Guide to optimal cleaning and maintenance of disc brakes for machines and equipment
Which cleaning agents are safe and effective for industrial disc brakes?
For industrial disc brakes, special brake cleaners based on alcohol or pure isopropanol (at least 70% solution) are recommended. These remove grease, oil, and dirt without leaving any residue, without attacking the materials. Definitely avoid oily substances such as WD-40 or aggressive household cleaners, as they can severely impair braking performance.
How often should disc brakes in production facilities be cleaned?
The cleaning intervals depend heavily on operating conditions and environmental pollution. A general guideline is a visual inspection and basic cleaning every three months or after about 500 operating hours. In dusty or humid environments, such as in the cement or food industry, significantly shorter intervals for cleaning disc brakes are necessary.
What are the main causes of brake squeal in industrial plants and how can I fix it?
Squealing in industrial brakes is often caused by contamination, glazed brake pads, or vibrations in the braking system . A thorough cleaning of the disc and the caliper, lightly sanding the pads, as well as the correct alignment of the brake caliper , can remedy the situation and restore the optimal function.
Can oil-soaked brake pads on industrial machines be cleaned or do they need to be replaced?
Caution is advised with oil-soaked brake pads. While the brake disc can be thoroughly cleaned, for the pads, a replacement is usually the safest and most economical solution. Oil penetrates deep into the pad material, and complete decontamination is often not possible, which endangers the braking performance and operational safety in the long term..
What torque should be considered when reattaching brake discs in industrial applications?
The correct tightening torque is crucial for the safety and function of the braking system. It is always the torque specified by the manufacturer of the brake or machine to be used, which is listed in the technical manual. Incorrect assembly can lead to serious damage or brake failure..
How does proper cleaning of disc brakes affect their lifespan and operating costs?
Regular and proper cleaning can significantly extend the lifetime of brake components, potentially by up to 20%. It prevents abrasive wear from dirt particles and corrosion, which reduces maintenance costs and increases plant availability..
What is meant by ‘glazing’ in brake pads and how can it be prevented?
Glazing refers to a hard, shiny surface on the brake pads, typically caused by overheating, which reduces friction and braking effect. Preventing it can be achieved through a proper brake design for the specific application, avoiding prolonged overload and selecting high-quality, temperature-resistant brake pads..
Why is the absolute cleanliness of the brake disc so critical for the coefficient of friction?
The cleanliness of the brake disc is directly responsible for the optimal coefficient of friction and thus for braking performance. Even the smallest amounts of grease, oil, or dirt can drastically reduce the coefficient of friction – by more than 50% in case of oil contamination – which leads to dangerously extended stopping distances and increased safety risks.
Regular cleaning is crucial: Properly cleaning disc brakes with suitable agents like isopropanol ensures the optimal braking performance and can extend the lifetime of the components by up to 20%..
Avoid contamination: Oil and incorrect agents can dangerously reduce the braking force – by over 50% in the case of oil.Oily pads should usually be replaced for safety reasons to ensure the full functionality..
Preventive maintenance pays off: Regular inspection and proper handling (e.g., torque) minimize long-term damage and downtime, which significantly increases operational safety..Learn how to professionally clean disc brakes to avoid squeaking, extend lifespan, and optimize the braking performance of your systems.
Squeaking or poorly braking disc brakes can severely disrupt the production process. Therefore, regular and proper cleaning is essential. In this article, discover the best practices and products for cleaning disc brakes. Need custom drive solutions? Contact us at ATEK Drive Solutions.
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Understand: Why clean disc brakes are crucial
Decreased braking performance and squeaky disc brakes often indicate dirty components. This article explains how to professionally clean and maintain disc brakes to ensure full performance and safety.
Why is a clean braking system so important?
A delayed response brake, e.g., on a production machine, is a avoidable risk. Regular cleaning of the braking system is crucial for operational safety and can extend the lifetime of brake components by up to 20%. Our overview of brakes provides further information.
Basics of disc brake function
Dirt affects the friction between the pad and disc. Even the finest dust can significantly reduce braking performance, similar to the aquaplaning effect, where a film of water prevents contact. A clean surface, the result of careful brake disc care, ensures the optimal coefficient of friction, specified, for example, for our industrial disc brakes..
Safety aspects in brake maintenance
Improper cleaning of brakes can cause damage. Wrong agents can attack materials or leave residues, which dangerously diminishes braking performance. This is critical in systems that must secure tons of heavy loads.Identifying: Causes and effects of brake contamination
Identify typical sources of contamination
Dirt that reduces braking performance often comes from environmental influences (dust, moisture) or operating fluids (oil, grease) due to leaks or careless lubrication. Especially problematic is stuck brake dust; a drive through dust can reduce performance by 10-15%. Suitable accessories can support the care of the braking system. Consequences of contamination for braking performance
Folgen von Verunreinigungen für die Bremsleistung
Dirty components reduce braking force, cause squeaking, or uncontrolled braking. Oily pads can lose coefficients of friction by over 50%, which drastically extends stopping distances. Regularly cleaning the brake discs, even with stainless steel variants, is therefore important.
