Everything you need to know about braking force in industrial applications – from definition to calculation.
What is meant by industrial braking force and why is it so important?
The industrial braking force is the force needed to intentionally decelerate or stop moving masses in machines and systems. It is crucial for the safety of personnel and equipment, which precision of processes (e.g., positioning of robot arms) and the efficiency of production, by optimizing cycle times, for example.
How do you calculate the required braking force for a specific application?
The calculation of the braking force requires taking into account parameters such as mass, speed, desired deceleration time, and friction values.. Formulas like FB = m * a or FU = 2 · FS · µG serve as the basis. ATEK Drive Solutions assists with the precise design, to avoid over- or under-dimensioning.
What factors most influence the braking force in industrial systems?
Important influencing factors include the system weight including dynamic loads, the friction values between brake components (depending on material, temperature, humidity), the chosen type of brake (e.g., pneumatic, electric) and the system stiffness, which ensures loss-free power transmission.
What is the difference between braking force and braking power?
Die braking force is the physical force that opposes motion. The braking power on the other hand, describes the energy converted per unit of time (PB = FB * v). In applications with rapid deceleration of large masses, the braking power is often the more critical parameter for the thermal load capacity of the brake.
How does ATEK Drive Solutions help in selecting the right brake and the optimal braking force?
ATEK provides comprehensive consulting and draws on a wide portfolio of industrial brakes. We analyze your specific application, calculate the necessary braking force and assist in selecting the optimal type of brake, including custom solutions and the use of online product configurators that can reduce the risk of miscalculation by up to 25%. Can incorrect braking force calculations lead to problems?
Yes, an
under-dimensioning can lead to der braking force kann zu safety risks, increased wear, and premature failures. An over-dimensioning causes unnecessarily high acquisition and energy costs.Therefore, a precise calculation is fundamental.
What role does system stiffness play for the braking force?
A high system stiffness is crucial for a precise and loss-free transmission of the braking force.Low stiffness can lead to an undefined pressure point, reduced braking effect, and longer response times, which diminishes the effective braking force..
How do modern technologies like sensors contribute to optimizing braking force?
Sensors in modern braking systems allow for the continuous recording of operational parameters such as wear, temperature, and current braking force. This data forms the basis for predictive maintenance,potentially reducing downtimes by up to 15% and optimizing braking performance. und die Bremsleistung optimiert werden kann.
Die Precise calculation and design of the braking force is fundamental for safety, efficiency, and longevity of industrial systems, where a holistic consideration of all system parameters such as mass, speed, and friction values is crucial.
Factors such as system weight, friction values, brake type, and system stiffness significantly influence the braking force; correct dimensioning avoids costs and risks, with tools like online configurators helping to mitigate the risk of miscalculation by up to 25%. Can incorrect braking force calculations lead to problems?
Future trends such as integrated brake systems in servomotors, intelligent sensors, and material innovations continuously optimize braking force and enable predictive maintenance, which can potentiallyreduce downtimes by up to 15%. Discover the essential aspects of braking force in drive technology. This article provides you with in-depth knowledge, practical insights, and expert tips for your applications.
Braking force is a decisive factor for safety and efficiency in industrial drive systems. Learn how to optimally utilize braking force and what role it plays in your applications. Do you need custom solutions? Contact us at kann.
Entdecken Sie die essenziellen Aspekte der Bremskraft in der Antriebstechnik. Dieser Artikel bietet Ihnen fundiertes Wissen, praktische Einblicke und Expertentipps für Ihre Anwendungen.
Die Bremskraft ist ein entscheidender Faktor für die Sicherheit und Effizienz industrieller Antriebssysteme. Erfahren Sie, wie Sie die Bremskraft optimal nutzen und welche Rolle sie in Ihren Anwendungen spielt. Benötigen Sie individuelle Lösungen? Sprechen Sie uns an unter Contact!
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Now request individual consulting!
Understanding the fundamentals of braking force in industry
An adequate braking force is critical for the safety and efficiency of industrial systems. This article explains the concept of braking force and its importance for drive technology.
