakes.
What future developments can be expected for hydraulically released, spring-loaded safety brakes in elevators?
Future developments aim for smarter systems with sensor integration for detailed condition monitoring and predictive maintenance. New brake pad materials promise reduced wear and lower noise emissions.. Integration into digital control architectures and cloud-based diagnostic functions will also play an increasingly important role.
Hydraulically released, spring-loaded safety brakes offer inherent fail-safe security through mechanical spring force and meet strict standards such as EN 81, making them a reliable choice for elevator systems.
These brake systems are characterized by superior performance features , including very fast response times of under 150 milliseconds and the ability to generate high, constant braking moments of over 5,000 Nm , while maintaining precise hydraulic control.
A careful design, the selection of high-quality hydraulic and spring components, as well as regular maintenance, are crucial for longevity and reliability. Modern systems also enable energy savings of up to 30% and pave the way for predictive maintenance concepts..Learn all about the operation, advantages, and applications of hydraulically released, spring-loaded safety brakes for elevators. A must for system builders and operators!
Safety brakes are the heart of any elevator system. In this article, discover how hydraulically released, spring-loaded systems ensure the highest safety standards and what advantages they offer over other technologies. Do you need a customized solution? [Contact us](/contact) for personal consultation!
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Safety brakes for elevators: hydraulically released, spring-loaded – function and importance.
Safety in elevators is a top priority. This article explains the function and significance of hydraulically released, spring-loaded safety brakes for elevator systems..Introduction to hydraulically released, spring-loaded safety brakes for elevator systems.
What defines these special brakes?
Safety brakes of this design, often referred to as hydraulically released, spring-loaded safety brakes for elevator systems use spring force for braking and hydraulics for releasing. Inherent safety is central: Without hydraulic pressure, the spring force takes effect. ATEK Drive Solutions employs such reliable brake systems as they effectively secure the elevator in the event of a system failure.
- Use spring force for braking and hydraulics for releasing.
- Provide inherent safety: Spring force acts in the event of hydraulic pressure failure.
- Are crucial for the protection of people and loads in elevators.
- Ensure braking action even in cases of control or hydraulic failures.
- The spring force acts constantly and independently of external energy.
- Core components include spring accumulators, brake discs/drums, and hydraulic cylinders.
Why are they so crucial for elevators?
These braking mechanisms are essential for elevator safety as they protect people and loads. Their design ensures reliable braking action even in the event of control or hydraulic system failures. The spring force acts continuously and is independent of external energy supply. According to EN 81-20, tests require braking distances of less than 1 meter at rated speed for such elevator brakes.
Overview of core components.
Core components of a hydraulically released, spring-loaded safety brake include the spring accumulator, the brake disc or drum, and the hydraulic cylinder or actuator. Pre-tensioned springs exert the necessary clamping force, while hydraulic pressure releases the brake. This principle significantly supports fail-safety. Such systems typically operate at pressures of over 100 bar. More information can be found under hydraulic brake systems..Understand operation and design principles.
The basic operating principle explains
In normal operation of a hydraulically released, spring-loaded safety brake for elevator systems, the applied hydraulic pressure keeps the brake pads away from the brake disc. If there is a drop in pressure, for example due to a leak or power failure, the stored spring energy comes into play. The spring force pushes the brake pads against the disc, thereby safely stopping the elevator. Response times to reach full braking moment can be under 150 milliseconds.
The invaluable aspect of the fail-safe mechanism.
The term “Fail-Safe” describes a core principle of these brakes: The hydraulically released, spring-loaded safety brake is closed in its rest position, meaning actively braking. Only the built-up hydraulic pressure opens it. Any loss of energy or failure of hydraulic pressure automatically leads to safe braking. For example, in the case of a cable break to the pump, the brake engages immediately. This is a crucial aspect of a reliable emergency stop brake..
Redundancy: Double safety for emergencies.
The EN 81 standard often requires redundant brake systems for elevator systems, meaning at least two independent brake units. This is particularly true for high speeds or heavy loads. If one brake system fails, the other takes over the full braking function. Two such brakes can act at different points of the drive train to further enhance safety. ATEK Drive Solutions, for example, offers servo gear motors with integrated safety brakes, which support this principle.Evaluate applications and benefits in elevator systems.
Diverse application areas in elevator technology.
Hydraulically released, spring-operated safety brakes are used in various applications in elevator technology. This includes passenger elevators, high-speed elevators (with speeds over 10 m/s), freight elevators, and special applications such as inclined elevators. Their robustness and ability to generate high braking forces make them ideal for demanding tasks. In panoramic elevators, for example, the brakes often require particularly quiet operation, which is achieved through optimized hydraulics.
- These brake systems are suitable for various types of elevators: passenger, high-speed, freight, and special elevators.
