Functionality, advantages, and areas of application of axial brakes in detail – expert knowledge for mechanical engineering professionals.
What are the main applications of axial brakes in the industry?
Axial brakes are used in various applications, e.g. in packaging machines, machine tools, robotics, conveyor systems, and stage technology.. Their strength lies in the reliable and precise deceleration, where a direct axial force input is required.
How do axial and radial brakes differ for industrial applications?
The main difference lies in the mounting and force application. Axial brakes act perpendicular to the rotation axis, radial brakes act parallel. For many industrial applications, the robustness, cost-performance ratio, and easy integration of the axial brake are more decisive than the adaptability often highlighted for radial brakes, which is primarily relevant in motorsport.
What advantages do axial brakes offer for machines and systems?
Axial brakes often provide a robust and cost-effective solution for standard and special applications. They are technologically proven, reliable in operation and often allow for easier integration into existing constructions. Certain designs such as floating caliper axial brakes can also compensate for slight alignment errors.
When should I consider a custom axial brake solution from ATEK Drive Solutions?
A custom solution makes sense when standard brakes do not optimally meet the specific requirements of your application – for example, in special installation situations, extreme environmental conditions, or specific performance demands such as high holding forces or short switching times. ATEK Drive Solutions also develops such special solutions in small series.
What is the benefit of systems such as Active Caliper Release (ACR) in axial brakes?
Active Caliper Release (ACR) minimizes the residual drag torque of the brake in the released state. This leads to significantly lower brake pad wear (a reduction of up to 90% is possible),reduced energy consumption and thus to lower operating costs and increased energy efficiency..
How do companies like ATEK Drive Solutions ensure the quality and quick availability of axial brakes?
ATEK Drive Solutions combines decades of experience in brake and gearbox manufacturing with newly developed expertise in servomotor production.. A modular system allows for millions of configurations and fast delivery times,supported by a large inventory of almost 500,000 individual parts and a modern digital infrastructure.
What factors are crucial when selecting an axial brake for my industrial facility?
Important factors include the required braking torque, available installation space, environmental conditions (e.g., temperature, dust, humidity), duty cycle, required switching times, and whether the brake is used as a holding, working, or emergency brake. A detailed requirements analysis by experts is essential.
Are axial brakes also suitable for applications with very high braking torques?
Yes, axial brakes can be designed for very high braking torques. For example, modern axial brakes for commercial vehicles like the SYNACT® generate over 30 kNm,and special floating caliper brakes used in heavy industry or lifting technology can apply braking forces of up to 370 kN. Axial brakes are
versatile and reliable components for numerous industrial applications that require a für zahlreiche Industrieanwendungen, die eine direct axial force input for precise stops and often offer an excellent cost-performance ratio as well as high adaptability through modular systems.
Modern axial brakes, for example with Active Caliper Release (ACR), significantly enhance efficiency by reducing brake pad wear by up to 90% and lowering energy consumption, resulting in significant cost savings and improved sustainability. The right selection and design of an axial brake, supported by
Die richtige Auswahl und Auslegung einer Axialbremse, unterstützt durch expert advice from system providers like ATEK Drive Solutions,, ensures optimal performance and durability, while access to custom solutions and a large inventory supports the realization of demanding drive tasks.Discover the world of axial brakes! This article provides you with in-depth knowledge about functionality, applications, and the benefits of this important component in industrial drive systems.
Axial brakes are essential for many industrial applications. Are you wondering whether an axial brake is the right solution for your specific requirements? Our experts are happy to advise you. Contact us now Contact us!
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Introduction to axial brakes.
What exactly do we understand by an axial brake??
Axial brakes are crucial in applications that require precise stops, such as in high-cycle packaging machines. The core principle of axial force input ensures a direct and reliable deceleration.They are important components in industrial systems, for example as part of complete drive systems at ATEK Drive Solutions.
The basic functionality explained simply
Brakes with axial force direction convert a control signal into a stop by pressing brake pads axially – along the axis direction – against a rotating disc or drum, creating friction. This frictional force converts kinetic energy into heat and slows down the motion.This principle is used, for example, in the SYNACT® axial brake for commercial vehicles, which generates over 30 kNm of braking torque. More on brake types..