What is braking force and why is it crucial for industrial drives?
The ability of a robotic arm on a production line to stop with millimeter precision illustrates the importance of precisely controlled braking force. This is not only a safety feature but also a quality factor. The effective braking force opposes motion and converts kinetic energy, for example through friction in an industrial disc brake, into heat.
Physical principles and important formulas
The exact prediction of the required braking force is based on physical principles. The basic formula FB = m * a (mass times deceleration) provides a guideline. In industrial applications, however, more complex factors such as the friction coefficient µ are often relevant, for example in the formula FU = 2 · FS · µG (braking force at the wheel = 2 * clamping force * sliding friction coefficient) for non-blocking wheels. Knowledge of these principles prevents costly planning mistakes.
Braking force vs. braking power: Clarity for your application
A high braking force is not necessarily equivalent to high braking performance. The braking force describes the strength of deceleration, while braking power (PB = FB * v) indicates the energy converted per unit of time. In dynamic applications, such as rapid deceleration of moving masses in presses, braking power is often the more critical parameter. ATEK supports the optimal design of both values, including the required braking force, for your braking systems..Mastering influencing factors on industrial braking force
System weight and dynamic loads in machines
The system weight, as with a fully loaded pallet transported by a storage retrieval device, can vary significantly. The braking force must be sized to safely decelerate the maximum load. For example, a conveyor system for loads up to 1,500 kg requires a correspondingly designed brake that provides adequate braking force . The correct capturing of dynamic load peaks is crucial for operational safety.
Friction values: Material selection and environmental conditions
The friction value between brake pad and brake disc or drum is not constant, which explains why brakes can fail more quickly in wet conditions. It is influenced by materials, temperature, humidity, and contamination and is a key factor for the achievable braking force. A typical friction value for organic pads on steel is about 0.35-0.45 when dry. Choosing the right material pairing for the specific environmental conditions of your system, as offered by ATEK as a brake manufacturer , is an important factor for braking capability.
Selection of the right brake type for your industrial system
The application determines whether a holding brake or a dynamic working brake is required. For emergency situations in elevators, for example, safety brakes are prescribed, often spring-actuated and electromagnetically released, which ensure reliable braking force operation. ATEK offers various types of brakes,from pneumatic to electric industrial brakes, for applications up to 10,000 Nm. The choice of brake type influences the braking force and control behavior.
The significance of system stiffness and precise power transmission
Low system stiffness, where parts of the braking system bend under load, leads to an undefined pressure point and reduced braking effect, which diminishes the effective braking force braking force. This is particularly critical in high-dynamic servo applications with required response times of less than 50 milliseconds. When designing brakes and integrating them into drive trains, maximum stiffness must be ensured for loss-free power transmission, a principle that ATEK follows.Correctly calculating and designing braking force
Practical calculation of braking force for industrial scenarios
To avoid over- or under-dimensioning of a brake, the calculation of the braking force requires consideration of all relevant parameters such as mass, speed, and desired deceleration times. For example, in drive technology, a braking moment of 200 Nm may be needed to stop a 500 kg load in 2 seconds, requiring a precisely determined braking force braking force. A precise calculation reduces costs and increases system life.
- Precise calculation incorporating all relevant parameters such as mass, speed, and planned deceleration times.
- Application of industry-standard safety factors (e.g., 1.5 to 2.0) for risk minimization and compliance with standards.
- Consideration of design criteria such as efficiency, thermal load capacity of components, and the expected lifespan of the braking system.
- Pursuit of a holistic design strategy that takes into account the entire lifecycle of the brake and its maintenance requirements.
- Consistent avoidance of over-dimensioning to save unnecessary acquisition and energy costs.
- Careful prevention of under-dimensioning to prevent safety risks, increased wear, and premature failures.
- Use of modern tools, such as online product configurators, to assist in preliminary selection and reduce miscalculations.
