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HOME (http://www.globalspec.com) PRODUCTS & SUPPLIERS (http://www.globalspec.com/productfinder) MOTION AND CONTROLS (/productfinder/motion_controls) CLUTCHES AND
BRAKES (/productfinder/motion_controls/clutches_brakes) LEARN MORE ABOUT ELECTRIC BRAKES

Electric Brakes Information

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(http://www.globalspec.com/SpecSearch/Suppliers/motion_controls/clutches_brakes/electric_brakes)

Electric brakes are devices that use an electrical current or magnetic actuating force to slow or stop the motion of
a rotating component. They are used in industrial and vehicular braking applications that require fast response
times and precise tension control.

There are two main types of electric brakes: magnetic and friction. Each has various subtypes. As described
below, the way an electric brake works depends upon these characteristics.

In addition to type, the GlobalSpec SpecSearch database allows industrial buyers to search for electric brakes by
operating specifications, engagement mechanism, measurements and shaft configuration, brake materials, and
features.

Types of Magnetic Brakes

Magnetic brakes are non-contact brakes that use magnetic fields to actuate the braking components. There are four types.

Permanent Magnet Brakes

Permanent magnet brakes stop or hold a load when electrical power is either accidentally lost or intentionally disconnected. They are
sometimes called "fail safe" brakes and use a permanent magnet to attract a single face armature. As the brake is engaged, the magnets
create magnetic lines of flux, which can turn to attract the armature to the brake housing. To disengage the brake, power is applied to the c
which sets up an alternate magnetic field that cancels out the magnetic flux of the permanent magnets. Permanent brakes are engaged wh
no power is applied to them and can hold or stop when power is lost or unavailable.

Design Tip: Multiple disks can also be used to increase brake torque, without increasing brake diameter.

Electromagnetic Brakes

Electromagnetic brakes have a coil in a shell, a hub, and an armature. An electrical circuit engages the brake as it
energizes the coil. The current runs through the coil and generates a magnetic field. The magnetic flux acts directly
between the armature and field. The armature is pulled into contact with the rotor when the magnetic flux overcomes
the air gap between the armature and field. All of the torque comes from the magnetic attraction and coefficient of
friction between the steel of the armature and the steel of the brake field. Deceleration occurs when the armature
contacts the field, and the torque transfers into the field housing and machine frame. Turing off power causes the
flux to fall rapidly, the armature to separate, and disengagement to occur. Springs are used to help push the
armature away from the surface and maintain an air gap.

Eddy Current Brakes

Eddy current brakes develop torque by the direct magnetic linking of the rotor to the stator. A magnetic field induces a voltage in moving
 Electric Brakes Search Form objects and the induced voltage causes an eddy current to flow in any conducting objects. The electrical current is sent to coils, which
alternate polarities, creating an electromagnetic field. This change in magnetic flux induces a small circulating current in the conductor calle
Search manufacturer catalogs by these an 'eddy current'.
specifications:
Eddy currents are generated in two rotors as they spin through the field and slow the rotation of the driveshaft. The first current created
Torque Rating: generates an opposing current. The counter-opposing flux and Lorentz force reduces the velocity of the object. Ohmic losses and significa
Less than 0.74 Ft-lbs heating are also produced by the current. Eddy current brakes must have a slip between the rotor and the stator to generate torque.
(javascript:void(0);) There are two types of Eddy current brakes.
Power:
Less than 0.012 HP (javascript:void(0);) Rotational or circular brakes are connected to a rotating coil and magnetic field between the rotor and the coil, creating a resistance that'
Speed: used to generate electricity. A braking force is possible when electric current is passed through the electromagnets.
Less than 350 rpm (javascript:void(0);)
Operating Voltage: Linear eddy current brakes consist of a magnetic yoke with electrical coil positioned along the rail. The coils are magnetized, alternating a
south and north magnetic poles.
Less than 18 volts (javascript:void(0);)
Brake Engagement:
Video Credit: Carleton Physics (https://apps.carleton.edu/curricular/physics/) via YouTube
Noncontact (javascript:void(0);)
Magnetic Particle (javascript:void(0);)
Friction (javascript:void(0);) Hysteresis Powered Brakes
Toothed (javascript:void(0);)
Wrap Spring (javascript:void(0);) Hysteresis powered brakes have a wide torque range. They have a reticulated pole structure and a specialty steel
Brake Operation: rotor/shaft assembly that are fastened together, but not in physical contact. The drag cup can spin freely until the field
Spring Actuation / Engage coil is energized by a current/voltage, creating an internal magnetic flux. The air gap between the pole structure and
(javascript:void(0);) the rotor becomes a flux field and magnetically restrains the rotor. This provides the braking action between the pole
Spring Return / Disengage structure and the rotor.
(javascript:void(0);)
Other (javascript:void(0);) When electricity is removed from the brake, the rotor is free to turn, and no relative force is transmitted between either
More Specifications >> part. Torque is only produced through a magnetic air gap that does not use friction or shear forces. Control over
torque is done through the DC current to the field coil. The amount of braking torque transmitted by the brake is
(http://www.globalspec.com/SpecSearch/SearchForm/motion_controls/clutches_brakes/electric_brakes)
proportional to the amount of current flowing through the field coil.

