Reliable brake solutions for demanding applications in crane construction – from standard to custom manufacturing.
What is the main function of a spring-operated disc brake on a portal crane?
Die Main function of a spring-operated disc brake is to securely hold the load on a portal crane, especially in the event of a power failure or emergency. It acts as an essential safety component.
Why is the ‘Fail-Safe’ property so important for these brakes?
Die ‘Fail-Safe’ property ensures that the brake automatically engages through spring force, when the energy supply (e.g., electrical, hydraulic) fails. This is crucial for system safety and prevents uncontrolled movements or falling loads, which is particularly essential in critical applications such as nuclear power plants or when handling heavy goods.
What advantages do spring-operated disc brakes from ATEK offer in harsh environmental conditions?
Spring-operated disc brakes from ATEK are designed for harsh environments.They offer high protection classes (e.g., IP66/IP67) against dust and moisture and can be equipped with special surface treatments such as nitrocarburizing, which make them extremely resistant to corrosion. This ensures a long service life and reliable function even under adverse conditions, such as those found in ports or heavy industry.
How is the correct braking torque for a spring-operated disc brake on a portal crane determined?
The required braking torque is calculated based on the maximum load, dynamic forces, and relevant standards. It is common to apply a safety factor (often between 1.5 and 2.5) to the static load moment. An accurate design, as offered by ATEK, is crucial to avoid underdosing and safety risks.
Can spring-operated disc brakes from ATEK be adapted to specific installation situations?
Yes, ATEK Drive Solutions specializes in custom drive solutions.Thanks to a modular system and strong engineering expertise, spring-operated disc brakes can be adapted to specific installation situations, space conditions, and performance requirements. Special solutions in small series are also feasible. What contribution do special surface treatments make to the durability of the brakes?
Welchen Beitrag leisten spezielle Oberflächenbehandlungen zur Langlebigkeit der Bremsen?
Special surface treatments like nitrocarburizing and post-oxidation significantly increase the surface hardness and corrosion resistance of the brake components. This leads to a significantly longer lifespan, especially in aggressive environments, and can enhance the wear resistance by up to 50%..
How does ATEK assist in the selection and integration of the right brake for portal cranes?
ATEK provides comprehensive technical consulting and support in the design and optimization of drive solutions. By closely collaborating with the customer, the ideal spring-operated disc brake for the specific portal crane application is selected and its seamless integration ensured. This also includes consideration of environmental conditions and maintenance requirements..
What role does sensor integration play in modern spring-operated disc brakes?
The integration of sensors enables a continuous monitoring of the brake status, for example, the wear of the brake pads or the switching state. This data forms the basis for predictive maintenance concepts,, thereby avoiding unplanned failures and increasing the availability of the system. Spring-operated disc brakes
Federbetätigte Sattelbremsen are essential for portal cranes, as their fail-safe function reliably secures the load in case of power failure, thus significantly enhancing system safety. Thanks to.
Dank robust construction, special surface treatments such as nitrocarburizing (+50% wear resistance) and designs like the double surface principle, these brakes offer+50% Verschleißfestigkeit) und Designs wie dem Doppelflächen-Prinzip bieten diese Bremsen maximum reliability and durability (>720 hours salt spray test) even under extreme conditions.>720h Salznebeltest) selbst unter extremen Bedingungen.
ATEK Drive Solutions delivers tailored braking solutions as a system provider, which impress with technical expertise, quick integration (up to 30 minutes time savings per brake), and comprehensive consulting. portal cranes,, die durch technische Expertise, schnelle Integration (bis zu 30 Min. Zeitersparnis pro Bremse) und umfassende Beratung überzeugen.Learn how spring-operated disc brakes optimize the safety and efficiency of portal cranes. Discover the advantages, application areas, and technical details of these essential components.
Portal cranes are indispensable for lifting and moving heavy loads. Spring-operated disc brakes play a crucial role in this. Are you looking for the optimal brake solution for your portal crane? Our experts are happy to advise you – contact us now. Contact us!
Do you need a customized braking solution for your portal crane?
Request your individual solution now!