Design criteria: Safety, efficiency, and lifespan
In addition to pure force, other factors are important in the brake design. Safety factors (e.g., 1.5 to 2.0 above the calculated requirement) braking force) are defined in many industrial standards. Thermal load capacity and wear also play a role. A holistic design approach, as pursued by ATEK, takes the entire life cycle of the brake into account.
Avoidance of over- and under-dimensioning
A wrongly sized brake incurs unnecessary costs: Over-sizing, especially in the braking force, leads to high acquisition and energy costs, while under-sizing results in safety risks and rapid wear. By using online product configurators, such as the one from ATEK for standard bevel Gear Boxes with integrated brake, a pre-selection can be made and the risk of miscalculation reduced by up to 25%. Correct sizing is fundamental for economical and safe operation.Ensure optimal braking force in key industries
Machine and plant engineering: Precise stopping and holding
In machine and plant engineering, for example in machining centers that require precise positioning of tools, precise braking force the required repeat accuracy (often below 0.01 mm). For such applications, customized industrial brakes. is required, precisely tuned to masses, dynamic requirements, and the necessary braking force as developed by ATEK. The integration of the brake into the machine control is an important aspect for performance.
Logistics and automation: Mastering dynamic movements safely
In logistics and automation, for example in stacker cranes in high-bay warehouses with speeds exceeding 5 m/s, brakes must withstand high dynamic loads and reliably handle many switching cycles (often >1 million/year), which requires a consistently high braking force braking force. Our braking solutions for logistics are designed for maximum availability and low maintenance effort.
Special applications: When standard brakes are not sufficient
For special applications where standard brakes do not provide the required braking force or specific characteristics, special solutions are required. For example, a customer in test stand technology needed a brake with a specific torque curve and low residual torque. A special solution developed by ATEK met these requirements and enabled a measurement accuracy of ±0.5%. The development of customized special solutions, even for small series, is a specialty of ATEK.Utilizing future trends in industrial braking systems
Integration of brakes into servo motors and mechatronic systems
The increasing system integration is changing braking technology. Modern servo motors, including those in the ATEK portfolio, often have integrated holding brakes, saving installation space and reducing system complexity. Such mechatronic units enable more precise control and fast response times (often <20 ms) of the applied braking force. The coupling of motor and brake supports the trend towards higher efficiency.
- Trend towards system integration: Brakes are increasingly being integrated into servo motors and mechatronic units, saving installation space, reducing system complexity, and improving response times.
- Intelligent brake control: Future brake systems will increasingly be equipped with sensors to continuously capture and monitor operating parameters such as wear, temperature, and braking force continuously.
- Predictive maintenance: The data obtained from sensors enables precise condition forecasting and demand-oriented maintenance planning, potentially reducing downtime by up to 15%.
- Material innovations for optimized characteristics: Research focuses on new materials with higher and more stable friction values, lower wear, and improved temperature resistance.
- Longer lifespan and higher performance: The use of modern materials, such as ceramic composite materials or special sintered metals, can extend the lifespan of brake pads in demanding applications by over 50%.
- Contribution to Industry 4.0: Intelligent, networked braking systems are an important component for realizing the flexible and efficient factory of the future.
Sensors and intelligent brake control for Industry 4.0
Future brakes will increasingly be equipped with sensors to continuously capture parameters such as wear, temperature, and the current braking force to continuously monitor their condition. This data enables predictive maintenance and optimization of braking performance during operation, potentially reducing downtime by up to 15%. Intelligent brakes are thus a component for the connected factory of Industry 4.0.
Material innovations and their impact on braking force
New materials play an important role in brake technology. Research focuses on materials with higher friction values, lower wear, and better temperature resistance, which directly influences the consistency and level of the available braking force influences. Ceramic composite materials or special sintered metals can extend the lifespan of brake pads in demanding applications by over 50%. ATEK follows these material developments to integrate technologically current solutions.
The careful design of the braking force is fundamental for powerful and safe industrial plants. This includes the correct calculation of the braking force, the selection of suitable components, and consideration of future trends. ATEK Drive Solutions provides support in selecting the appropriate braking solution for specific requirements and the optimal braking force. For individual advice, we are available.