Magnetic Brake Comparison

This table compares the different types of magnetic brakes.

Type Application Advantages Disadvantages

Permanent magnetic brake
Electromagnetic brake
Eddy current brakes
Hysteresis powered brakes
For electric motors, robotics,
holding brakes for Z axis ball
screws and servo motor brakes
Copy machines, conveyor drives,
packaging machinery, printing
machinery, food processing
machinery and factory
automation
Train and roller coaster brakes
Food and drug packaging
operations, clean rooms,
environmental test chambers,
load simulation for life testing on
rotating devices, capping,
bolting and other screwing
applications
High and accurate torque, long Require a constant current contr
life, unaffected by power supply, to offset the permanent magneti
safe and easy to use field
Fast response time, smooth, Braking force diminishes as spee
reliable, and backlash free diminishes, load cannot be held
operation, produce high torque, a standstill causing safety
automatic air gap available concern.
Noncontact, Frictionless,
Unusable at low speeds,
resettable, light weight, few
generates heat
moving parts
Long, maintenance-free life, cost
effective, operational,
Experience a salient-pole
smoothness, torque
phenomenon called "cogging", a
repeatability, broad speed range,
undesirable, pulsating output
environmental stability, high-
torque which prevents smooth
dissipation capability. The torque
and efficient operation of these
remains constant and smooth
systems
and responds with increases and
decreases in current.

Types of Electrically Actuated Friction Brakes

Although many electric brakes use mechanical methods for actuation, others rely upon friction. There are several types of frictional brake
devices. Each is described below.

Band Brakes
Band brakes are the simplest electric brake configuration. They are often used as a back-stop mechanism to prevent reverse rotation. Thes
brakes have a flexible band of leather, rope, or steel with a friction lining that is wound around a rotating drum. One end of the band passes
through the fulcrum of the actuating lever and frictional torque is then generated when tension is applied to the band. The band will lock up
brake for rotation in one direction and when friction is placed on the band, it loosens for rotation in the opposite direction.

Band brakes are often used in lifting applications to prevent the object being hoisted from falling when the user stops pulling. The ratio of b
tensions is given by
Where, T1 = tension in the taut side
T2 = tension in the slack side
µ = coefficient of kinetic friction
β = angle of wrap
If the band is wound around a drum by a radius R, then the braking torque is:

Drum Brakes
Drum brakes are commonly used on automobile rear wheels. They operate by forcing the friction-lined brake shoes against the inner surfac
of the rotating drums. A drum brake has two brake shoes, a piston, an adjuster mechanism, and an emergency brake mechanism and sprin
The shoes expand against the inside surface of the brake drum, and slow the wheel down. The harder the linings are forced against the bra
drum, the higher the braking force that is applied.

