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Trade Shows2021-08-02T22:39:31+00:00

Learn More About the Newest Products from Force Control Industries

Visit Us at the following upcoming Trade Shows.

Force Control Industries is continually upgrading and developing new products for many major industries. To this end we participate in some of the major trade shows related to our products. This is the perfect time to see and touch new products, speak with knowledgeable application engineers, learn about the benefits of Oil Shear Technology, and make some good friends.

Give us a call and we can set up a private meeting with sales, engineering, or management to discuss new projects, or special situations.

Our upcoming trade show schedule

MINEXCHANGE 2022 SME Annual Conference & Expo
Booth #2111

SME - Mine Exchange

February 27 – March 2, 2022

Salt Palace Convention Center

Salt Lake City, UT

Learn how Force Control brakes featuring Oil Shear Technology extend life, and reduce maintenance, on brakes for cranes, hoists, winches and conveyors. See an operating motor brake, understand oil shear technology, and see the new hazardous duty brake.

The Iron & Steel Technology Conference (AISTech)
BOOTH # 1232

AISTech

May 16-19, 2022

David L. Lawrence Convention Center

Pittsburgh, PA

Learn how Force Control clutches and brakes, featuring Oil Shear Technology, extend life and reduce maintenance on cranes, shears, hoists, conveyors, elevators and much more. Ask about hazardous duty brakes, MIL-Spec brake motors and high-temperature brakes.

36th ANNUAL ELKO MINING EXPO
BOOTH #TBD

Elko Mining Expo

June 6-10, 2022

Elko Convention Center

Elko Nevada

Stop by to talk with one of our application engineers. They will explain how Force Control clutches and brakes featuring oil shear technology will help reduce maintenance, increase production, and improve safety. Brakes and clutches are available for conveyors, trippers, cranes, winches, hoists, and many other applications in the mining industry.

ELECTRICAL APPARATUS SERVICE ASSOCIATION ( EASA )
BOOTH # 335

EASA-2022

June 26-28, 2022

America’s Center

St Louis, Missouri

Learn how Force Control brakes featuring Oil Shear Technology extend life, and reduce maintenance, on brakes for cranes, hoists, winches conveyors, trippers, palletizers, stackers, elevators, and much more. Ask about hazardous duty brakes, and low temperature brakes.

AUTOMOTIVE TESTING EXPO
Booth #10026

AutoTestExpo

October 25 – 27, 2022

Suburban Collection Showplace

Novi, MI

Learn about Low Speed-High Torque Load Brakes featuring Oil Shear Technology for smooth to 0 RPM controllable load for continuous extended testing. Load brakes are available from 50 Lb. Ft. to 200,000 Lb. Ft. They are the perfect way for absorbing load at the final drive on tractors, off road equipment, ATV’s, snowmobiles, trucks, mining machines, gearboxes, and much more.

Force Control dynamometers featuring Positorq Oil Shear Load Brakes absorb extreme torque at very low speed (down to zero rpm), so that they can accurately capture data at these critical junctures, when dynos equipped with traditional load brakes cannot. Oil shear technology can provide instant load spikes and static lock-up of up to 3-times the continuous load rating.

High cycle counts (up to 300 torque changes per minute) allow tests with a hammering effect on the tested product. Quick, controllable response allows virtually unlimited test capabilities, while their extremely quiet operation allows gearbox, transmission, or final drive noise testing. High-torque, low speed testing is commonly used for testing life cycles, shock loading, overall machine life/performance and more for snowmobiles, forklifts, 2-wheel/4-wheel/6-wheel drive tractors or tracked vehicles, commercial truck axles, helicopter transmissions, gun turrets, winches, hoists, and more.

Proven oil shear technology eliminates wear for service free endurance testing. A variety of sizes and arrangements for shaft mounting, flange mounting, coupled and vertical/horizontal mounting. Units can be supplied with torque arm and load cell, all controls for the cooling system and actuation.

Oil Shear Technology is a system of providing a film of transmission fluid between the friction discs and drive plates of a mechanical multiple disc type of friction brake. As the discs and plates are brought together, squeezing the fluid film, it goes into hydroviscous shear. This phenomenon transmits torque through the fluid through laminar flow.

This phenomenon is based on the laminar flow of the fluid film between the friction discs and drive plates. The fluid tends to flow in layers with each layer moving at consistently different speeds between the rotating friction disc and the static drive plate. As the pressure squeezing the disc and plate together increases the hydroviscous force of the molecules sliding past each other, it increases the torque. Therefore, simply controlling the pressure on the friction stack controls the torque.

