Braking system for

hoist
► The electrical portion of the hoist is designed to provide sufficient torque to
turn the drum and raise or lower the rope, conveyance and payload.
► 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
Magnetic brakes

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

► There are four types:

► 1 permanent magnetic brakes
► 2 electro magnetic brakes
► 3 eddy current brakes
► 4 hysteresis powerd brakes
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 coil, which sets up an alternate magnetic
field that cancels out the magnetic flux of the permanent magnets.
Permanent brakes are engaged when no power is applied to them and can
hold or stop when power is lost or unavailable.
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 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 called an 'eddy current'.
Hysteresis Powered Brakes
► Hysteresis powered brakes have a wide torque range. They have a reticulated pole structure and
a specialty steel rotor/shaft assembly that are fastened together, but not in physical contact.
The drag cup can spin freely until the field coil is energized by a current/voltage, creating an
internal magnetic flux. The air gap between the pole structure and the rotor becomes a flux
field and magnetically restrains the rotor. This provides the braking action between the pole
structure and the rotor.
►
► When electricity is removed from the brake, the rotor is free to turn, and no relative force is
transmitted between either 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 proportional to the amount of
current flowing through the field coil.
Electrically Actuated Friction Brakes

► Band brakes
► Drum brakes
► Disk brakes
► Cone brakes
Band Brakes
► Band brakes are the simplest electric brake configuration. They are often used as a back-stop
mechanism to prevent reverse rotation. These 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 the 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 band 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
Drum Brakes

► Drum brakes are commonly used on automobile rear wheels. They operate by
forcing the friction-lined brake shoes against the inner surfaces of the rotating
drums. A drum brake has two brake shoes, a piston, an adjuster mechanism, and an
emergency brake mechanism and springs. The shoes expand against the inside
surface of the brake drum, and slow the wheel down. The harder the linings are
forced against the brake 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 released, as well as to help hold the brake shoes in place and return the
adjuster arm after it actuates
Disc Brakes
► Disc brakes consist of a caliper that squeezes brake pads against a rotating disc. 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.
► 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
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 product to units of power (Watts). Conversion factors for commonly used torque and speed units are given in
► 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.
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
Research Question

► Describe in with the aid of diagrams the caliper brake system and the disk
brake system