A Beginner’s Guide to the Types of Brakes in Industrial Mining

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Braking systems are a necessary piece of equipment whenever you use machinery in your industry. 

The brakes are essential to safety, and in industrial mining, they must overcome the conditions of working on the surface and underground. They must be capable of stopping and holding on slopes and ramps while carrying full loads. 

Because of the increased use of automation in industrial sectors, the braking market is expected to grow, making the quality of control and efficiency in brake systems vital.

Whether for your railcar or another piece of equipment, read on for the beginner’s guide to the types of brakes used in industrial mining equipment. 

Railcar Brakes

Railcar brakes are crucial in the industrial mining industry. There are three main options for railcar braking systems. 

Dynamic Wheel Brakes

Dynamic braking is a consistent form used for railcars. It uses the kinetic energy of the turning wheels, and with the electricity generated, it causes the train to decelerate and stop.

They respond more rapidly than air brakes and reduce wheel wear. It’s a safe and efficient way to make the train slow down and stop. 

Tripper Rail Clamps

This braking application is the type you need if the mining equipment you’re using needs to be locked in place. They are spring-set and hydraulically released so that when you remove the power, the brakes kick in, gripping the rail. 

As well as holding positions, these brakes work for emergency stops and lockdowns. 

Wheel Gripper

This static braking system grips the track and holds it in place. It’s used for purposes such as railcar dumping. 

They’re mounted on the inside or outside of the rails and are either spring-applied or pressure-applied. So even in the event of power failure, the memory circuit will hold. 

Braking Systems

You need a reliable braking system with all the heavy equipment on mining sites. Brakes in the mining industry have to survive harsh conditions and maintain quality performance – reliability is vital. 

Understanding the basics helps you anticipate possible maintenance requirements. 

Drum

A drum brake is a dynamic brake. If you need something cost-efficient, then this is an ideal brake system. Lower torque or less space is when this application comes in. 

When you apply the brake, the shoe in the wheel hub pushes against a drum giving you a safe and compact brake. 

Disc Brakes

Disc brakes are also dynamic brakes, and they’re often considered the best choice of braking systems.

If you have unlimited space and high torque, these are your equipment’s brakes. They have a metal disc in the front wheels, and when you apply the brakes, a hard pad presses on the disc, causing it to slow down. 

Hydraulic

Hydraulic brakes are spring-loaded. Pressure on the brake shoes forces them against the drum and provides adjustable torque. As a result, hydraulic brakes last a long time in harsh environments like mining. 

Industrial Mining Braking Systems

If you would like additional details, contact us.

3 Tips for Choosing an Industrial Braking System

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Industrial braking systems are one of the most critical pieces of technology around. In essence, the job of a braking system is to absorb energy and bring whatever it is on to a halt.

Read below for three of the most practical tips for choosing the right industrial braking system to match all your needs.

1. Ensure a Warranty Is Included

Your braking system components are constantly exposed to varied types of pressure. So first, ensure all elements have a factory warranty to protect you from defects. Then, should something go wrong, you could quickly get the part replaced.

2. Get Braking System Parts from a Trusted Brand

With so many brands to choose from today, stick to the tried and tested brands known for braking components and have the backing to support their customers. 

Quality should never be compromised when choosing a brand, as the fallout could be catastrophic.

3. Know What Type of Braking System You Need 

Choosing the correct braking system will be a significant factor in whether it suits your needs or not. The following types of braking systems and tips will help you decide.

Spring Applied Brakes

Spring applied brakes act to decelerate a load in the event of a power failure or however you choose the release mechanism to be disengaged. This type of system is suitable for robotics and automation engineering solutions.

Fail-Safe Brakes

Fail-safe brakes are designed to kick in when there is an immediate power cut. Fail-safe brakes have one purpose, and that is to avoid catastrophic accidents. Such a brake system will be applicable for an elevator. 

Pneumatic Brakes

Pneumatic brakes are one of the older brake systems; they use compressed air to drive a piston and apply force to a braking pad. A straightforward system, you can use pneumatic brakes in almost every braking system.