The torque is proportional to pressure on the friction stack which is controlled by actuation pressure. This pressure can be provided by a proportional regulator for pneumatically actuated units, or a proportional regulator or servo valve in hydraulically actuated, more responsive systems.

With the fluid layer between the friction disc and drive plate there is no tendency to stick slip or chatter at very low differential speed, providing a smooth transfer of torque down to 0 rpm.

The second part of the equation is heat energy that must be dissipated from the system. Using Oil Shear Technology, the fluid is circulated through the friction stack and is cycled out of the brake to a forced lube cooling system. The cooled fluid cools the brake components including the friction material, eliminating the typical degradation found in dry friction brakes. This also allows for a more compact load brake that can, in many cases, be directly mounted to the axle, or output of the test device. The cooling system typically includes cooling oil pumps, motors, filters, over temperature switches, optional hydraulic actuation pump and motor, flow switches, fluid level sight gauge, optional tank heater, and heat exchangers. Heat exchangers can be oil-to-water or oil to air.

 

The cooling system can be designed for one load brake or several. Some cooling systems are designed multiple load brakes, such as 4-wheel vehicles using 4 brakes. The hydraulic actuation system can be built into the cooling unit utilizing the same fluid.

The Force Control Industries Positorq load brakes using Oil Shear Technology are available in a variety of sizes ranging from 50 Lb. Ft. (68 Nm) to 300,000 Lb. Ft. (406,700 Nm) and can absorb up to 3000 thermal horsepower (2237 Kw). Mountings vary from flange mount, to foot mounts, to shaft mount. Custom designs and load carrying capacity are commonly developed for specific applications.

 

Ohio’s Reading Rock had limited idle time throughout a four-year stretch when the market was at or near peak, producing 22 million 8-in. block Û enough units, placed end-to-end, for a round-trip to the Golden Gate Bridge from the company’s suburban Cincinnati plant with sufficient leftovers to build several large schools. Brakes and clutch-brakes incorporating oil shear technology proved instrumental in the producer’s block machinery running up to three shifts, six to seven days a week.

 

Shear Efficiency 

Pretty much everything in the plant that has a motor is equipped with a Force Control clutch-brake or brake, notes Reading Production Manager Phil Thacker. Oil shear technology is employed in the braking systems to transmit torque between lubricated surfaces. The circulating fluid cools and lubricates friction surfaces to eliminate wear and dissipate heat. Without direct contact between friction surfaces during acceleration or deceleration, adjustment or replacement of discs is unnecessary.

By contrast, dry-clutch and conventional brakes curtail uptime, since they employ a sacrificial surface (typically, a brake disc or pad) to engage load. Lacking means to remove heat generated by disc/plate engagement, brake materials must absorb the heat; and, extreme temperatures lead to surface-material degradation and glazing. The ensuing torque fade causes positioning errors, which require adjustment or friction-surface replacement.

Since Reading Rock operates a single production line, i.e., one pathway is defined from dry-materials batching and mixing to final exit of pallets carrying cured block, faulty functioning of any component will bring the entire process to a halt. Consequently, the producer chose to equip its main drive with a Posidyne clutch-brake to control indexing of the machine for pallet conveyance, bringing in molds, and depositing concrete. After the mix is placed, vibrators shake the forms to ensure proper density of the block; once completed, the main drive indexes again, and the cycle repeats. Clutch-brakes cycle faster than most prime movers, Force Control affirms, increasing block machine speeds and productivity per shift.

The Posidyne clutch-brakes at Reading Rock use oil shear technology to provide a fluid film between friction surfaces. As the brake is engaged, automatic transmission fluid is compressed and its particles sheared, thus transmitting torque to the other side. Torque transmission causes the stationary surface to turn, accelerating to the same speed as the moving element. Since fluid particles in shear bear the brunt of acceleration, Force Control explains, wear and tear are virtually eliminated by the time the surfaces actually meet or lock up.

Besides transmitting torque, oil shear technology dissipates heat by a patented fluid-recirculation system. Moreover, the fluid continually lubricates all components and provides a cushioned stop that reduces shock to the drive system, further extending service life. Unlike dry-clutch brakes, the totally enclosed oil shear system is impervious to external elements found in wet or dusty plant environments.

