Focus on Sci. & Tech. Grasp Details

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3 Focus on Sci. & Tech. Grasp Details B Series Safety brake, adopts modular design and has multiple functions, which can facilitate super rapid response with its professionally designed for low power electromagnetic coils, delicately upgraded magnetic circuit structure and special circuit board. S Series Safety brake, of high corrosion resistance and high protection, can be directly applied in open air. C Series Power-on brake, keeps interchangeability with the majority of mainstream product in the market, for extensive application. P Series Power-on brake, with backlash compensation and torque adjustability, is developed by UHT specifically for various electric cars. BH Series UHT developed the brake specifically for wind power field with features as highly-sealed and highly corrosion resistant, which can be uni-directional or bi-directional. Meanwhile we can design brakes with specific functions according to personal needs of customers.

4 Company Profile Catalog Brake Model Selection B Series- Spring-loaded Electro-magnetic Brake Features& Applications Operation Principle Rated Data Instruction for Installation Installation Dimension Table Instruction for Adjustment Attachments Product Definition Selection Form S Series- High Sealing Spring-loaded Electro-magnetic Brake Features& Applications Operation Principle Installation Dimension Table Instruction for Installation and Adjustment Product Definition Selection Form C Series- Spring-loaded Electro-magnetic Brake Features& Applications Operation Principle Installation Dimension Table Instruction for Installation Size Selection Product Definition Selection Form Rectifier Application for Crane Application for Wind Power Application for Forklift Truck Definition of symbols Braking torque required for dynamic load : Braking torque required for both dynamic and static load : Decelerating torque : Load torque : Rated torque of brake : Load moment of inertia : Relative rotation speed : Braking power : Friction power : Kinetic energy of gravity load : Quality of gravity load : Gravitational acceleration : Brake delay time : Friction coefficient : Friction plate equivalent radius : Friction torque : The resultant force on the armature : The spring force on the armature : The electromagnetic force produced by coil

5 Brake Model Selection Brake model selection depends totally on type of brake application. B Series brakes can be applied to general situations like power-off braking; S Series of high protection class for environments with more dust or outdoors; crane dedicated brakes for hoisting purpose; low-noise brakes for elevators, stages and other cases of low noise request. If you have special requirements on the response time or other functions of brakes in application environments, please contact suppliers. After the confirmation of brake model, the braking torque should be calculated based on the condition of loading. The calculation rules are shown below: Safety factor: K 2 Load calculation: The dynamic load is usually calculated according to the following formulas: Generally, both dynamic load and static load coexist in practical use, M load ). K M k when the braking torque and static torque have the same direction when the braking torque and static torque have the opposite directions With the known power of brake motor, the braking torque can be estimated according to the following formula: Calculation of friction power: If the braking frequency is very high and the frictional power consumption for each braking is large, the thermal load needs to be considered. The formula for calculating frictional power consumption is as follows: when the braking torque and static torque have the same direction when the braking torque and static torque have the opposite directions Notice: When calculating the friction power in the process of descent in the field of hoisting, the kinetic energy converted from the gravitational potential energy of load during the process of braking delay should also be considered in addition to the inertia of the system. The specific value should be: The actual friction power with gravity load is:

6 S Series High Sealing Spring-loaded Electro-magnetic Brake Features High protection fully sealing structure, protec n level up to IP56, salt spray corrosion, suitable for port, metallurgy, m ng equipment and other harsh environments. Applications: Port Machinery Crane Metallurgy Machinery Material Handling Machinery Light Industrial Packaging Textile and Printing Wood Working Machines

7 S Series Operation Principle Cylindrical Pin Hub Screw Stator Flange Rotor Spring Coil Friction disk Armature When braking, the Rotor (4) installed on hub (2) with the splines is pushed by Springs (8) towards Flange (3) via Armature (6), so as to produce the braking torque and the air gap between Armature (6) and Stator (9). When the brake is released, the stator Coil (7) will be driven by DC current, and the magnetism generate force produced would make Armature (6) push Springs (8) to draw to the stator, when the Rotor (4) is released, braking action is cancelled. Axial movement component Rotating component Fixing component Assembling surface

8 S Series Installation Dimension Table Mounting Screw Size Rated torque Mk (Nm) Maximum speed n (r/min) Standard voltage V (VDC) Rated capacity P (W) Rated air gap S (mm) Maximum air gap Smax (mm) Radial dimensions Axial dimensions Manual release angle а

9 Mounting Screw Size Rated torque Mk (Nm) Maximum speed n (r/min) Standard voltage V (VDC) Rated capacity P (W) Rated air gap S (mm) Maximum air gap Smax (mm) Radial dimensions Axial dimensions Standard of keyway refer to GB/T1095. Not specified unit: mm

10 S Series Instruction for Installation and Adjustment 3.Rotor 10.Screw 4.Hub 5.Shaft 7.Coil 6.Flange Check whether the brake resistance is normal. Fix Hub(4) on Shaft(5) axially. A clearance of mm is usually maintained between the hub and the installation surface so as to avoid obstructing the rotation of the shaft. The existence of this gap prevents collision between the hub and the friction dual faces in excessive axial movement. Do not knock the hub brutally; avoid inclined assembly. To preclude axial float of the hub, please fix it on the shaft with a C clip ring. Install the brake wholly on Hub(4), to ensure the rotor meshes well with the spline teeth of the axle sleeve. In order to lower noise, seal with silica gel between the hub involute tooth profile, and then load the rotor. Make adjustment to align the motor s seam allowance with the flange s seam allowance. Fix the brake on the motor with Set Screw(10). Check the air gap. Ensure the friction surface is protected from lubricating oil or grease. Energized

11 Installation mode: Check the air gap and resistance before installation. Fix hub on the shaft of generator with a shaft ring. Install the brake on end covers of electric generators, mind that keep the rotor and tooth of hub in alignment and fasten mounting screws. Power test. Data of installation and adjustment Unit: mm Size Rated air gap Tightening torque Screw size Allen wrench size Service life (adjustment) Adjustment is needed once the brake air gap S reaches the Smax. Friction power consumption is a function of a multitude of factors, such as moment of inertia, braking speed, braking frequency and friction surface temperature. Therefore it is necessary to make some adjustment so as to keep the friction power consumption in an optimum status.