Electromagnetic Brakes

As the name suggests, electromagnetic brakes use electromagnetic force to cause friction, which asserts the necessary stopping action. Therefore, this system is perfect for avoiding the heat dissipation that friction brakes cause.

Hydraulic Brakes

Hydraulic brakes use compressed brake fluid to generate the required baking force. Hydraulic braking systems are known for being simplistic and very reliable and are the primary type of braking systems in industrial applications. From winches to cranes, hydraulic braking systems should be your number one system to turn to. 

Make the Right Choice Today

Choosing the right braking system doesn’t have to be complicated. The right braking system coupled with a trusted manufacturer will not only keep your machine operator healthy, but your machine will stand the test of time.

Are you looking for the best industrial braking system parts on the market? Not sure where to look? Go to our manufacturer’s page and find the best components available on the market! 

7 Signs You Need to Replace the Brakes on Your Farming Equipment

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Keep reading to learn the warning signs that indicate your farm equipment brakes are beginning to fail. 

1. Noise

First and foremost, odd noises as you break indicate you may have a problem with your brakes. This is hard to determine since farm machinery makes a lot of noise anyway. The average tractor produces between 85 and 100 decibels. 

If you know what to listen for, you’ll hear the brakes failing before they completely give out. Listen for scraping, grinding, screeching, or squeaking noises. As the brakes wear down, the discs and calipers will rub together and make these noises. 

If you hear these noises, take your tractor in for replacement brakes and an overall equipment maintenance check. 

2. Pulling

Sometimes you can feel if the brakes are beginning to fail. For example, you may have a problem operating the machine when it begins to pull to one side or another as you brake. This pulling indicates uneven wear on the drums. 

You may have a problem with brake fluid as well. Either way, take the machine in for a brake maintenance check. 

3. Less Responsive

They should respond by slowing down the machinery when you press the brakes. If you notice the responsiveness beginning to lower, it’s time to have our brakes checked. When you find yourself pulling levers harder or pressing down on the pedal with more ferocity, beware. 

4. Vibrating

While driving the vehicle and then applying brakes, the vehicle should not vibrate. If it does, check your rotors. A vibrating vehicle indicates you may have warped rotors. 

Older rotors are especially susceptible to warping. Over time the friction and heat will warp them, and they won’t sit flush on brake pads. Then your vehicle wobbles as you brake hard. 

5. Grinding

No amount of grinding when you brake is healthy. If you hear or feel grinding, your brake pads have disintegrated. The compromised pads now put your rotors at risk. 

Take your equipment to a mechanic immediately before you do further damage. 

6. Soft Brakes

You have a problem when you step on the brake pedal goes to the floor easily. Most likely, your brake pads have worn out. You also may have a leak in your air brake line. 

7. Bad Smells

Overheated and compromised brakes will put off a sharp, chemical odor. When you smell this as you apply the brakes, stop your vehicle and move it to a safe place. Check to ensure you don’t have smoke from the brake area. 

Keep Farming Equipment Safe

You can best keep your farming equipment safe by conducting regular maintenance on the equipment. Check your brakes regularly, and heed the warning signs above. Doing so will save your equipment and possibly your life. 

Do you need new brake equipment? If so, contact us. We have a variety of equipment in stock and are ready to help you maintain your agricultural equipment. 

A Complete Guide to Phenolic Laminates and Their Uses

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Machine and equipment breakdowns cost businesses money. So it’s vital to choose durable parts to withstand heavy use over a long period. Phenolic laminate parts are the ideal solution for many industries.

The use of this composite material is growing rapidly across different sectors. Analysts predict that the phenolic resins market will grow to $12.6 billion by 2030.

Advances in technology have made these products more affordable and versatile. As a result, manufacturers are switching from metal or plastic to phenolic laminate. Keep reading to learn more about this composite material and its applications.

What are Phenolic Laminates?

A phenolic laminate is made by applying heat and pressure to layers of material. Makers impregnate layers with thermosetting resins for strength.