Long-term damage from lack of maintenance
Dirty brakes often suffer from permanent damage. Dirt particles act abrasively and accelerate wear. Neglected brake maintenance often leads to corrosion on brake calipers or seized pistons.; winter salts can quickly cause corrosion damage without thorough cleaning of the brake components. Act: Effectively clean disc brakes – methods and agents
Handeln: Scheibenbremsen effektiv reinigen – Methoden und Mittel
Select suitable cleaning agents
For cleaning, clean special brake cleaners (alcohol-based) or pure isopropanol (70% solution ideal) are suitable. These gently dissolve dirt, effectively remove fats/oils, and evaporate without residue. Avoid products like WD-40 or aggressive household cleaners (oil content, material attack); oily residues can reduce braking force by up to 60%. More about cleaning disc brakes here.
- Use special brake cleaners based on alcohol or pure isopropanol (70% solution) to clean your disc brakes..
- Avoid products like WD-40 or aggressive household cleaners that leave residues or attack materials.
- Wipe the brake disc with a clean, lint-free cloth and cleaner; disassemble it for a thorough cleaning of the disc brake..
- Pay attention to the correct torque (e.g. 6 Nm) when reattaching the brake disc.
- Inspect brake pads for glazing or oil; lightly sand glazed pads or replace oil-soaked pads.
- Clean the brake caliper carefully with a brush and special brake cleaner.
Step-by-step guide to cleaning the brake disc
To clean the brake disc, apply cleaner to a clean, lint-free cloth and thoroughly wipe the brake disc, especially the contact ring. For an intensive cleaning, disassemble the brake disc (often with Torx T25), paying attention to correct torque (e.g., 6 Nm) when reattaching. Our overview of brake types provides insights.
Properly handle brake pads and calipers
Examine brake pads for glazing (hard, shiny surface) or oil traces. Lightly glazed pads should be carefully roughed up with fine sandpaper (e.g. 120 grit).; replace heavily oil-soaked pads (decontamination difficult). Clean the brake caliper with a brush and special brake cleaner clean, to maintain the overall braking system.Address: Overcome specific brake problems such as squeaking and oil contamination
effectively eliminate squeaking noises
Squeaking is often caused by dirt or light pad glazing. A thorough cleaning of the disc brakes and light sanding of the pad surface often helps; removing brake dust can reduce noise-causing vibrations by up to 80%. Anti-squeal paste (on the back of the pad, not the friction surface) can also help.
Dealing with oiled brake components
Act quickly with oil on the brake: Thoroughly clean the brake disc immediately with brake cleaner/isopropanol clean. Caution with brake pads: Replace heavily oil-soaked pads (safest solution), as oil penetrates deeply and simple cleaning of the brake pads often is not enough. Burning out is risky/not sustainable; new pads (often <30 euros) restore safety.
Understand and address glazing of the brake pads
Shiny, poorly gripping pads indicate glazing (often caused by overheating). Carefully remove the glazed layer with sandpaper (until matte); grind evenly and parallel to the backing plate. In case of frequent occurrence, adjust braking style or consider temperature-resistant pads (industrial disc brakes.)Prevent: Maximize lifespan and performance through preventive maintenance
Establish intervals for preventive maintenance
The frequency with which you should check and inspect your clean depends on operating conditions and usage intensity. As a rule of thumb: At least every three months or after about 500 operating hours a visual inspection/basic cleaning; with heavy use/dirt environment, a more frequent care of the braking system. is necessary. Brakes in the food industry often require daily checks.
- Adapt inspection and cleaning intervals for the brakes to operating conditions (rule of thumb: every 3 months or 500 operating hours).
- Carefully cover the brake disc and caliper when lubricating adjacent parts to avoid contamination and the need for unscheduled cleaning of the disc brake. .
- Avoid touching the brake discs with bare hands to prevent the transfer of skin oils.
- Ensure correct brake adjustment, especially the centered alignment of the brake caliper.
- Invest in high-quality brake pads that produce less dust and offer consistent performance.
- Increase the frequency for the maintenance and cleaning of the disc brakes with intense use or in heavily soiled environments.
- Consider that even the smallest amounts of oil (less than 0.1 ml) can significantly affect friction and require immediate cleaning of the brake .
Tips for avoiding contamination
To minimize contamination: Be careful when lubricating nearby parts. Cover the brake disc and caliper during such work. Do not touch brake discs with bare hands (skin oils reduce performance). Less than 0.1 ml of oil can significantly reduce friction, necessitating immediate cleaning of the brake components .
Importance of correct adjustment and high-quality components
Correct brake adjustment affects cleanliness and function; incorrect alignment leads to uneven wear/dirt accumulation. Pay attention to centered brake caliper alignment and suitable, high-quality brake pads. Quality pads (e.g., from ATEK) produce less dust and provide consistent performance, which can extend the intervals for the clean .
Careful clean and maintenance are crucial for the function and safety of disc brakes. The right methods and means ensure reliable braking performance and a longer lifespan of the components. Quality and precision are essential here. Contact us for customized braking solutions.