12 Attention for installation For the friction dual faces, the surface roughness Ra shall not exceed 3.2, the surface shall be made of smooth cast iron or steel; the friction face shall be free of any sharp point. A friction disk or flange may be used where no suitable smooth face is available. The length of key of the fixed sleeve should be the same as the length of the sleeve keyway. Temperature: The insulation level of the brake is 155, the brake shall work at an ambient temperature of -20 ~50. Humidity and water droplets: If water droplets attached on the surface of friction, friction will be temporarily low before drying, please take the strategy of protection cover installation. The brake surface will produce gel when working in high temperature difference environment, which can be solved by using heating zone or high grade packaging. In addition water attachment will lead to rust, which may cause locking in serious situation. Ventilation: The brake had better install in well-ventilated environment, because friction power consumption is transformed into heat. If forced cooling by air blower, it is very effective to increase the friction work. Please monitor the temperature while poor ventilation condition. Antirust: Poor storage, harsh environmental conditions and other factors will cause brake rust. The friction surface of the serious corrosion will affect the braking torque, damage the friction surface, even cause locking, although slight corrosion will not. Sparks: Brake may produce sparks because of friction. Please consider the explosion-proof design if it is used in flammable and explosive environment. Magnetic shielding of stator: The brake influenced by the measurement instruments and machines In the vicinity of it may have noise or false action, which can be solved by magnetic shielding device. Non conducting magnetic material is usually used as the material of the mounting surface and shaft of the stator. Wire protection: Brake cable of UHT has many advantages such as UV protection, anti aging, cold resistance and heat resistance and so on. If the wire is damaged, it will cause short circuit or open circuit, which should be prevented at the beginning of the design. Common Malfunction Analysis Coil anomalies (including coil short circuit, open circuit, and abnormal insulation): Measure coil resistance and insulation resistance with a multimeter and a megger, check whether coil resistance and insulation is good or not. If the coil resistance or insulation is abnormal, please replace the stator. Deviation of air gap and handle gap (including too-big or too-small): Check the gap with feeler to make sure it is in specified range. Control Sequence problem: Mismatch of the electric machinery start/stop control program and brake response time, may aggravate the wear, reduce service life of the brake and the electric machinery, and even worse, wear to out of service in 3-5 days or over burnt coil. Rotor life problem: Please replace the rotor when it wears to very thin. Line problem: Please check whether the line connection is normal. Action problem: Verticality between mounting end face and shaft is too big. Rectifier exceptionally: Please check whether input and output voltage of the rectifier is normal. Micro switch become invalid, check with a multimeter whether the micro switch contact can be triggered by braking normally and whether the micro switch can be triggered manually. If the micro switch cannot be triggered manually (broken) or it cannot be triggered by braking after adjusting, please replace the micro switch.

13 Micro switch The micro switch can detect whether the brake is released and feed back a switching value signal, to prevent the generator starting when the brake is in the operating state and protect the motor effectively. The micro switch connection mode is showed in the picture. NC NO Blue Black Brown Yellow & green Instruction for use of the micro switch Adjust the air gap between the armature and the stator to the standard value while actuation detection. After the brake is powered, test whether the micro switch has the ON/OFF signals with the multimeter. If there is not a signal, check whether the brake is released (i.e. the armature is drawed by the stator coil). If it is released, open the brake and adjust the screws on the armature, which touch the micro switch contacts, until the micro switch has the signal that the brake can be released; then tighten the screws with glue and nuts. The electric generators cannot be started until the micro switch has a signal. The micro switch s trigger position can be adjusted as well to realize the gap detection. When the air gap is too long, the micro switch will not be triggered, the generator s contactor cannot actuate, so the motor will not be started. In this case, adjust the clearance between the armature and the stator to the standard value. Actuation detection and wear detection cannot be done by the same micro switch. Only one of them can be chosen. If both actuation detection and wear detection are required, please inform the supplier. Stator Cylindrical pin Hexagon socket set screws with flat point Locknut Armature Micro Switch

14 S Series Model Description Special Order Code Micro Switch Oil Sealed Aperture (mm) 0:Dust-shield without Holes Hub Aperture (mm) Coil Voltage (VDC) Attachment 0:None 1:Hand Release S6.3-S100 2:Dust-shield 3: Hand Release & Dust-shield S6.3-S100 Rotating Part 0:None 1: Rotor 2: Axle Sleeve 3: Rotor& Axle Sleeve Size: Brake Series No.

15 S Series Selection Form Customer Name Size Voltage AC DC Other Other Braking Torque Cable Length Standard Special please indicate (cable length mm bare wire mm) Hub Aperture. Key width mm. Deep groove Micro Switch Seal Manual Release Motion detection Wear detection Dust-shield Oil seal, oil seal installation section of the shaft diameter mm Hand release Screw release Other Requirements Special Applications Brake Type

16 Tianjin UHT Science and Technology Co.,Ltd. No.7, Xiangrui Road, Tianxiang Industrial Park, Xiqing Economic Development Zone, Tianjin Zip code: Tel: Fax: