Wear to spring-applied brakes

INTORQ spring-applied brakes are wear resistant and designed for long maintenance intervals. The friction lining, the tooth system between the brake rotor and the hub as well as the brake mechanics, however, are all of course subject to function-related wear. For safe and trouble-free operation, the brake must therefore be checked, adjusted or replaced on a recurring basis.

The following table describes the various causes of wear and their effect on the components of the spring-applied brake. For calculating the service life of the rotor and brake and for determining the maintenance interval to be specified, the decisive influencing factors must be quantified. The most important factors here are the dissipated friction energy, the initial speed of the braking and the operating frequency. If several of the causes of wear to the friction lining occur simultaneously in an application, the influencing factors need to be added when calculating the wear.

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Maintenance and inspection of spring-applied brakes

For safe and trouble-free operation, spring-applied brakes must be checked and maintained on a recurring basis. In the plant, the expenses associated with service work can be reduced by ensuring that the brakes are easily accessible. This should be taken into consideration when fitting the drives in the plant and during installation.

The necessary maintenance intervals for working brakes are derived initially from the load on the brake in the application. When calculating the maintenance interval, all causes of wear must be taken into consideration. For low-load brakes, e.g. holding brakes with emergency stop, it is recommended that a regular inspection is carried out at fixed time intervals. To reduce costs, the inspection can be performed during other regular maintenance work carried out at the plant.

If the brakes are not maintained, this can result in failures, loss of production or damage to the plant. Therefore, a maintenance concept adapted to the operating conditions and brake loads must be drawn up for each application. The following table lists the maintenance intervals and work required for the INTORQ spring-applied brake series. Maintenance work is to be carried out in line with the detailed descriptions in the INTORQ operating instructions for the respective brakes.

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As a general rule, during inspection and maintenance work the following must be taken into consideration:
  • Remove any contamination from oils and greases with a brake cleaner, determining the cause of the problem and then, if necessary, replace the brake. Any dirt or particles in the air gap between the stator and armature plate can affect the function and must be removed.
  • After replacing the rotor, the original braking torque is only reached after the friction surface has been broken in. After changing the rotor an increased initial wear occurs on worn-in armature plates and flanges. In this case, adjust the air gap early on if necessary.