Many drum brakes are self-actuating, which means that shoe mounting can be designed to assist in their own operation. The self-actuating
mechanism uses a wedging action to assist the lining to grip the rotating drum when the brakes are applied. This extra braking force allows
drum brakes to use a smaller piston than disc brakes. The springs are used to pull the shoes away from the drum when the brake is release
as well as to help hold the brake shoes in place and return the adjuster arm after it actuates.
 Video Credit: Crash Forensics (http://www.crashforensics.com/) via YouTube

Three drum brake designs are generally used.

Single leading shoe designs use a single wheel cylinder with two pistons. As the brakes
are applied, both shoes (leading and trailing) press against the brake drum. The leading
shoe is self-actuating, while the trialing shoe is forced off the drum. This arrangement
works well going forward and reverse.

Twin leading shoe designs have an actuator for each brake shoe

Duo-servo designs use a single wheel cylinder with two pistons with a high self-actuating
force. Since the lower ends of the shoes are linked but not firmly anchored to the backing
plate, the shoe floats within limits. As brakes are applied, both shoes are carried around
the drum, until the secondary shoe contacts the anchor pin and the self-actuating force of
the primary shoe is transferred to the secondary shoe through their lower linkage. Force is
applied to the secondary shoe from both ends, causing the wheel to slow. This design is
common on rear wheels and it works in both the forward and reverse direction.
For the drum brakes to function correctly, the brake shoes must remain close to the drum
without touching it. As the shoes wear down, they can get too far away from the drum and the piston will require more fluid to travel that
distance. To correct this, an automatic adjuster is used to fill the gap created as the brakes wear.

Design Tip: With hard use, brake "fade" can occur eventually. Brake fade is the gradual loss of brake stopping power during
prolonged or strenuous use. Very high temperatures occur at the brake drum, and that causes deterioration in the frictional value o
the lining or pad material. This is common in drum brakes.

Disc Brakes

Disc brakes consist of a caliper that squeezes brake pads against a rotating disc. They can be used on all four wheels of a vehicle or on the
front brakes in conjunction with rear drum brakes. The most common type of disc brake is the single-piston floating caliper. The main
components of this type are the brake pads and the caliper, which contains a piston; and the rotor, which is mounted to the hub. On driving
wheels, the disc is mounted onto the driving axle and may be held in place by the wheel.

The brake caliper system is attached to the vehicle axle housing or suspension and the brake is
usually attached as close to the wheel as possible. When no current is flowing in the coil, the motor
is braked by two compression springs squeezing the brake pads and the brake rotor together.
Friction between the pads and rotor slows the disc down. When current flows into the core, it
counteracts the piston force, pulling the brake pads towards it, and the brake is released. A lot of
friction is generated during braking, and this creates heat in the system. Since the brake parts must
be able to withstand high temperatures and are often exposed to air and vented, cooling is much
faster than for drum brakes.

The single-piston floating-caliper disc brake is self-centering and self-adjusting. Self-centering

means that the caliper can slide from side to side so it will move to the center each time the brakes
are applied. The pads always stay in light contact with the rotor so less force is needed to engage
the brakes.

Cone Brakes
Cone brakes include a cone that is lined with heat- and wear-resistant material that presses against a mating cup surface. They have a cup
and a cone, which is lined with a heat- and wear-resistant friction material. During actuation, the cone is pressed against the mating cup
surface. Cone brakes are not commonly used.

Friction Brake Comparison

This table compares different types of friction brakes.