You can then use various phenolic materials to create different types of laminates. The most popular are linen, canvas, paper, or glass cloth.

The resulting product is a hard, durable component. And it’s this strength that makes it perfect for use in many industries.

What are the Benefits of Phenolic Laminates?

Yes, phenolic composites are strong, but this is not the only benefit. Phenolic laminates can also be molded into shapes and sizes to suit different needs. Standard forms are sheets, rods, or tubes which can be cut to size.

This composite laminate is also water-resistant and lightweight. Thus, it often makes an excellent replacement for metal parts.

Another benefit is that phenolic laminates are resistant to various chemicals and heat. Some phenolic composites are infused with epoxy resins that make them fire-resistant.

Also, this material does not conduct electricity, making it an excellent insulator. And lastly, phenolic laminate products can be self-lubricating. This helps machine parts last longer due to reduced friction.

Phenolic Laminates Uses

Phenolic laminates have many applications across diverse industries. This is thanks to their versatility and outstanding electrical properties.

For example, the electronics industry uses phenolic composites for insulation and switches. Another common use is for terminal boards since non-conductivity is of utmost importance.

Manufacturers also use this composite material to produce bushings for off-road agricultural equipment. Another application is for making bearings.

These bearings are often used for paper and aluminum mill machinery. High pressure and chemical tolerance allow them to last longer than metal bearing.

Phenolic composites also make for excellent railcar parts. Common uses are for vertical liners and wear pads on passenger and freight trains. These phenolic components perform better thanks to high impact resistance and sliding lubrication.

Another use is industrial brake and clutch parts for overhead crane linings. You can even use phenolic laminate to create parts, such as center plates for passenger cars.

A Versatile Solution for Industries

The applications for phenolic laminates are endless. They are suitable for everything from aerospace to marine to electrical industries.

Also, phenolic laminates are great for producing parts of nearly all sizes—for example, everything from small terminal boards to big gears.

This composite material often outperforms metal and plastics. The main reason is that it is more resistant to pressure and shock. Another significant benefit is that phenolic laminates are less prone to corrosion.

We offer a variety of phenolic laminate products for many industries. Contact us today to request a free quote.

Machining Rotors: A Guide to Replacing Brake Rotors

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The brakes are one of the most important parts of industrial equipment.

When your equipment’s brake rotors get worn down, it puts the lives of your employees, customers, and those around them in danger. So when the time comes to replace a piece of equipment’s brake rotors, it’s always better to be safe than sorry.

Knowing what you will need to make the job as easy and efficient as possible is good. So read on to find out more about the process of replacing and machining rotors.

Replacing vs. Machining Rotors

If a brake rotor is warped, scored, or rusted, you can either replace or machine it.

Machining rotors can help increase stopping power, promote longevity, and reduce the runout of a brake rotor. However, it’s a time-consuming fix that is difficult to do correctly and can lead to poor quality rotors and safety issues.

Plus, even when done correctly, it can only add so much more lifespan to a rotor.

You replace a rotor if it wears below its minimum thickness or cracks or is too warped, scored, or rusted to be machined. In addition, you should also replace brake rotors if any scores or grooves are too deep or there are severe cracks. Further, replace blued rotors, as they are likely about to warp or crack.

How to Machine Rotors

Machining rotors is the process of removing metal from the surface of a rotor to make it flat or give it a more uniform layer of friction.

The process typically starts by sanding the rotors with 120 grit sandpaper. After removing any built-up deposits and dirt, it is time to cut, trim, and thin the rotor’s surface on a lathe.

After resurfacing the rotor, test the equipment to ensure the rotors have regained a sufficient level of friction.

Replacing Brake Rotors

If a rotor is too damaged, rusted, or warped to machine, you need to find a replacement.

The most common type of replacement rotor is the one-piece rotor. It has a solid body with a hat cast together with the outer ring. One-piece rotors are easy to make and most common for replacement rotors.

However, they are susceptible to warping. While some modern and high-end one-piece rotors may have heat dissipation, others are likely to distort when exposed to extreme heat.

