Comprehensive guide to the functionality, selection criteria, and application areas of safety brakes in the industry.
What is the fail-safe principle in safety brakes?
The fail-safe principle ensures that a safety brake automatically transitions to a safe, braked state in the event of a power failure or the defect of a critical component. The braking force is typically generated by preloaded springs that act in the de-energized state, thereby reliably holding or slowing the load.
When do I use a working brake and when do I use a holding brake?
A working brake (or service brake) is used to actively decelerate movements from dynamics, for example, to quickly stop machines. A holding brake primarily secures the standstill of a load that has already been brought to a halt, but must also be able to perform dynamic braking in an emergency, such as during a power failure.
What role does the correct sizing of a safety brake play?
The correct sizing is crucial for the safety and reliable function of the system. It must consider the maximum load moment, required safety factors (usually between 1.5 and 3), the braking work that occurs in emergencies, and the necessary switching times, especially for vertical axes, in order to effectively protect people and machines.
Why are certifications like DGUV Test or TÜV important for safety brakes?
Certifications by independent organizations like DGUV Test or TÜV confirm that the safety brake has passed strict tests and meets specific safety standards and regulations (e.g. EN ISO 13849). This gives users the assurance of using a tested and reliable component for safety-critical applications.
How does an electromagnetic spring-applied safety brake work?
In an electromagnetic spring-applied safety brake, preloaded springs press against an anchor disc in the de-energized state. This compresses friction pads, which are connected to the shaft to be braked, against a fixed counter surface (e.g. motor shield) and thus generates the braking torque. When the integrated electromagnet is energized,. Diese presst Reibbeläge, die mit der zu bremsenden Welle verbunden sind, gegen eine feste Gegenfläche (z.B. Motorschild) und erzeugt so das Bremsmoment. Wird die integrierte Magnetspule bestromt, a magnetic field builds up, which attracts the anchor disc and thus releases the brake, allowing the shaft to rotate freely.
What should I consider when I need a custom safety brake solution?
When it comes to custom safety brake solutions, it is important to choose a partner with comprehensive system expertise and proven experience in developing special solutions. The ability to optimally integrate the safety brake into the entire drive system and to precisely address individual requirements such as installation space, specific braking torque, environmental conditions, and required service life are crucial. A modular system from the supplier can offer high flexibility and quick implementation times .
Safety brakes are essential components for the protection of personnel and machines in industrial applications. Through the fail-safe principle, they ensure reliable holding or stopping, especially in the event of a power failure, thereby significantly reducing accident risks..
The correct selection between working and holding brakes, as well as different designs such as spring-applied or permanent magnet brakes is application-specific. A detailed analysis of the requirements can reduce unplanned downtime by up to 20% and increase the system efficiency..
A precise sizing taking into account load moments, safety factors, and switching times as well as adherence to standards and certifications are essential for reliability. Modern monitoring systems can also optimize the maintenance intervals and extend the lifespan of the brakes by up to 15%..Learn everything about safety brakes: From the basics to the different designs and the most important selection criteria for your specific application. Ensure maximum safety in your drive technology!
Safety brakes are essential for reliably stopping moving loads and protecting people and equipment. Whether in robotics, mechanical engineering, or stage technology – the right safety brake can save lives. Do you have questions about the optimal solution for your application? Contact us now Contact now!
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Introduction to safety brakes.
Safety brakes are critical components in mechanical engineering for the protection of personnel and equipment. Their correct selection is crucial for operational safety and application-specific requirements.
The invisible lifesavers of your machines.
In automated production facilities, such safety devices can often make the difference between smooth operation and costly accidents in the event of unexpected drive failures. One example is the packaging industry, where rapid stops ensure product quality and operator safety.
More than just a component: A necessity.
For industries such as the brake motor in mechanical engineering or stage technology, where suspended loads need to be secured, integrating a reliable braking device is a legal and ethical obligation. It minimizes downtime and secures the longevity of the system.
Basic principles for guaranteed safety.
Most models operate on the fail-safe principle: In the de-energized state, they remain closed, safely holding the load. This principle is essential in power failure or emergency situations, as in elevator applications with FPC brakes that trigger mechanically in the event of overspeed.Functionality and principles of safety brakes.
The core: The spring-applied principle
Preloaded springs generate braking force by compressing friction pads while at rest. The release, that is, the opening of the brake, occurs through power supply – electromagnetically, pneumatically, or hydraulically.Electromagnetic spring-applied brakes, for example, on the B-side of electric motors with brakes, close immediately in the event of power loss.
- The spring-applied principle uses preloaded springs for generating braking force when at rest.
- The release, that is, the opening of the brake, occurs through power supply (electromagnetically, pneumatically, or hydraulically).
- Electromagnetic spring-applied brakes are characterized by immediate closing in the event of power loss.
- The fail-safe principle ensures that the safety brake automatically transitions to a safe, braked state during power failure.