Mechanism Application Advantages Disadvantage

Automatic transmissions, Simple, inexpensive, easy to Poor heat dissipation capacity, wear
Band backstops, bucket conveyors, make, reliable, low friction lining is uneven from one end
hoists maintenance the other.
The friction area is covered by lining, s
Shoe mounting can be designed most of the heat must be conducted
to assist their own operation through the drum to reach the outside
Drum Rear automobile brakes
(self-actuating), don’t need a air to cool, difficult to get water out of
break booster the drum if driven through water, not a
efficient in reverse
Automobile brakes, often front Brake fade is rare, can operate Generate high heat from friction, no
Disc
wheel after being exposed to water self-servo effect

Friction brakes are used in industrial applications such as in agriculture, ATVs, aerospace and construction equipment, or mining, milling an
manufacturing projects.

Operating Specifications
Specifications for electric brakes include:

Torque rating is the turning force of an object. The maximum torque rating for the brake should be greater than or equal to the application’s
requirement. To determine this requirement, the following equation can be used.

Where,
T = full-load motor torque (in lb-ft)
5252 = constant (33,000 divided by 3.14 x 2)
HP = motor horsepower
Rpm = speed of motor shaft (rotations per minute)
Power is defined as the rate of doing work. For rotational power, such as a brake, the calculation can be done by:

Where,
Prot = rotation mechanical power
M = torque
ω = angular velocity
It is important to consider the units involved when making the power calculation. Such a reference is used to convert the torque-speed prod
to units of power (Watts). Conversion factors for commonly used torque and speed units are given in the following table.

Torque Units Units Speed Conversion Factor

oz-in RPM 0.00074
oz-in rad/sec 0.0071
in-lb RPM 0.0118
in-lb rad/sec 0.1130
ft-lb RPM 0.1420
ft-lb rad/sec 1.3558
N-m RPM 0.1047

Speed rating applies only to rotary brakes

Operating voltage is the input voltage that must be supplied to the electric brakes. Electric brakes can be designed to run on either AC or
power. A wide range of input voltage specifications is available to suit various applications.

Brake capacity depends on five factors:

Unit pressure between brakes
Contacting area of braking surface
The radius of the brake drum
The coefficient of friction
The ability of the brake to dissipate heat that is equivalent to the energy being absorbed.

Engagement Mechanisms
There are a variety of engagement methods for electric brakes.

Non-contact brakes use methods such as magnetic fields and eddy currents.
Magnetic particle brakes have a space between the coil and the shaft, which is filled with magnetic powder. The brakes engage with
the application of an electric current to stainless steel particles in the gap between the output disk/shaft assembly and the housing. As
the current is increased, the magnetic flux becomes stronger and increases the torque produced.
Friction brakes generate friction between contact surfaces.
Wrap spring brakes transmit torque from the input to the output through a wrapped spring that uncoils to disengage the brake.
Electric brakes with teeth engage only during stops or at slow speeds.
Oil shear brakes achieve engagement through the viscous shear of transmission fluid between the brake plates.
Spring-return brakes require power to engage. The spring engages during operation and requires power to disengage. Spring-
actuated brakes are also called power-off brakes, fail-safe brakes, and safety brakes.
Spring-actuated brakes require power to disengage. A spring is used to disengage the brake. Spring-return brakes are also called
power-on brakes and non-fail-safe brakes.

Brake Measurements
Selecting electric brakes requires an analysis of measurements and mounting configurations. Important measurements include:

Diameter -- The bigger the rotor, the less force required to apply to the brake. The smaller the rotor, the more pressure or force needed
for the brake (compared to the larger rotor) to stop.
Length -- The dimension along the axis of rotation.
Weight -- The weight of the brake.

Brake Material Properties

Desirable properties for friction materials/linings include:

A high coefficient of friction.

Resistant to wear effects, such as scoring, galling, and ablation.
Constant friction value over a range of temperatures and pressures
Resistant to the environment (moisture, dust, pressure)
Good thermal properties, high heat capacity, good thermal conductivity, ability to withstand high temperatures and contact pressures
Good shear strength to transferred friction forces to structure
Safe to use and safe for the environment

This table describes important properties of materials used for brakes and clutches.