Distinction from radial brake: What is relevant for industry?
In contrast to radial brakes, which are often used in vehicle construction, other criteria than radial arrangement are often relevant for industrial applications. Key factors here are the robustness, adaptability, and cost-performance ratio of an axial brake.While radial brakes offer advantages in adapting to different disc sizes for racing motorcycles, this is less relevant for many stationary machines in the industrial technology. Functionality and areas of application of axial brakes
Funktionsweise und Anwendungsbereiche von Axialbremsen
The operating principle: Axial force for reliable deceleration.
Axial brakes generate braking force by pressing pads axially (parallel to the shaft) against a brake disc or spreading them in a drum. This is necessary, for example, when a heavy conveyor belt needs to stop suddenly. This direct force input allows for good controllability and high braking torques,as required in lifting technology with forces up to 370 kN for floating caliper brakes. This principle supports operational reliability.
- The operating principle is based on axial force input, enabling reliable deceleration and good controllability.
- High braking torques, as required in lifting technology (up to 370 kN), are achievable through this principle and support operational reliability.
- Such braking devices are used in various industrial areas such as machine tools, packaging systems, robotics, and automation.
- Their adaptability allows for use in special environments, e.g. low noise in stage technology or as hygienic design in the food industry.
- An example in mechanical engineering is the electric axial brake with spring energy storage for textile machines, which holds securely in a power-off state.
- The selection of the suitable brake depends on specific environmental conditions and performance requirements, such as rotor hold brakes in wind turbines (>100 kNm).
Diverse application areas in the industry
Axial brakes are found in numerous industrial applications, from machine tools and packaging systems to robotics and automation. Their adaptability makes them suitable for many specific requirements.An example is the use of ATEK brakes in stage and theater technology, where quiet, precise stops are required. They are also prevalent in the food industry, often as a hygienic design variant.
Specific examples from mechanical engineering
In mechanical engineering, for example for a textile machine that requires a fast-reacting, compact brake, an electric axial brake with spring energy storage can be used, which holds securely in the power-off state. The selection of the appropriate brake solution with axial force depends on environmental conditions and performance requirements.Large axial brakes serve as rotor hold brakes in wind turbines, resisting extreme weather conditions and generating braking torques of over 100 kNm.Axial vs. radial brakes: A comparison.
Mounting and force application in detail.
The construction difference lies in the mounting: In axial brakes, the brake pads act perpendicular to the rotation axis, while in radial brakes they act parallel. This different arrangement influences force input and the stiffness of the brake caliper.For many industrial applications, such as in ATEK, the axial design offers a good balance between performance and installation space.
Advantages of axial brakes in industrial systems.
Industries rely on brakes with axial force transmission due to their often more robust and cost-effective design for standard applications. They offer proven technology with high reliability and are often easier to integrate into existing constructions.. Floating caliper axial brakes, for example, allow for an even pressure distribution even with slight alignment errors due to their axial mobility, which extends the lifespan of the brake pads. When are radial brakes the better choice?
Radial brakes can be advantageous in high-performance motorcycle racing, where maximum caliper stiffness and easy adaptation to different disc diameters (using spacers) are required.
However, for most industrial applications, these specific advantages are less decisive than overall costs and durability. A well-designed axial brake, such as the ABM isaac4 with 6 pistons, can achieve comparable braking performance in the industrial segment.. Eine gut ausgelegte Axialbremse, wie die ABM isaac4 mit 6 Kolben, kann vergleichbare Bremsleistungen im Industriesegment erzielen.Technical aspects and designs of axial brakes.
Variety of designs: From disc to drum brakes.
Common types of axial brakes are disc brakes (pads pressed axially on the disc) and drum brakes (brake shoes axially against the drum wall). A special, flexible design is the floating caliper brake, suitable for applications with limited installation space., as its axial caliper mobility ensures an even distribution of pressure. ATEK offers manufacturer expertise for various designs.
- The designs include disc and drum brakes, complemented by flexible floating caliper brakes for limited installation space and even pressure distribution.
- The braking torque is a central technical parameter (e.g. SYNACT® over 30 kNm) that defines the deceleration performance.