Slotted and drilled rotors are also typical in heavy equipment. They are useful for environments that are wet and have increased temperatures or in applications that require consistent braking.

 Knowing When to Replace Brake Rotors

Brake rotors are an essential part of many modern braking and safety systems. 

Whether you are replacing or machining rotors, it is crucial to keep quality in mind to ensure the safety of your customers and employees. If a brake rotor is worn or broken, it can have a disastrous effect on those operating industrial machinery and your profits.

Contact us today to learn how our industrial brakes and clutches can benefit you.

3 Tips for Choosing an Industrial Braking System

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Industrial braking systems are one of the most critical pieces of technology around. In essence, the job of a braking system is to absorb energy and bring whatever it is on to a halt.

Braking components can operate at temperatures up to 3500 degrees celsius on average! But, of course, what’s not so hot, is braking systems failing.

Read on below for three of the most practical tips for choosing the right industrial braking system to match all your needs.

1. Ensure a Warranty Is Included

Your braking system components are constantly exposed to varied types of pressure. So first, ensure all elements have a factory warranty to protect you from defects. Then, should something go wrong, you could quickly get the part replaced.

2. Get Braking System Parts from a Trusted Brand

With so many brands to choose from today, stick to the tried and tested brands known for braking components and have the backing to support their customers. 

Quality should never be compromised when choosing a brand, as the fallout could be catastrophic.

3. Know What Type of Braking System You Need 

Choosing the correct braking system will be a significant factor in whether it suits your needs or not. The following types of braking systems and tips will help you decide.

Spring Applied Brakes

Spring applied brakes act to decelerate a load in the event of a power failure or however you choose the release mechanism to be disengaged. This type of system is suitable for robotics and automation engineering solutions.

Fail-Safe Brakes

Fail-safe brakes are designed to kick in when there is an immediate power cut. Fail-safe brakes have one purpose, and that is to avoid catastrophic accidents. Such a brake system will be applicable for an elevator. 

Pneumatic Brakes

Pneumatic brakes are one of the older brake systems; they use compressed air to drive a piston and apply force to a braking pad. A straightforward system, you can use pneumatic brakes in almost every braking system.

Electromagnetic Brakes

As the name suggests, electromagnetic brakes use electromagnetic force to cause friction, which asserts the necessary stopping action. Therefore, this system is perfect for avoiding the heat dissipation that friction brakes cause.

Hydraulic Brakes

Hydraulic brakes use compressed brake fluid to generate the required braking force. They are known for being simplistic and very reliable and are the primary type of braking systems in industrial applications. From winches to cranes, hydraulic braking systems should be your number one system to turn to. 

Make the Right Choice Today

Choosing the right braking system doesn’t have to be a complicated affair. The right braking system coupled with a trusted manufacturer will not only keep your machine operator healthy, but your machine will stand the test of time.

Are you looking for the best industrial braking system parts on the market? Not sure where to look? Go to our manufacturer’s page and find the best components available on the market! 

What Are the Essential Parts of a Wind Turbine?

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Last year, wind turbine generation accounted for around 9% of power in the United States. Wind turbines continue to provide a more significant portion of domestic energy as companies and customers seek new renewable energy sources. 

Have you ever wondered what parts a wind turbine technician must work on? Then, read on to learn what components make up a wind turbine.

Generator (Nacelle)

Generators use electromagnetic induction to create electrical voltage (electrical pressure) that is transferred to the power grid. 

You can have a simple generator with a coiled wire known as a conductor and a series of magnets that wrap around the conductor. Voltage is produced when the conductor and magnets begin rotating near one another. The wind is the force that turns the rotary blades. 

Voltage drives electrical current through what is known as an alternating current. This step powers lines for the distribution of power. The wind turbine slip ring transfers electrical power from the rotating unit through a stationary part of the turbine. 

The “nacelle” is the part considered to be the head of the turbine. The blade assembly attaches to the front of the unit, known as the nacelle. A standard nacelle weighs around 72 tons.

A nacelle typically houses a gearbox assembly, braking system, turbine generator, and electrical power transmission system. 