Coefficient of Friction Temp.(max) Pressure (Max)

Material Combination
Wet Dry Deg.C MPa
Cast Iron/Cast Iron 0,05 0,15-0,20 300 0,8
Cast Iron/Steel 0,06 0,15-0,20 300 0,8-1,3
Hard Steel/Hard Steel 0,05 0,15-0,20 300 0,7

Shaft Configurations
Brakes are mounted on a shaft which, can come in three configurations:

In-line shafts are along the axis of the load

Parallel shafts are parallel to the load but not in-line with it.
Perpendicular shafts are at a right angle to the axis of the load

Special Features
Electric brakes are available with a variety of special features. Some devices use:

Electrical or electronic signals to monitor parameters such as position, speed, torque, lockup, or slip status.
Prevention of play or backlash during load engagement and prevent direction reversal during load disengagement.
Washdown-capable electric brakes use housing materials that are rated for washdown cleaning.
 References
Advantages of Hysteresis Devices (http://www.magtrol.com/brakesandclutches/advantages.html)

Bhandari, V. B. Design of Machine Elements. New Delhi: Tata McGraw-Hill, 2007. Print.

Brakes (http://www.cdxetextbook.com/brakes/brake/topic.html)

Hysteresis Brakes and Clutches (http://www.electro-meters.com/Assets/PDF_files/Magtrol/Dynamometers/hysteresis.pdf) (pdf)

Industrial Clutch/Brakes: How they work (http://www.ogura-clutch.com/products/industrial/howtheywork/electromagnetic-particle-

brake.html)

Module 12: Design of Brakes (http://nptel.iitm.ac.in/courses/Webcourse-

contents/IIT%20Kharagpur/Machine%20design1/pdf/mod12les2.pdf) (pdf)

Orthwein, William C. Clutches and Brakes: Design and Selection. New York: M. Dekker, 2004. Print.\

What's Inside: Brakes (http://auto.howstuffworks.com/auto-parts/brakes)

Image Credits:

Ogura (http://ogura-clutch.com/) | PrecisionTork (http://www.precisiontork.com/) | Scioly (http://www.scioly.org/) | How Stuff Works

(http://auto.howstuffworks.com/auto-parts/brakes/brake-types/disc-brake2.htm)

Read user Insights about Electric Brakes (/insights/80/electric-brakes-design-trends-applications-buying-advice-from-technical-experts)

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(http://www.globalspec.com/learnmore/motion_controls/clutches_brakes/electric_clutch_brake_assemblies)
Electric brake and clutch assemblies consist of elements for both the connection and disconnection of shafts (clutch) and for the
slowing or stopping of shafts (brake) in equipment drives.

Hydraulic Brakes (http://www.globalspec.com/learnmore/motion_controls/clutches_brakes/hydraulic_brakes)

Hydraulic brakes use a fluid to transfer pressure and actuate the braking mechanism.

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Hydraulic clutches are assemblies consisting of elements for the connection and disconnection of shafts (clutch) in equipment drives.

Mechanical Brakes (http://www.globalspec.com/learnmore/motion_controls/clutches_brakes/mechanical_brakes)

Mechanical brakes convert kinetic energy to other energy forms, primarily heat. They decelerate shafts and linked components via
friction between a rotating body and wear-resistant material.

Mechanical Clutches
(http://www.globalspec.com/learnmore/motion_controls/clutches_brakes/mechanical_clutches)
Mechanical clutches are assemblies consisting of elements for the connection and disconnection of shafts (clutch) in equipment drives.

Pneumatic Brakes (http://www.globalspec.com/learnmore/motion_controls/clutches_brakes/pneumatic_brakes)

Pneumatic brakes are assemblies consisting of elements for the slowing or stopping of shafts in equipment drives. Air is required to
activate the brake.

Pneumatic Clutches
(http://www.globalspec.com/learnmore/motion_controls/clutches_brakes/pneumatic_clutches)
Pneumatic clutches are air-actuated assemblies consisting of elements for the connection and disconnection of shafts (clutch) in
equipment drives.

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