- Efficient heat dissipation, often supported by special materials such as stainless steel pistons, is crucial against brake fading under high loads.
- Systems like Active Caliper Release (ACR) contribute to the reduction of residual drag torque, wear, and energy consumption.
- High-strength aluminum alloys are used for caliper housings (e.g. CNC-milled ABM isaac4) to achieve high rigidity at low weight.
- The selection of materials, such as stainless steel for pistons, directly affects corrosion protection, heat dissipation, durability, and overall performance of the safety brakes.
Important technical parameters in focus
When designing, the braking torque is crucial, indicating the deceleration force (e.g. SYNACT® axial brake over 30 kNm). Efficient heat dissipation, supported by materials such as stainless steel pistons, prevents brake fading under high loads. Systems like Active Caliper Release (ACR), known from commercial vehicle brakes, minimize residual drag torque and reduce wear and energy consumption.
Materials and their impact on performance
The material of the brake affects performance. High-strength aluminum alloys for housings (e.g. CNC-milled ABM isaac4 caliper) offer high rigidity at low weight. Special stainless steel pistons improve heat dissipation and corrosion protection. ATEK Drive Solutions pays attention to material selection to ensure durability and performance of the safety brakes, even under demanding conditions such as in heavy industry.Current developments and future perspectives
Trends: weight reduction and efficiency increase
A development trend in axial brakes is weight reduction to improve overall energy efficiency. The SYNACT® axial brake is for example 4 kg lighter than its predecessor model, contributing to CO2 reduction. At the same time, the minimization of residual drag torques through systems like Active Caliper Release (ACR) reduces brake pad wear and energy consumption. These optimizations can be found in electric brake solutions.
- An important trend is weight reduction (e.g. SYNACT® 4 kg lighter) to increase overall energy efficiency and reduce CO2 emissions.
- The minimization of residual drag torques through systems like Active Caliper Release (ACR) lowers brake pad wear and energy consumption.
- Sustainability is promoted through design for industrial remanufacturing, extending the lifecycle of these brake systems.
- Future developments focus on minimizing brake dust and noise emissions to meet environmental regulations.
- Axially acting brakes are being optimized for use in hybrid and electric drives, often serving as safety or parking brakes.
- The integration of sensors for monitoring brake status and for predictive maintenance is an important development step.
- These advancements improve system diagnostics and can reduce downtime of plants, for example in logistics and warehousing.
Sustainability: remanufacturing and emissions minimization
Sustainability is promoted through design for industrial remanufacturing, extending the lifecycle of axial brakes. Future developments aim to minimize brake dust and noise emissions, to comply with environmental regulations. ATEK Drive Solutions pursues these approaches for sustainable pneumatic brakes and other types.
Integration into modern drive systems
Axial brakes are optimized for use in hybrid and electric drives, often serving as safety or parking brakes. The integration of sensors for monitoring brake status and for predictive maintenance is an important development step. This improves system diagnostics and can reduce downtime of plants, such as in logistics and warehousing.Selection criteria and purchasing advice for axial brakes
The right questions before making a decision
Before selecting an axial brake for applications in machine engineering or the packaging industry, the required braking torque, installation space, and environmental conditions must be analyzed. A detailed requirements analysis is crucial for the appropriate braking solution and avoids misinvestments. It must be clarified whether the brake should function as a holding or dynamic brake. ATEK supports in the design of hydraulic brakes and other systems.
Technical support and service as a success factor
In complex drive solutions, technical consulting is important, not just comparing technical data. The expertise of an experienced provider supports the design and optimization of the axial braking unit. ATEK Drive Solutions offers products, consulting services, and develops custom special solutions, even for small series, backed by an inventory of nearly 500,000 individual parts.
Cost-benefit analysis and long-term consideration
The most economical axial brake is not always the cheapest. Total cost of ownership (TCO), maintenance intervals, availability of spare parts, and lifespan must be taken into account. A high-quality braking device with axial force that offers good value for money can provide long-term savings. For example, a brake with Active Caliper Release (ACR) can reduce pad wear by up to 90% and lower maintenance costs.
