5 Myths You Probably Believe About Brake Rotors

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Brake rotors are among the most important parts of industrial machinery. Having the right rotors can mean the difference between life and death. The same can apply to anything mechanical that may require a brake rotor or a braking system.

Unfortunately, there are some common myths circulating about the use of brakes, and chances are you might believe they are true.

In this article, we will try to dispel some of the common myths related to brakes that you probably believe in, so listen up.

Wet or Damp Rotors Affect Performance

It has often been said that once a brake rotor gets wet that it will impact its performance. However, this is not necessarily the case as modern braking systems don’t suffer any loss of performance like the old-fashioned drum brakes did.

The design of modern rotors allows for constant braking performance in most conditions. Due to their effectiveness, it is something we often take for granted..

The same can also be said in the industrial market, as rotor braking systems have many uses across different industries. Wind turbines, cranes and general heavy machinery also require brake rotors that need constant braking performance.

Brake Noise is Acceptable

Rotors are designed to make noise once they need replacing, it is often thought that brake squealing is normal, but this isn’t the case. Although it might be a minor fault, the noise will be indicating some form of issue that needs inspecting.

The best advice on brake noise is to get any noise inspected rather than ignoring it.

Brakes Need Time to Warm Up

Over the years it has been suggested that brakes need to be warm to be most effective, but again this is not the case as the materials used today can operate effectively with varying temperatures.

The only exception to this is high-performance racing pads, and these are not used in industrial environments.

Warping Brake Rotors

In the past, it has been suggested that rotors can warp and cause vibration, but this is, in fact, a myth. Brake vibration has many explanations some of which can be explained by the thickness of the brake, as well as brake torque variations. These are more likely to be the cause of vibration rather than warping.

All Rotors are Similar

Not all brake rotors are the same, even if it’s the correct one for a vehicle. The quality and driver needs can affect the behavior and synergy.

Low-cost options may also offer inferior performance, so this is worth considering when making your final choice. Higher cost options are not always suited to everyone as the benefits may not always outweigh the costs.

Don’t Believe Everything You Hear

If you are ready to learn more about the true benefits of brake rotors are why they are so incredibly important, feel free to contact us today for a non-obligational talk about your needs.

The Best of SEW Eurodrive Products

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There’s a reason SEW Eurodrive products are some of the best in the biz. They’ve been in the game since 1931 and show no signs of slowing down.

They started with a bang, coming up with innovation after innovation.

They were the first to produce a variable speed gear motor. They also were the first to incorporate an energy-efficient copper rotor into their motor.

With a history full of so many firsts, you know their products are top notch. But which one is best for your industry?

We’ve got a list of their top five products that stand out from all the rest. Find the part you need to have in your industry – keep reading!

Helical Gearmotor R Series

The Helical Gearmotor R series comes in different stage sizes to meet anyone’s needs. There are six single-stage sizes and 14 two- and three-stage sizes available.

This produces the ideal ratio between power and area available. Because of this, SEW Eurodrive’s range of torque and reduction ratios are among the most varied in the industry.

Helical-Worm Servo Gearmotors

Need something quiet that saves space? This is the gear unit for you.

There’s a longitudinal application of force on the input shaft which helps to keep the torque impulses quiet. No matter what kind of force you throw at this, it remains silent.

How quiet is it? It’s so soft, you can use it for a stage elevator!

M Series Industrial Gears

Here’s a high-performing gear that can take anything you throw at it. Plus, it’s available in both vertical and horizontal designs, making it extremely versatile.

Because of its high torque transfer capacity, it delivers power like no other. With its high thermal ratings, it can keep going longer and under harder conditions, too.

The best part about it? It can handle a torque range of 53,000 to 1,600,000 lb-in.

Screw Conveyor

This SEW Eurodrive product has a wide range of applications across many industries. That’s why it’s one of our top five essentials.

What makes SEW’s better than the competition? SEW ships the conveyor drive as a gear unit with a c-face motor adapter or in a gearmotor configuration.

Right out of the box, you’re saving on maintenance costs and keeping your company efficient.

DRS and DRN Motors

Here’s a modular motor and brake motor that is so efficient, it can replace a servo in some cases. It runs quietly, too, making it another perfect option for theater use.

With its high stability and high cycling capacity, you’ll want to use them everywhere.

Add SEW Eurodrive To Your Business Today

Whether you’re looking to keep a good supply of machine parts on hand or need custom options for a project, SEW has something for everyone. There are many reasons to trust them to deliver high quality and high performance.

If you’re ready to optimize your operation, we’re here to help you find the best SEW Eurodrive products to keep your business on track.

Have a rush order or a hard-to-find part? No problem! We can handle that too. Contact us today to kick your company into high gear with high-quality, high-performance parts!

 

Scan-Pac Friction Products: What You Should Know

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With a variety of friction product manufacturers on the market, it can be tough to find out how to get the best materials at the best cost.

The quality of friction material in your equipment has a huge impact on safety, stability, and longevity.

Below is a quick overview of what you should know about Scan-Pac, an excellent friction products manufacturer.

1. History

The company was founded in 1973 in Menomonee Falls, Wisconsin. Scan Pac was the original fabricator of Johns Manville calendared friction materials.

During its 44 years in business, the company has gone through multiple expansions in its facilities and product line.

2. Expansive American Manufacturing

Scan-Pac’s three manufacturing facilities, located in Menomonee Falls, Wisconsin and Magnolia, Texas, make up a combined 100,000 square feet of manufacturing space.

The company uses the following equipment in its manufacturing labs:

  • CMM
  • Chase Machine
  • Universal Testing Machine
  • Impact Tester
  • Gogan Hardness Tester
  • Rockwell Hardness Tester
  • Soxhlet Apparatus
  • Furnace
  • Specific Gravity Analyzer
  • Particle Size Analyzer
  • Moisture Analyzer
  • Melting Point Analyzer
  • Viscometer
  • Cure Time & Gel Time Tester

Each manufacturing plant specializes in the production of certain materials, ensuring the efficient production time and expertise among staff.

3. Serving Various Industries

Scan-Pac provides a large number of industries with friction materials.

These markets include:

  • Agricultural
  • Oilfield
  • PT Equipment
  • Cranes
  • Material Handling
  • Paper Production
  • Railroad and Rail Parts
  • Wind Power
  • Construction
  • Winches
  • Metal and Aluminium

Each of these markets has unique needs, and with a certification of quality management excellence, the company has a great reputation with satisfied customers around the globe.

4. Diverse Product Line

On the products page of Scan Pac’s website, there is an expansive list of materials produced by the company.

From Gatke materials to flexible products and Gemini woven, molded, or extruded materials, the materials produced will fit the needs of many projects.

There are even dedicated pages set aside for oilfield related materials, truck blocks, and sintered products.

5. Worldwide Distribution

Wherever you’re located, these products will likely be available.

The company has over 20 distributors worldwide, with 19 in North America alone!

6. Scan-Pac Helps You Pick The Right Materials

One of the most popular features on the company’s website is the material recommendations tool.

By browsing to this tool, you can select from a variety of categories such as caliper brakes, wear products, band brakes, and more.

From there, Scan Pac allows you to select from a list of uses from elevator brakes to oilfield products and windmills.

When you choose the equipment you need parts for; you’ll then be presented with a recommendation of one or more materials complete with part number, the coefficient of friction, and wear rate.

This tool is extremely helpful as it allows you to quickly find the exact part you’ll need and to contact a distributor with all necessary information!

Some of the Best Organic Friction Products!

As you can now see, Scan-Pac is a company that has a history of excellence offering a robust product line.

If you need assistance sourcing friction products, we can help!

Check out the industries we serve and let us know more about your specific needs.

Demag Cranes: Why The Investment is Worth It

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When it comes to buying a new crane, you understandably want top quality.

The loads these systems are expected to bear can be significant, and investing in an inferior piece of equipment could mean slower — and riskier — operations.

To that end, Demag cranes are heralded worldwide for their craftsmanship, dependability, and durability. Whether you’re looking for a universal or specialized crane solution, you can’t go wrong by selecting this brand.

Today, we’re breaking down a few reason why this brand is tops, and why the industry agrees.

Ready to learn more? Let’s go!

1. There’s a Demag Crane to Fit Every Need

Their impressive product portfolio isn’t just limited to a handful of crane designs. Rather, you’ll have your pick from single-grinder overhead traveling cranes, double-grinders, suspension cranes, wall-mounted options and much more.

After browsing the wares, if you still aren’t seeing the exact tool you need, the company’s more than willing to help you customize a crane to fit your requirements and processes.

This means you’re not stuck improvising with an ill-fitted tool. Instead, you’re sure to get a valuable piece of equipment that can transform the way your company works.

2. You’re Investing in More Than Equipment

Sure, you can go out and buy a crane and use it within your facility. There’s no guarantee it will work in your environment or facilitate your workflow. Moreover, there’s also a major safety risk to installing or using it without proper support or training.

When you buy a Demag crane, you’re also receiving top-of-the-line end-to-end professional support. You will have access to a team of specialized experts who can walk you through every step to make sure you and your employees understand the total solution.

From initial design and preplanning to installation and maintenance, the staff takes the guesswork and the risk out of any DIY endeavor you’re considering. There’s also a spare parts inventory and on-call, around-the-clock customer service. That way, if your crane breaks down in the middle of the night, you could be back up and running before the sun comes up.

3. It’s a Forward-Facing Brand

Are you working with a worn and outdated crane? Simply replacing it with another one might not be in your budget at the moment. If this is the case, Demag offers refurbishment and modernization services that can help you update and outfit your existing crane to handle current and future load requirements.

In addition, the brand is consistently delivering new and innovative product launches that take its product line to a different level. If you’re looking for a crane solution that’s capable of supporting you well into the future, you can’t beat this brand.

We’ll Help You Invest in a New Crane Today

As an authorized Demag dealer, we know the brand inside and outside. We’re qualified to consult you on the best crane for your business needs and can help you narrow your selection down based on price point, usage requirement, size standards, and more.

Contact us. We’ll help you take this important first step toward securing the crane of your dreams.

Overhead Crane Maintenance Checklist

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About 72 fatal crane accidents happen each year.

It’s no secret that working with big machinery can be dangerous. That’s why safety is always a priority.

Preventive methods should be taken to ensure safety while using an overhead. Here’s an overhead crane maintenance checklist to follow.

When To Perform Overhead Crane Maintenance

While designated personnel should perform required maintenance and repairs, the crane operator should conduct daily inspections before and after each use.

According to OSHA, a safety check should be done at the beginning of each shift.

A well-trained and qualified crane operator should ensure all equipment is ready for use.

A daily inspection chart should be signed off each day by the operator to ensure the safety inspection is complete.

What The Checklist Includes

An overhead crane maintenance checklist includes three different checkouts:

1. Area Check

This check is to ensure the area around the crane is clear. Some of these activities include:

  • Know the location of the crane disconnect switch.
  • Make sure there are no warning signs present
  • Check to make sure workers are not working near the area
  • Look ahead to verify there is nothing around the area where the load will be moved.
  • Check to make sure the below-the-hook devices are designed for the crane in use and will safely be able to lift the load.
  • Make sure that the load capacity is equal to or less than the capacity of the crane.

2. Preliminary Check

Once the area check has been performed, the operator can begin the preliminary check of the equipment. This should be done before he or she touches any controls.

  • Check the electric systems, bridge, runway, trolley, and hoist to make sure there are no loose, broken, or damaged parts.
  • Make sure the wire rope is seated in the drums grooves properly.
  • Ensure that the open power source is secure and there is nothing close.
  • Check the strain reliefs or brushings to make sure that no wires are pulled.
  • Make sure there is no damage to the pushbutton pendant.

3. Equipment Safety Check

After the preliminary check is complete, the crane operator must perform a safety check of the crane itself to make sure it is in working order. This is to ensure there is no potential for malfunction.

Several different categories need to be signed off when checking the equipment.

  • Check all powered systems. Including, making sure the power button is not sticky, the hoist hook rises, and the upper limit switch is functioning properly.
  • Make sure all hooks are in working condition. There should be no more than 10% wear on any part of the hook.
  • Ensure there is no damage or cracks on the bottom block assembly. The sheaves should be able to rotate freely and smoothly.
  • Make sure there are no broken wires on the wire rope and load chain. There should be no kinks, cuts, or thermal damage to any ropes or chains.

Safety Comes First

Taking the time to make sure the crane is in safe operating status will prevent accidents on the job site.

Remember, this is not a comprehensive safety checklist. For any questions or needs, you may have, feel free to contact us.

We’re here to make sure any project you have will be successful.

AC and DC Motors: What You Need to Know

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Do you know the difference between AC and DC motors?

If you’re shopping for motors, it’s helpful to know how each one works so you can decide what’s best to meet your needs. That’s why we’ve put together this essential guide to help you learn the difference between AC and DC.

Read on to find out what you need to know!

AC and DC Motors: A Short Guide

Most motors are either direct-current (DC) or alternating-current (AC). Let’s take a look at the basic difference between the two types of motors.

The essential difference between the two motors is right there in the name. AC motors use an alternating current to change electrical energy into mechanical energy. DC motors use direct current to achieve the same goal.

However, there are more detailed differences in the way each type of machine operates depending on its power source. Let’s take a closer look at what those are.

DC Motors: The Details

DC motors usually use a system of carbon brushes plus a commutation ring to change the current’s direction using a rotating armature. Fixed magnets inside the motor interact with an internal rotor to get the motor to turn.

Because of the carbon brushes, DC motors tend to have more limited lifespans. Most can last for about 1,000 to 1,500 hours, but if under a heavy load they may last for as little as 100 hours or less.

In ideal conditions, DC motors can operate much longer, though. These motors are very efficient, and lose efficiency only in a few specific areas. The winding and friction of the brushes are two places where these motors lose efficiency.

AC Motors: The Details

The AC induction motor, a common type of AC motor, uses a system of coils that get their power from the AC input voltage. This input voltage creates a stator field, which in turn induces the rotor field.

Another kind of AC motor, the synchronous motor, works using precision supply frequency. This kind of motor uses a current from either permanent magnets or slip rings to create a magnetic field.

AC synchronous motors are faster than AC induction motors because the induction motor’s speed is slowed down by the lack of synchronization.

AC motors are designed to operate according to a performance curve that aligns with the motor’s greatest efficiency. If the motor operates at a different point on the performance curve, efficiency will be lost.

Because AC motors need to use extra energy to create a magnetic field, they operate less efficiently than DC motors.

AC and DC Motors: What’s Best for You?

Both of these motor types operate differently and have a different performance. Depending on the task at hand, one kind of motor may be right for the job.

When you need to have external control of the motor speed, DC motors are usually best. However, AC motors are ideal when you want a strong performance for a longer period.

You should also consider wear and tear, and the cost of replacement parts. An electric DC motor will usually have more moving parts that are more costly to replace. For cheaper repairs, you’ll want an AC electric motor.

Need to buy the perfect motor for the job? We’ve got what you need! Check out our selection here.

The Top 5 Best Brake Pads Qualities

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Brake malfunction can cause serious damage to your personnel, equipment, and facility, possibly including the injury or death of personnel.

For example, Toyota recommends replacement of forklift brake shoes every 5000- 7000 hours. Cranes have hour maximums and brake lining thickness minimums. Elevators do too.

The most important safety feature on any piece of industrial equipment is the ability to stop.

If you are in the market for the new brake pads, we have the definitive list of the five qualities to look for in the best brake pads for industrial machinery. Keep reading to learn more.

What Do You Need to Stop?

Not all applications are the same.

Typically an elevator is equipped with a negative electromagnetic brake.

A 50 to 60-ton rough terrain crane is designed for operation on compacted earth as well as in narrow spaces. It uses a double caliper brake system, with two disc brakes per wheel.

Disc brakes slow, hold, and stop high kinetic energy (very fast-moving or heavy) loads, absorbing kinetic energy very quickly, if necessary. They are suited to applications that require high speed or high energy stops, high torque or high tension control. They absorb the energy generated by braking, then release it as heat.

Disc brake pads should be inspected for wear and replaced regularly.

Your unique combination of needs can only be met by specific brake pads. With a broad range of brake pad manufacturers available, finding the best brake pads for your use starts with determining the solution you need.

What Kind of Machinery Needs Brake Pads?

A broad range of heavy-duty industrial machinery might need brake pads. Some examples to consider:

  • Bottling Machinery
  • Conveyor Systems
  • Cranes
  • Elevators
  • Forklifts
  • Marine Winches
  • Packaging Machinery
  • Paper Handling
  • Printing Presses
  • Roller Coasters
  • Wire Tensioning
  • Wind Energy

You may have hydraulic brakes, electromagnetic brakes, spring applied brakes, active pneumatic brakes, or dual function brakes for multiple purposes. The right pad is available!