Rotor blades

Rotor blades act as barriers to the wind. When gusts hit the blade, which is typically turned toward the direction of the wind, the wind forces the blades to turn. This activates the generator and transfers the wind into electricity. 

Some turbines have built-in systems that automatically adjust the blades’ angle to control the energy output. This can be particularly important for accounting for high wind speeds.

Tower

The height of a tower is a critical component of wind tower design. Wind generally increases with height. Near the ground, the surface of the ground creates friction that slows low-level winds. 

This is why wind towers are typically designed to reach heights up to 150 meters tall. Up there, the wind gusts are more powerful even as turbulence rises.

Foundation

The foundation structure bears the dynamic and static loads that are created by the wind turbine. Typically, the foundation is created from a mesh of steel and concrete that roots the generator to the ground for greater stability. 

Wind Turbine Parts

Wind turbine technology is both fascinating and essential to our economy. Although the units appear straightforward, many intricate moving parts must be maintained and repaired as needed.

If you operate wind turbines, Kor-Pak manufactures and supplies OEM and aftermarket parts that can meet your needs. To request a quote from one of our team members, leave us a message, and someone will reply promptly. 

How Does an Industrial Container Crane Work?

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The city of Boston is home to one of the largest container cranes in the country. The two 205-foot cranes are expected to come online sometime this year. Container cranes are an indispensable part of the shipping industry. 

Have you always wondered how a container crane works? Read on to learn how a crane for shipping containers lifts heavy loads and more. 

How Does a Container Crane Work

Although many of us are familiar with how freight by rail works, shipping is the leading means of transporting goods between countries. A container crane is a large hoisting device that lifts shipping containers.

The cranes primarily unload or load containers from a ship. Or they move containers around a shipping yard. Container cranes are a type of gantry crane. This means that they rely on an overhead beam.

Unlike moveable cranes that move agricultural goods and other products, a container crane is generally stationary. These are large, powerful machines that require extensive training to operate. 

Design Profiles

A container crane may feature several design profiles depending on where it will be used. For example, a full-gantry unit straddles a body of water. 

Full-gantry units lift containers from below the ship. A half-gantry unit is very common in U.S. ports and extends over a port’s edge.

Some designs use high-profile arms that swing out to move containers. 

The operating system varies widely. For example, some rely on a hydraulic lifting mechanism.

Others use a hybrid-electric system. Either may rely on an electric or diesel fuel generator.

Cab Operator

Container cranes could not operate without the skilled guidance of a cab operator. The operator typically sits in an operating cap positioned above the hoist. This gives the operator a clear view of the operations below. 

Most container cabs can traverse the length of the beam. This allows the operator to position the spreader. They can then lift the containers as needed.

A container crane operator must undergo certification and training to ensure they know how to operate cranes. Safety is always a top concern.

Operators are often tasked with looking for defects before each use. This typically means an inspection before each workday. 

Learn More About Construction Cranes

Each container crane is customized to meet the needs of each port. Whether using a full-gantry or half-gantry crane, the system for lifting and moving shipping containers is incredibly efficient and powerful.

Whether you need commercial drum breaks, calipers, clamps, or something else for your business, we’re here to help. Give us a call, and we’ll help you find a free quote on whatever product you are looking for. 

 

3 Things To Know About Friction Material

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The U.S. manufacturing industry accounted for more than 10 percent of the nation’s gross domestic product in 2020. With a number like that, it’s easy to see how important it is to keep this industry running smoothly. A lesser-known but essential part of the manufacturing sector is friction materials.

While you may not have heard of these, friction material is essential in many manufacturing industries. Read on to learn three important things about these materials. 

1. What Is a Friction Material?

Systems with multiple moving parts in contact with one another use friction material. These materials are many different substances, including ceramics, paper, sintered metal, and metal alloys. The type of substance selected for friction material depends on several factors. These include:

  • Performance requirements
  • Temperature
  • Speed of the moving parts 

2. What Are the Uses for Friction Materials? 

The parts that friction materials are made into have specific functions within certain systems. Some of them include:

Friction Disc

Friction discs, also called clutch or brake disks, are part of the braking systems on cars and other machinery. The friction disc material attaches to a metal plate.