- Manufacturers like Mayr rely on redundant spring systems to ensure sufficient braking force even in the event of a spring break.
- In addition to spring-applied brakes, there are also permanent magnet brakes with advantages such as play-free operation and fast switching times.
- The choice of design depends on specific application requirements such as switching frequency and compactness.
Always safe: The fail-safe principle explained.
The fail-safe principle ensures that the holding device automatically transitions to a safe, braked state in the event of a power supply failure or a critical component failing. Even in the event of a spring break, there must often still be sufficient braking force available, which manufacturers like Mayr ensure through redundant spring systems and tests., what manufacturers like Mayr ensure through redundant spring systems and tests.
Variety in construction: Common designs.
In addition to electromagnetic spring-applied brakes, there are permanent magnet brakes (advantages: play-free operation, fast switching times; typically open at wear limits). The choice of design depends on the requirements of the specific industrial brakes-application (e.g. switching frequency, compactness, as in KEB solutions). (z.B. Schalthäufigkeit, Kompaktheit, wie bei KEB Lösungen).Areas of application and examples.
Working brake or holding brake: What do you need?
Working brakes actively decelerate movements (e.g. table saw). Holding brakes primarily secure standstill, but must also be able to perform dynamic braking in emergencies (e.g. AGV from Kendrion INTORQ in emergency stop).
Safety in the vertical: Gravity-loaded axes.
In vertical axes, they prevent Safety brakes uncontrolled descent (person/machine protection). SITEMA offers KSP (pneumatic) and KSE (electric) series, often DGUV Test certified.
Special cases: From wind power to stage technology.
In wind turbines, they secure pitch/yaw systems (KEB). In stage/lifting technology, double or emergency stop brakes (Roba-stop-stage from Mayr) are often used for redundancy/quiet operation. Modern systems are adaptable..
Mobile helpers and heights: AGVs and elevators.
Kendrion INTORQ supplies brakes for AGVs/AMRs (emergency stops, holding during power failure). Mechanically triggered safety brakes such as the FPC series for elevators kick in during overspeed (certified to EN 12158).Selection criteria and sizing.
Asking the right questions: Application and standards.
The selection of a suitable safety brake is based on the analysis of the application, applicable standards and regulations. Environmental conditions (e.g. maritime corrosion risk) and installation options are relevant factors.. For cranes: fail-safe spring-actuated brakes.
- The selection of the safety brake must be based on a thorough analysis of the application as well as applicable standards and regulations.
- Important factors in the selection are environmental conditions (e.g. corrosion risk) and available installation options.
- For maximum safety in critical applications, redundancy through double brakes or the use of different brake types/positions is recommended.
- The correct sizing of the holding torque, considering the load moment and a safety factor (typically 1.5-3), is crucial.
- For vertical axes, switching times may be more important than pure holding torque to prevent unacceptable accelerations.
- The ability of each braking componentto absorb dynamic braking energy must be checked, especially in applications such as servo gear motors.
- Modern monitoring technologies, from simple microswitches to systems like the Roba-brake-checker, are essential for condition monitoring and predictive maintenance.
More is more? Redundancy for maximum safety.
In critical applications, redundancy is utilized: double brakes or various redundancies (different brake types/positions). Systems such as Roba-stop-stage brakes significantly increase failure safety (e.g., stage technology).
Numbers, data, facts: The correct sizing
The holding moment (based on load moment and safety factor 1.5-3) is a central value. Switching times can be more critical in vertical axes (to prevent excessive acceleration). The ability to absorb dynamic braking energy must be checked (design Servo gear motors with safety brake).
Always in view: Modern monitoring technologies
Simple micro switches indicate the state (open/closed). More advanced systems serve detailed monitoring/predictive maintenance. The Roba-brake-checker from Mayr analyzes current/voltage curves for anomaly/wear detection.Manufacturers and certifications
The specialists in the market: An overview
Mayr: Focus on fail-safe principle, wide product range, 100% end-of-line tests. SITEMA: Specialization in Safety braking devices for gravity-loaded axes. KEB: Spring-applied and permanent magnet brakes. Kendrion INTORQ: Market leader for brakes in AGVs/AMRs. Siebenhaar: hydraulically ventilated disc brakes.
Proven safety: Important certifications
Certifications by independent organizations confirm conformity with safety standards. DGUV Test Certificate (SITEMA KSP series) for the German market. TÜV certifications (CE/UL for SITEMA KSE series) for international use. EN 12158 (FPC Safety brakes) for lifting equipment. These certificates attest to tests of safety brake.
Quality and customization: What manufacturers provide
Good manufacturers offer product quality and customization to specific customer requirements (standard products/custom solutions). Examples: Adjustment of braking torque, special coatings, integration into complex braking technology-systems. ATEK Drive Solutions: modular construction system.
The selection of the correct emergency stop brake requires expertise and consideration of all aspects from function to application. This investment protects machines and employees. We are available for individual consultation.