Which Brake Pad is Right for Your Application?

Several different styles of brake pads are available to fit different requirements. Each model offers different standard features and configuration options.

Consider your operating conditions:

  • Indoors or outside, ambient temperature, mounting orientation, and any hostile environments such as exposure to salt water, excessive humidity, or contaminants
  • Required stop time, in seconds
  • Number of stops per minute, hour, or day
  • Maximum allowable disc diameter and thickness
  • The amount of energy/heat generated

Based on your operating conditions, the five criteria for best brake pads used for industrial machinery are:

  1. Materials- choose from semi-metallic, rigid molded, or sintered friction pads for resistance to heat
  2. Maintenance- choose pads with thorough testing and quality assurance
  3. Performance- look for the most reliable and well-tested pads for your application
  4. Friction- for high heat dissipation select cutting-edge technology sintered pads
  5. Long Life- OEM or reverse engineered replacement, look at the replacement and ongoing maintenance costs

Detailed specs for all products and manufacturers we recommend are available on our website, and we’re only a quick contact away if you have questions or need recommendations for the five best brake pads specifically for your application.

Brake Pad Replacement: How Often it Needs to Be Done

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Brake pads on a machine can be made from a variety of materials including metallic, semi-metallic, or synthetic composites. They perform the integral function of slowing down and stopping a machine from being compressed against a vehicle’s rotors.

But every time you press your brakes, that friction causes wear that brings you one step closer to needing a brake pad replacement.

Knowing when to replace your brake pads is essential to the safety of your machine for you and other people on your work site. Your worn pads could keep you from making a firm stop if there’s a malfunction. The extra fractions of a second because of weak pads could cause a fatal accident.

If you’re not a machining expert or have never replaced your brakes before, not to worry here are four indications that it’s time for a brake pad replacement.

1. Squeaky Brakes

If you hear squeaking brakes, it’s likely not a bug; it’s more of a feature. Sometimes industrial brakes are built with a small metal indicator that makes a noise when the brake material loses some thickness.

If you hear it every time you brake, your brake pads might need a brake pad replacement.

Be aware that weather or climate can just as easily affect your brakes. Wet or humid conditions or a layer of dust build-up could make this sound as well. After the weather clears, if the noise goes away, you’ve just worn off the thin layer of dirt or rust that was created by the weather. Otherwise, bring it to a specialist.

2. You Don’t Know When They Were Last Changed

If you recently inherited a piece of machinery or don’t have maintenance records for a piece of machinery, take a look at the brakes. Every machine has different indicators of wear and tear, so get to know what to expect.

Often, pieces of equipment like wind turbines change hands over the years. Get to know what to expect from their brake pads, so you know when to start changing them.

3. Metal Grinding

If things get really bad or if your brake pads suddenly fall off, the piece behind the pads will start making direct contact with your rotor. You will hear a metallic grinding noise to correspond to this issue.

Have it looked at ASAP because this grinding could cause severe and expensive damage to your machine.

4. Replacement Indicators

If you’ve got a newer machine, it might be able to tell you when your brake pads are wearing down. Double check with a manual online or in your main office to see what the light means.

Know When It’s Time For a Brake Pad Replacement

Your brake pads should last for a number of years, depending on how much wear and tear you put on your machine. But even if they haven’t worn out, they could become dry and cracked.

They’re one of the cheaper components on any machine. If you feel it’s time for replacement brakes contact us.

3 Benefits That Come with a High-Quality Torque Limiter

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A recent torque limiter report stated the importance of higher-quality torque limiters. “Where operator safety is the primary concern, higher standards are vital, and experienced suppliers’ sound advice is recommended.”

Yes, there is a cost to putting the best limiter (also called an overload clutch) into your systems. But, the benefits outweigh the initial cost.

Critical Nature of a Torque Limiter

Any time torque transmits from one machine component to another, there’s a chance a jam could happen. A jam can prevent the rotation of a drive component.

When working with high-torque, heavy-duty equipment, everyone’s goal should be same. Balance efficient production with protection of both human and machine. Even momentary overload can cause injury to people and damage equipment beyond repair.

