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Innovative Brake Concept
Extensive optimisation potential for safety brakes
mayr power transmission have presented a new brake concept at the Hannover trade fair. The basic concept behind the innovation was the optimisation of safety brakes seen from completely different aspects and their specific adaptation for each respective application. Looking at today's all-round brakes from this standpoint, it be came apparent that they still have substantial optimisation potential.
- A new brake concept wi th outstanding positive characteristics results from the combination of a construction space-, magnetic flow- and performance-optimised safety brake with an accurately adapted control module.
It all started with the idea of developing an electromagnetically releasing safety brake with minimum energy consumption. The structural design and the magnetic flow have been optimised for quite some time using modern construction tools and FEM calculation methods. However, these brakes still have a substantial energy-saving potential if the brake and the control system are treated as one unit. Both components must be optimally matched to one another.
Standard rectifiers are not suitable for this purpose. In standard rectifiers, the mains AC voltage and the rectified voltage always have a fixed ratio. Therefore, a new electronic wiring unit for the brake electromagnet has been developed. It contains a special rectifier with an unusual feature. Independent of the mains voltage and the frequencies generated, it always emits a steady DC voltage. Actually, there are two voltages. When the brake is switched on, the electronic system energises the brake with a very high voltage for a short period of time. During this phase, a large magnetic force is necessary to attract the anchor over an air gap. Once the anchor lies against the magnet body, a much smaller magnetic force is sufficient to keep the brake open. Therefore, it is now possible to lower the voltage substantially. Most of the energy-saving potential in our new concept is based on these properties. Voltage ratios of up to 4:1 are possible between releasing and holding. If the voltage is reduced to one quarter of the value after brake release, the coil capacity and therefore also the energy consumption decrease to 6.25 percent. Therefore, optimum wiring generates enormous optimisation potential. On conventionally operated brakes, however, the voltage usually remains unchanged and a huge amount of energy is wasted unnecessarily.