Which applications are hysteresis couplings particularly suitable for?

Hysteresis couplings are the first choice when a specific torque must be continuously maintained or a tensile force needs to be controlled without wearing mechanical components in the force path. Typical examples include: Constant tension control at winding stations Torque limitation in sensitive drives Tightening closures where a defined tightening torque is required In these applications, the coupling ensures defined operating states while simultaneously protecting the system.

Hysteresis couplings: Contactless torque transmission

Hysteresis couplings transmit torque via a magnetic field without direct contact between input and output side. They are designed so that controlled slip occurs once a set threshold is reached, keeping the torque constant. This allows you to avoid torque peaks, precisely adjust torques, and achieve smooth rotational motion.

Contactless torque transmission based on the hysteresis principle
Adjustable limiting torque with high repeatability
Defined slip operation for continuous torque transmission
Wear-free drive with no friction linings in the torque path
Suitable as a coupling or as a brake

Hysteresis couplings at a glance

Hysteresis couplings are part of the magnetic couplings from mayr® power transmission. These magnetic continuous slip clutches are available in various construction sizes and torque ranges. The products cover low to medium torques and are designed for continuous or intermittent slip operation, provided the thermal limits are observed. The hysteresis couplings can be used both as a coupling between two shafts and as a brake, for example at winding or tensioning stations.

Operating principle of hysteresis couplings

In hysteresis couplings, permanent magnets generate a magnetic field that penetrates a rotor made of hysteresis material. This material is permanently magnetized and re-magnetized. The resulting magnetic forces transmit the torque without any friction surfaces sliding against each other.

Operation below the limiting torque

The coupling and output run synchronously, and the set torque is transmitted with virtually no slip.

Operation above the limiting torque

If the operating torque exceeds the preset threshold, a relative motion occurs between the input and output side. A defined slip develops, while the torque is essentially maintained at the set value.

Thermal aspect

The power loss generated during slip operation heats the coupling. This heat must be dissipated to the environment, which is why the permissible power loss and the permissible slip operation must be taken into account during dimensioning.

In this way, the hysteresis principle provides contactless torque transmission and ensures reliable, reproducible torque limitation with a structurally designed, continuous slip operation.

Typical application fields for hysteresis couplings

Hysteresis couplings are used when a constant torque or uniform tensile force is required throughout the process and, at the same time, sensitive components need to be protected from overload. They combine defined torque limitation with wear-free, constant torque transmission.

Industries

Packaging and filling technology
Printing and paper industry
Plastics and film processing
Textile and wire processing
Food and beverage industry
Chemical, pharmaceutical, and cosmetic industry
Railway technology
General mechanical and plant engineering

Application scenarios

Web tension control during winding and unwinding of films, paper, wires, or yarns
Constant tensile force in continuous production processes
Torque limitation in drives for mechanical overload protection
Screw-capping processes, e.g., closing containers with reproducible torque
Torque limitation in point machine drives
Braking tasks where an adjustable counterload in continuous slip operation is required

Your benefits with hysteresis couplings from mayr power transmission

In many applications, a specific torque must be reliably maintained—whether to close products with a defined force, keep web tensions constant, or protect drives from overload. Friction-based solutions are often prone to wear and change their behavior over the course of operating time.

Hysteresis couplings from mayr® deliver a reproducible torque that is defined via a scale or adjustment function and maintained at a constant level through slip during overload. Torque transmission is magnetic and contactless, which means no abrasion or wear, for example on friction linings, occurs. This reduces maintenance effort and ensures that the set behavior remains stable in the process over the long term. Thanks to the compact design, low moment of inertia, and the option to use them as a coupling or brake, these solutions are suitable for a wide range of machine concepts.

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FAQ - Frequently asked questions about hysteresis couplings

Hysteresis couplings are the first choice when a specific torque must be continuously maintained or a tensile force needs to be controlled without wearing mechanical components in the force path. Typical examples include:

Constant tension control at winding stations
Torque limitation in sensitive drives
Tightening closures where a defined tightening torque is required

In these applications, the coupling ensures defined operating states while simultaneously protecting the system.

Since the torque is transmitted magnetically—and therefore without sliding friction surfaces—hysteresis couplings do not exhibit the typical wear associated with friction-based couplings. With correct dimensioning in terms of limiting torque and power loss, the couplings generally operate maintenance-free. Regular visual inspections of the installation and its surroundings should nevertheless be part of the machine's overall maintenance plan.

Slip is an integral characteristic of the system. Once the set limiting torque is reached, a defined relative speed develops between the drive end and the output side. This relative motion is the prerequisite for maintaining the torque at a constant level and dissipating the excess energy in the form of heat. Slip thus ensures that the system is not subjected to impermissible overload and that torques remain reliably limited.

If deviations from the expected torque, excessively elevated surface temperatures, or unusual noise and vibration phenomena occur during operation, this may indicate incorrect dimensioning, thermal overload, or mechanical damage. Heavy shock loads or contact with ferromagnetic particles can also impair the function. In such cases, the operation should be reviewed, the thermal dimensioning checked, and the coupling inspected by qualified personnel if necessary.

The limiting torque is determined by the coupling's dimensioning and the set position of the adjustment mechanism. Within the specified operating limits, this torque remains largely constant. Manufacturing and temperature influences as well as high slip speeds can affect the behavior but are accounted for in the technical documentation and dimensioning guidelines. For applications with particularly tight tolerances, dimensioning in consultation with the specialists from mayr® is recommended.

Electromagnetic clutches generate the magnetic field underlying their function by means of an energized coil. They are typically actively switched. Hysteresis couplings work with permanent magnets and a hysteresis rotor. Torque transmission is permanently present, and the torque is defined by the structural design and a mechanical adjustment. As soon as the system enters an overload condition, the coupling regulates to the set torque value via slip without being actively switched.

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