Clutch Facing

Clutch facings reduce the noise a clutch makes and allow for smoother transitions. These materials need to function under extended periods of stress and high heat. 

Brake Pads

The material used in brake pad production includes semi-metallic, non-asbestos organic, and ceramic materials. Regardless of the material, the operation is the same as the pads apply friction to the rotor. 

Brake Blocks

Brake blocks are a simple mechanism for stopping the motion of a wheel. Typically made of hard material or rubber, their simplicity allows for production from cheap low friction materials, such as rubber or resin. 

3. How Are Friction Materials Produced?

The first step in the production of friction material is the selection of raw materials. There are several substeps to be taken when selecting these materials, including whether you are producing low or high friction materials and if you are using organic, inorganic, or metallic materials. 

Once raw materials are selected, they are bonded with phenolic resin. This binding agent is used because of its ability to withstand heat and resist combustion and conduction. 

The raw materials are then blended. This process will determine the grade and cost of the finished product. The final step is the performing process, which shapes the friction materials into the final shapes to be used in operation. 

Are You Ready to Purchase Friction Materials? 

The type of material that you will need depends on multiple factors and the end use. Both the blending and performing process will determine the final product.

If you’re ready to begin the process of finding the perfect friction materials, contact us for all your needs

 

 

Different Types of Railcar Parts and How They Work

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Although passenger and freight railcars have different purposes (transporting people versus transporting goods), they tend to share a lot of the same railcar parts. 

Sourcing and maintaining those parts is essential to any successful railcar operation. 

Let’s take a look at the various railcar parts. 

Railcar Parts: Mover Parts 

The mover parts of a railcar ensure that everything’s running smoothly as passengers or freight goes along the tracks. A brief list of railcar mover parts includes the following:

Couplers

Couplers connect the railway vehicles.

Rather than one standard kind of coupler, many different types of designs and materials are in use. These  range from mechanical couplers such as the buffer and chain or link and pin to semi-automatic couplers such as the Janney coupler.

Axles & Wheels

The rail axle and wheels work together to form a wheelset that keeps the railcar moving along the track. The wheels are typically made of steel and heat-treated to add extra strength. 

Most modern freight railcars have three or four wheelsets to support heavy freight loads. 

Cylinders

The cylinders help generate power for railcars. Made from steel, these are essential components for the diesel engine railcars that carry most of the world’s freight. 

Railcar Parts: Friction Wear Parts

Friction wear parts play a vital role in applying pressure to certain railcar parts to control speed. Some of the most common friction wear parts include:

Brake Shoes and Brake Pads

By pressing against the wheel tread, brake shoes and pads can slow or stop a wheel. Each railroad car has its own brakes to control its wheels. When working together, they bring the entire railcar to a stop. 

Typically, pads and shoes are made from cast iron and composite materials. 

Center Plates

Center plates are a kind of steel or forged steel plate that supports the car body on its trucks. Through this support, the center plates allow the trucks to turn. 

Railcar Parts: Rubber Parts 

Rubber parts have a variety of different functions for railcars. Let’s take a look at two common ones. 

Motor Mounts

Most railcars carry heavy loads that cause quite a lot of vibrations. Motor mounts help manage the effects of those vibrations by creating stability support. 

Rubber Seals & Gaskets 

Rubber seals are primarily used to prevent unwanted leaking from windows, doors, ceilings, engines, and more.

These work together with gaskets to prevent fuel, oil, and grease leakages. For example, nitrile gaskets help secure manway (or utility hole) nozzles on railroad tank cars. 

Railcar Parts With Kor-Pak

After correctly identifying the parts of a railcar, you can better hone in on the particular railcar parts that need adjustment or repair. You’ll want to find a railcar parts supplier with experience and expertise to ensure a quality job. 

Kor-Pak has provided rubber parts, friction wear parts, and other railcar parts to satisfy clients for many years. Contact us today to see how we can help.