Understanding: The role of spring-operated brakes in portal cranes
In case of a power failure, the reliable function of a spring-operated disc brake an on portal cranes protects against serious incidents. As important safety components, e.g. in handling nuclear fuel elements, their failure must be excluded. The selection of the correct gegen schwerwiegende Vorfälle. Als wichtige Sicherheitskomponenten, z.B. bei der Handhabung von Brennelementen in Kernkraftwerken, muss ihr Versagen ausgeschlossen sein. Die Auswahl der korrekten safety brake, especially a suitable spring-operated brake for portal cranes,, is crucial for operation and system safety.
Their main task is the immediate, safe holding of the load during energy loss. In ports, where portal cranes, containers are loaded, an industrial brake, such as the spring-operated disc brake, must also be reliable after many cycles and under harsh conditions. Fail-safety is fundamental. ATEK Drive Solutions GmbH develops suitable braking solutions, including specialized spring-operated disc brakes for portal cranes,, based on experience and modern brake technology..Optimize: Utilize functionality and advantages effectively.
Basic principle of operation
The function without electricity, a core feature of the spring-operated disc brake for portal cranes,is based on spring force. In normal operation, external forces (electromagnetic, pneumatic, hydraulic) keep the brake pads away from the brake disc. In the event of a power failure, pre-tensioned springs press the pads against the disc. This mechanical redundancy is the core of the fail-safe property.Example: Hold a 50-ton load of a portal crane in case of control failure by such a spring pressure brake.
- Function reliably without electricity thanks to pre-tensioned spring force – typical for a spring-operated disc brake,.
- Provide inherent fail-safety through mechanical redundancy.
- Characterized by high robustness (often IP66+) and resist dust and spray water, ideal for use in on portal cranes protects against serious incidents. As important safety components, e.g. in handling nuclear fuel elements, their failure must be excluded. The selection of the correct.
- Require low maintenance, minimizing service intervals and reducing operational costs.
- Enable a long service life, often over 1 million cycles without pad replacement.
- Compact design facilitates integration, even in limited installation space on portal crane systems..
Advantages over other braking systems
In addition to fail-safety, these brakes, especially the spring-operated disc brakes for portal cranes,, are robust (often IP66+), resistant to dust/spray water – ideal for foundries or port facilities. Low maintenance is another advantage of these safety brakes for portal cranes.. Modern ATEK designs minimize service intervals and reduce operating costs.. A well-designed brake can achieve >1 million cycles without pad replacement. Compact design facilitates integration even in limited space, as in servo gear motors with integrated brake..Application: Federbetätigte Sattelbremsen master critical portal crane-sectors.
Nuclear power plants and sensitive areas
In nuclear power plants, the highest reliability of brakes for portal cranes is necessary. Here, spring-operated disc brakes are often used, as they secure the handling of fuel elements, where failures could have serious consequences. federbetätigte Sattelbremsen zum Einsatz, da sie das Handling von Brennelementen sichern, wo Fehler gravierende Folgen hätten. The brakes must also be fully functional immediately after long periods of inactivity.ATEK provides solutions for extreme requirements (e.g., lifespan of 40 years), especially in the design of spring-operated disc brakes for portal cranes, such environments. This operational safety is also crucial for fail-safe brakes for crane winches. essential.
Machine and plant engineering
In mechanical engineering, precision and safety in moving heavy components are important. A portal crane,equipped with a reliable spring-loaded brake,, could position a 20-ton press mold. Brake failure can cause material damage and endanger employees. Spring-operated disc brakes ensure secure holding of the load during emergency stops.ATEK’s modular system allows the design of the spring-operated brake for the respective portal crane to specific load profiles and environments.
Logistics and heavy industry
In heavy-duty industries (steelworks, shipbuilding), the loads are high. portal cranes, often moving loads >100 tons. Uncontrolled descent would have devastating consequences. ATEK’s fixed caliper brakes for the heavy-duty industry., often designed as robust spring-applied disc brakes for portal cranes, are intended for extreme conditions, provide high braking torques and long service life under harsh conditions (e.g., 24/7 container terminal).Select: Define criteria for durable and safe braking performance
Braking torque and safety factors
The braking torque considers more than the maximum load. When selecting a spring-operated disc brake for portal cranes, , a safety factor of 1.5-2.5 on the static load torque is recommended (application & standard dependent). An undersized brake, especially in a safety-relevant spring-applied disc brake for a portal crane, poses a significant safety risk. A 10-ton crane brake on a portal crane, often requires >1500 Nm holding torque for dynamics/emergencies. The correct design of such spring-applied brakes for portal cranes is part of the ATEK brake technology consulting.