Additionally, using a Posidyne clutch-brake offers potential energy cost savings, due to lower inrush currents and reduced power factor imbalance. Torque on the clutch-brakes can be adjusted by the actuation system to provide proper acceleration and deceleration. Posidyne oil shear clutch-brakes are also employed on the vibrator drive to settle concrete in block molds. When vibrator shafts are driven by a clutch-brake, the motor runs constantly. No starting and stopping with a clutch-brake-driven assembly ensures smoother, constant operation and decreased cycle time, Force Control asserts, plus extended motor service life.

Upon completion of the vibration cycle, the brake is released and weights drop into the bottom position, owing to the assembly’s built-in neutral gear. Both weights thus remain synchronized during start-up, imparting vibration of predetermined amplitude to the shaft Û preferable to starting the cycle with weights in varying positions and imparting more (or less) severe amplitude, causing shock to the system, shortening component life, and compromising block density.

The Ê- to 5-hp motors driving the conveyor, elevator and finger cars are equipped with MagnaShear brakes featuring a totally enclosed oil shear design. Force Control product engineers observe that MagnaShear brakes are used in all areas of green and cured block handling, due to their oil shear durability, electric actuation, simple control logic and spring-set load holding.

Half-Blocks, Full Treatment

To fill half-block forms, Reading Rock used SmartPac vibrator shafts for mold vibration. Previously, actuating the system directly from the motor allowed only on or off vibrator operation. More recently, a technology upgrade enabled personnel to regulate amplitude and frequency. Now, the plant enjoys greater flexibility, double the service life of earlier designs, and rapid compaction and finish times. Further, maintenance requires only greasing a bearing every eight hours and periodically tightening mounting bolts. Overall, Reading Rock attributes increased operational uptime to Force Control Oil Shear technologies.

Fairfield, OH ­ – Force Control Industries announces the addition of Mike Fox as new Western Regional Manager, supporting reps and distributors, OEM and industrial customers in the Western Region of the US and Canada. Fox has over 15 years of industrial equipment and power transmission components sales, and experience in many environments, including food and beverage processing, chemical processing, HVAC, wastewater, and general manufacturing.  He comes from MasterDrive, a sheave and bushing manufacturer.  In this newly created position, Fox will work from his home office in Salt Lake City, covering northern California, Oregon, Washington, Idaho, Montana, Wyoming, Alberta, and British Columbia and Alaska.

He can be reached at mfox@forcecontrol.com or (801) 380-4038.

Clutch Brakes Designed for Harsh Environments

Force Control Industries (Fairfield, OH) announced its Fan Cooled Posidyne clutch brakes which allow rapid and precise stopping, starting, speed change and positioning even in harsh environments. Oil Shear technology transmits torque through lubricated surfaces so there is no wear and no heat build-up so the clutch brakes require no maintenance or adjustment.

Fan cooling provides as much as 4.5 times the cooling capacity of non-fan models. The addition of a fan is recommended for applications where the input shaft rotates at high speed (1800 or 1200 rpm). Elevated ambient temperatures will impact the radiation cooling effect. If additional cooling is required, options available include liquid cooling, external cooling packages and forced lube cooling. Fan Cooled Posidyne clutch brakes allow cycle rates of up to 300 cycles per minute. They are ideal for applications with frequent start-stop cycles. Faster production rates and significantly longer service life yields increased uptime, productivity and ROI.

Posidyne clutch brakes are field proven in diverse applications such as packaging lines, food and chemical processing facilities, lumber mills, shingle plants, fiberglass insulation production, metalworking and more. The Posidyne clutch brakes are designed with low inertia cycling components which requires less motor horsepower to accelerate the load and less torque to stop the load. Posidyne clutch brakes feature a multiple disc design that produces high torque from a small package. Re-circulating the fluid dissipates the heat of engagement, which is a common cause of downtime with other clutch brake assemblies. An actuation system allows torque in the clutch and brake to be precisely controlled. Manifold mounted control valves reduce response times by eliminating hoses and fittings and are recommended for high cycle applications. By reducing the high-starting inrush currents and the associated power factor imbalance in the motor these clutch brakes can also reduce energy costs. The Posidyne clutch brake can be actuated by air or hydraulic pressure for use in a plant or outside remote applications. The hydraulic actuation package includes a hydraulic pump, solenoid valve, regulators and a filter. A heat-exchanger can be added for additional cooling.

The Posidyne® is inherently explosion proof with the addition of an explosion proof actuation valve, or locating the valve in an explosion proof cabinet. Multiple sizes are available to suit particular applications from ½ to 350 HP (99 Lb. In. to 79,000 Lb. In.) with cooling options, control logic and mounting arrangements to simplify and speed installation.

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