A torque limiter is a mechanical protection. It’s a device that engages in the event of an overload, and the load separates from the drive. The limiters that have rotating balls or rollers you can augment with a limit switch. The switch can override the motor drive system and activate an emergency stop.

Keeps Overload in Check for Heavy Equipment

A precise torque limiter keeps overload in check when it comes to high horsepower drives.

High horsepower drives mean larger gearboxes and motors. As the size increases, the power density can become disproportionate between driveling components.

The overload clutch needs to remain compact but also be robust enough to handle the larger load.

This component is small but essential. It is often out-sized as drive requirements extend into the thousands of horsepower.

The majority of torque overload release devices have low release values. These values are often too low for heavy equipment.

Heavy equipment requires torque levels beyond 10 KN. Such machines include gas turbines and industrial crushers. It also includes oversized recycling equipment and windmill test stands.

Extends the Life of Your Drive System

When a drive system overloads, a quality limiter immediately disengages the drive system. This protects the machinery. The system resets, and operation resumes.

This protection extends the life of the entire drive system. It also reduces downtime caused by equipment damage and the resulting repair time.

Greater Accuracy of Torque Limitation

A quality overload clutch means more precise torque limitation and increased up time. Inaccurate torque limitation can mean unplanned downtime.

A target accuracy range for limiters is +/-5 percent. Lower quality limiters range from about +/-15-20 percent accuracy.

Longer Life Even at High Speeds

You may pay a higher price for a better limiter. But, the investment will pay for itself later. For example, torque limiters like the Autogard Series 400 have a reverse-to-reset design. There are two sets of balls on concentric pitch circles.

The Autogard and similar models provide a longer life than lesser quality limiters. This makes it practical for high-speed applications while keeping the automatic resetting feature.

Contact Us for a Quote

We carry several brands and versions of torque limiters. And we have experience in all types of heavy equipment.

If you have questions about a limiter, please contact us for a consultation. We can find the model best fits your needs.

How to Find the Best VFD Drive Repair Service

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It’s an old cliche, but it holds true: Time is money.

For every workday your equipment is down, your company loses valuable production time.

Industrial motors use approximately 25% of the electrical energy around the world. Many of these motors run better when using a Variable Frequency Drive (VFD).

A VFD drive is a motor controller that varies the frequency and voltage of an electric motor. Due to the wide use of VFDs, VFD repair is a specialized skill.

VFD drives vary in components and configuration. Thus, repair technicians must be able to apply expertise and safety precautions specific to the type of VFD they are working with.

Here are some tips for finding the best VFD drive repair service.

VFD Drive Preventive Maintenance

We need to make one brief note about prevention before we go any further.

You can prevent most repairs with routine maintenance on your VFD. Technicians should perform preventive maintenance on a periodic schedule. For some units, once a year is effective.

The cost of the repair itself is expensive. Coupling that with the downtime you incur can be a hit to your efficiency percentages.

Whenever possible, some manufacturers keep backup VFDs on hand to keep production going during the repair period.

Read the Reviews

Look up several repair providers. Spend some time on their website. Read testimonials from past customers.

But don’t stop there. Search the web for other customer reviews. Word of mouth still holds a lot of weight, so ask your business associates who they would recommend.

Look for Experience

An established repair company will be sure to state their strengths on their website and marketing materials.

You want a company with years of experience. And you want experienced technicians to come out and do the job right the first time.

VFD service technicians should be able to troubleshoot a wide range of issues, from standard repair to advanced robotics. Techs should be able to find the cause of failure and present solutions right away.

Ask Questions

Once you’re ready to contact a service provider, prepare some questions. While cost is a practical concern, it should not be your only one.

What is their availability? Are they interested in hearing the results of the diagnostics your in-house technicians ran? Are they familiar with your particular VFD unit?

The VFD repair company should be able to service both AC and DC VDFs. Those repairs should include a full warranty on new installations as well as repaired units.

The company should service all major brands including Magnetek, Avtron, Vacon, Yaskawa, Siemens, and Allen-Bradley. Their service experience should also include some older and obsolete models.

Find Your Repair Service Today

Inevitably, any VFD is going to need repair, even those with impeccable maintenance logs attached to them.

When that happens, take these extra steps to help you find the right repair company for the job.

If you’re looking for full-service VFD repair, please contact us. We’ll get your unit back in service quickly and at optimal efficiency.