- Precise calculation of the braking torque including adequate safety factors (typ. 1.5-2.5) to avoid undersizing the brake for your portal crane.
- Careful consideration of the environmental conditions (dust, moisture, corrosion) in the material selection and surface treatment of the disc brake.
- Selection of suitable materials (e.g., stainless steel) and advanced surface treatments (e.g., nitrocarburizing) for maximum durability of the spring-applied brake.
- Ensuring easy integration through compact design and standardized interfaces of the brake on the portal crane.
- Minimizing maintenance effort to optimize life cycle costs and ensure the operational readiness of the fail-safe brake.
Environmental conditions and material selection
Environments (dust, saline air) affect the lifespan. Proper material choice and surface treatment are crucial for the reliability of a spring-applied disc brake for portal cranes. For corrosive environments, as often encountered in portal crane systems. the port area, ATEK offers stainless steel components or special coatings (up to IP67). Nitrocarburizing the brake disc can increase wear resistance by 50%.
Integration and maintenance effort
Compact dimensions and standard interfaces (e.g., ATEK NFF series) simplify the installation of the spring-applied disc brake on the portal crane. Life cycle costs depend on maintenance effort. ATEK brakes, especially the spring-operated disc brakes for portal cranes,, are low maintenance. Direct mounting on the motor flange saves up to 30 minutes of installation time per brake, relevant for electric motors with brakes.Innovate: Utilize technical details for peak performance and reliability
Double face design for maximum force
High braking forces in a compact design, as often required in spring-operated disc brakes for portal cranes, , are made possible by the double face design: two friction surfaces per brake caliper act on the brake disc. This nearly doubles the braking torque compared to single face brakes of the same size. ATEK’s NFF 400 thus generates up to 4,400 Nm, ideal for heavy gear boxes an portal cranes. The technology enables space-saving solutions for demanding applications with spring-applied brakes.
- Application of the double face design to achieve high braking forces in a compact design, which nearly doubles the braking torque in disc brakes for portal cranes .
- Application of advanced surface treatments such as nitrocarburizing and post-oxidation for superior durability of the spring-applied brake components.
- Increase in corrosion resistance and surface hardness through these special treatments, ideal for aggressive environments where portal crane brakes operate.
- Proven resilience of treated parts, for example, over 720 hours in salt spray test (DIN EN ISO 9227).
- Integration of sensors for intelligent monitoring of brake wear and current switching status in spring pressure brakes for portal cranes.
- Use of sensor data for predictive maintenance concepts to prevent failures.
- Development of intelligent brake functions as a contribution to Industry 4.0 applications and increased plant efficiency, even with brakes for portal crane systems.
Special surface treatments for longevity
For extreme conditions to which spring-operated disc brakes for portal cranes, may be exposed, ATEK employs advanced surface treatments. Nitrocarburizing and post-oxidation of steel parts increases corrosion resistance (similar to stainless steel) and surface hardness. These treatments extend the life of brakes for portal cranes in aggressive environments. Such treated brakes withstand the salt spray test (DIN EN ISO 9227) for >720 hours.
Sensor integration and intelligent braking
Modern spring-operated disc brakes for portal cranes, can have sensors for wear and switching status monitoring. Data enables predictive maintenance, preventing failures. A sensor, for example, reports 80% friction material wear, making replacement predictable. Intelligent functions are a step towards Industry 4.0 components and part of ATEK’s emergency stop brakes, which are often used as safety brakes on portal cranes .Secure: Shape the future of your plants with spring-operated disc brakes for portal cranes, spring-applied disc brakes for portal cranes
are essential safety components. Their fail-safe function, robustness, and low maintenance make them sind unverzichtbare Sicherheitskomponenten. Ihre Fail-Safe-Funktion, Robustheit und geringer Wartungsaufwand machen diese brakes for portal crane systems the preferred choice for safety-critical applications. The correct design and selection of a spring-applied disc brake for your portal crane, taking into account environmental conditions and reliability requirements (even after downtime), is crucial. Future developments in spring-applied brakes for portal cranes include: higher power density, expanded sensor technology (predictive maintenance), and deeper digital integration. ATEK Drive Solutions GmbH supports you in utilizing these technologies.
For the safety and efficiency of your portal cranes, contact us for comprehensive consulting on spring-applied disc brakes and the tailored ATEK solutions for your portal crane application.