- They are characterized by robustness and high braking force, ideal for demanding operating conditions.
- They offer crucial advantages over electromagnetic brakes due to their power-independent, mechanically stored braking force.
- The hydraulics allow for sensitive yet powerful brake actuation.
- They advantageously combine the constant, reliable spring force with precisely controllable hydraulics.
- They must meet strict normative requirements such as EN 81, for example, holding 125% of the rated load.
Clear advantages over alternative systems
A clear advantage of hydraulically released, spring-loaded safety brakes for elevator systems. over purely electromagnetic brakes lies in the mechanically stored braking force, which operates independently of a power supply. The hydraulics also allow for sensitive and yet powerful actuation. The combination of constant spring force and controllable hydraulics is particularly advantageous here. A high energy density also enables compact designs, even for braking torques exceeding 5,000 Nm. Further fundamentals can be found in general brake technology.
Keeping normative requirements in mind (EN 81)
The EN 81 standards series, especially parts EN 81-20 and EN 81-50, defines detailed safety requirements for elevators and their components, including the brakes used. It requires, among other things, redundancy and specific testing procedures for hydraulically released, spring-operated safety brakes. Compliance with these standards is a vital aspect of product development and quality for ATEK Drive Solutions. For example, EN 81-20 states that the brakes must safely hold the elevator at 125% of the rated load.Mastering technical aspects and design considerations
Precisely selecting hydraulic system components
The precise selection of hydraulic components such as pumps, valves, and accumulators is crucial for the overall performance of a hydraulically released, spring-loaded safety brake for elevator systems, brake system. Rapid switching valves, for example from manufacturers like Bosch Rexroth, minimize the brake’s response time. Hydraulic accumulators can compensate for pressure fluctuations in the system. The correct sizing of all components influences not just the function but also the energy efficiency of the brake system. Optimized hydraulic units can reduce energy consumption by up to 30%.
Optimizing spring design and material selection
The springs are a key safety element in hydraulically released, spring-operated safety brakes.Their careful design regarding wire diameter, number of turns, and material choice significantly determines achievable braking force and the brake’s lifespan. The use of high-strength spring steels ensures consistent performance over many cycles. The selection of the right spring package is an important engineering step in the design of such elevator brakes. Processes such as shot peening can additionally double the lifespan of the springs. Further details can be found under spring-operated hydraulic disc brakes..
Intelligently integrating monitoring and control
Modern hydraulically released, spring-operated safety brakes brakes often come with integrated sensors, such as micro or proximity switches, that report the current state of the brake (released or closed) to the elevator control. This feedback is essential for safe operation. Continuous monitoring of the brake system allows for early fault detection. In case of deviations from the set values, the control can safely stop the elevator and issue a maintenance notification.
Noise reduction for maximum ride comfort
Noise reduction is an important comfort aspect when operating elevators and thus also for the brakes used. Safety brakes. The use of quiet hydraulic pumps, dampened valves, and flow-optimized lines can significantly reduce the operating noise of the brake. A target level of often below 55 dB(A) is aimed for. Special housings and sound insulation measures can further dampen sound emissions. ATEK Drive Solutions also places great emphasis on quiet solutions in the development of industrial brakes. Maintenance, testing, and anticipating future developmentsEnsuring regular maintenance and inspection
Regelmäßige Wartung und Inspektion sicherstellen
Regular maintenance is essential for the long-term reliability of hydraulically released, spring-loaded safety brakes for elevator systems. brake systems. This includes checking the oil level and condition, inspecting hoses and seals, and monitoring the thickness of the brake pads. An annual maintenance interval is common. Proactive maintenance prevents unexpected failures and prolongs the lifespan of the brake system. A detailed maintenance plan, as provided by ATEK Drive Solutions, is very helpful in this regard.
Adhering to testing procedures and certifications
Before hydraulically released, spring-operated safety brakes being used in elevator systems, they must undergo extensive testing procedures and be certified accordingly. Independent organizations, such as TÜV, verify compliance with the relevant standards, particularly EN 81-20/50. Such certifications confirm the product safety and compliance of the brakes. Type testing typically includes dynamic overload tests and testing of the emergency stop function.
Identifying future trends and innovations
The development in the area of hydraulically released, spring-operated safety brakes for elevators aims for smarter systems. This includes sensor-integrated brakes for detailed condition monitoring and the realization of predictive maintenance concepts. New brake lining materials promise reduced wear and lower noise emissions. The integration into digital control architectures is steadily increasing. In the future, cloud-based diagnostic functions might also play a role. For more information on related topics, see safety brakes for vertical axes..
Choosing the appropriate safety brake is a crucial factor for the overall safety of an elevator system. In particular, hydraulically released, spring-operated systems offer a high degree of mechanical safety. For detailed advice on your specific application, ATEK Drive Solutions is happy to assist you.
