Brake and clutch systems play a significant role in assuring the safety and efficiency of heavy duty manufacturing processes requiring high cycle rates. They are relied upon in various applications, including heavy machinery, mining equipment, and other industrial purposes. Thus, ensuring the systems are carefully selected and maintained is essential for preventing costly and dangerous incidents.
Force Control Industries has served many fields with high-quality brakes for over 50 years! We offer top-notch clutches, brakes, clutch/brake combinations, dynamometer systems, and custom drives and controls. Further, we are committed to providing our customers with the most efficient solution for their needs.
How Brakes and Clutches Work
Brakes and clutches are both essential components of many types of machinery, and they work by utilizing frictional forces to control motion. Brakes use friction to stop or slow down the movement of a rotating component, typically a wheel, rotor, or shaft. When a brake is actuated, force is applied to the brake pads or shoes, which press against the rotor or drum.
Clutches serve various purposes in machines and devices. They can control a machine’s speed or protect it from damage. For instance, power drills use clutches to limit torque and prevent workpiece damage. Similarly, machines that require frequent starting and stopping use clutches to reduce wear and tear. Clutches vary in design and operation depending on the machine’s torque transfer, speed, and response time requirements. However, despite these differences, the basic principles of connecting and disconnecting two rotating components remain the same across all types of clutches.
Types of Brake and Clutch Systems
High-cycle and heavy-duty brake and clutch applications are designed for use in demanding industrial environments that require frequent and rapid braking and clutch engagement. These systems are constructed to withstand the severe use and high-frequency cycles typical of applications that require frequent stopping and starting.
Here are some of the most common types of systems for these applications:
Disc Brakes
Disc brakes use a rotating disc and a fixed caliper to create friction, which slows down or stops the motion of a vehicle or machine. When the brake pedal is pressed, the caliper squeezes the brake pads against the rotating disc. This creates friction that decelerates or stops the vehicle or machine. They are often used in heavy-duty applications because of their high heat dissipation.
Drum Brakes
Drum brakes use a rotating drum and fixed shoes to create friction and halt the movement of a machine or vehicle. The drum is attached to the part of the vehicle that rotates, such as the wheel, while the shoes remain immobile. Pressing the brake pedal forces the shoes to come into contact with the drum’s interior, producing friction that slows or stops the motion.
Electromagnetic Brakes
Electromagnetic brakes employ electromagnetic force to bring a machine or vehicle to a stop. Typically spring-set, electric release (fail-safe), an electromagnet pulls back on a thrust plate to release the brake stack. When power is lost or killed, spring force closes the brake stack.
Friction Clutches
Friction clutches are a mechanism that transfers engine power to the transmission via friction. They are popular in heavy-duty applications due to their simplicity and dependability. They are also economical to produce and maintain and can withstand high torque and weighty loads without rapid wear and tear.
Hydraulic Clutches
Also called fluid clutches, hydraulic clutches are activated or disengaged by hydraulic pressure. They are known for their flexible performance and capacity to handle high torque levels. In addition, they are easier to engage than friction clutches, making them a more convenient option.
Key Components of a Standard Brake or Clutch System
For applications with heavy loads and frequent use, brake and clutch systems require components that can withstand extreme heat and stress. The key elements found in most systems include the following:
Friction Surfaces
Frictional surfaces, such a ss pads, discs, or shoes, are typically made of composite materials consisting of metallic or ceramic fibers and organic resins. Moreover, they are commonly found in disc brake systems.
Calipers
Calipers apply force to the brake pads or shoes, which generates friction and halts the vehicle’s or machine’s motion. They are available in various configurations — such as floating and fixed versions — and help ensure the safety and dependability of the braking system.
Rotors
Rotors work with the brake pads to stop or slow down the vehicle or machine. Depending on the purpose, they typically consist of a metal disc that revolves around the wheel and comes in various sizes and designs. Drilled or slotted rotors can disperse heat more efficiently and enhance braking performance.
Clutch Discs
Clutch discs are metal components located between the flywheel and the pressure plate. Upon engaging the clutch pedal, the pressure plate disengages the clutch disk, allowing it to rotate without constraint. On the other hand, releasing the pedal causes the pressure plate to press against the clutch disk, engaging it with the flywheel.
Flywheels
Flywheels store rotational energy using their mass and inertia. They are used in engines and other machinery to smooth out the power delivery and reduce vibrations caused by the reciprocating motion of the pistons.
Heavy-Duty Applications and Industries
Heavy-duty and high-cycle brake and clutch systems are utilized in various applications and industries that require regulating and stopping large and heavy machinery. These systems are designed to withstand high stress and use over extended periods, making them suitable for demanding environments.
The following are examples of specific applications and industries that require high-cycle systems:
Heavy Machinery
Cranes, excavators, bulldozers, and other types of machinery are designed to handle large loads and operate in rugged environments. Due to the size and weight of these machines, they must be equipped with strong brakes and clutches to ensure safe and precise operation. For example, cranes need a system to stop or slow down quickly and precisely to prevent accidents.
Manufacturing Equipment
Stamping presses and forging machines shape metal into specific forms in manufacturing industries like automotive, aerospace, and metalworking. These machines apply extreme forces and require precise control to ensure accurate and consistent results. Therefore, the required systems must be strong enough to control the machines’ motions and protect them from damage.
Electromagnetic Brakes
Electromagnetic brakes employ electromagnetic force to bring a machine or vehicle to a stop. Typically spring-set, electric release (fail-safe), an electromagnet pulls back on a thrust plate to release the brake stack. When power is lost or killed, spring force closes the brake stack.
Mining Equipment
Haul trucks, loaders, and drilling rigs operate in harsh environments and carry large amounts of materials, generating significant heat and wear. Therefore, the brakes on mining equipment must be strong enough to bring the vehicle to a stop quickly and safely, even when fully loaded. Meanwhile, the clutch must handle high torque and heavy loads.
Force Control: The Leading Provider of High-Quality Brake and Clutch Systems
Since 1969, Force Control Industries has been a reliable provider of clutches and brakes for various applications! Some industries we currently serve include the automotive, food and beverage, marine, and material handling sectors. Moreover, thousands of Force Control products operate worldwide with minimal maintenance expenses and downtime.
Contact us today for more information!