Brake Clutch and Friction Systems Needed In Heavy Industry

Crane Brakes

Crane Brake

A typical braking system applies a (i.e. electromagnetic) force to apply friction, or mechanical resistance. This friction causes heat in its attempt to slow down and even stop a device in motion or to simply maintain it’s position without any motion.

Think of pressing your brake while driving your car. Your foot sends hydraulic brake fluid to a piston which in turn causes each brake pad to apply friction on your tires’ brake discs. The friction slows down each wheel and eventually stops your car.

Heavy Industry Brake, Clutch and Friction Systems

In heavy industry the brake, clutch and friction system is also used to slow and stop passenger or freight trains, wind turbines, cranes or hoists, etc. Even though there many types of brake system designs, their operation remains basically the same – to stop the movement.

When it comes to the selection of a heavy industrial brake, clutch and friction system it is imperative that one understands some key variables. These requisite and relevant variables are most critical to selecting the optimal product for your application.

I suggest there are three primary steps one should take in properly assessing an application.

  1. Recognizing and realizing the application and its fundamentals is the first step in the brake, clutch and friction selection process. To do so, you should identify the industry, application and specific parameters involved for the particular application. Is it a static or dynamic application? What is the operating environment like? (I.E. Is it hazardous?) What is the brake function and requirements? What is the system being used for?
  2. Now you must understand how to use this information and apply it to your specific application. In order to do this, one must fully understand exactly what these variables mean. You must comprehend such concepts as: static vs. dynamic; full motor and mechanical braking torque; friction coefficient as well as several others. These will be paramount when it comes to properly selecting a brake, clutch and friction material.
  3. Once you understand the variables and industry application specific aspects to your application it is time to apply these fundamentals and select your brake, clutch and friction material. You might consider collaborating with application engineers to perform a careful due diligence. This will ultimately lead to a better decision making process.

There are many brake and clutch manufacturers and many options to choose from. Our fast paced and price sensitive society has propelled business culture into often times rushing to decisions. This definitely has not necessarily helped industry as a whole.

At times the least expensive option is not the best alternative nor does the good old boy network work to your advantage. Take your time to investigate your alternatives.

This may help you make the best decision about a capital business expenditure. Ultimately in the long run it may prove to save your company a great deal of time and money.

Kor-Pak Corp. is an industrial brake and clutch specialist.  Learn more about how Kor-Pak can help you resource your industrial brake, clutch and friction parts.

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GKN Stromag Named A Key Player In Brakes Clutch Market

GKN Stromag LogoA February, 2016 report by Global Industry Analysts, Inc. (GIA) named GKN Stromag a key player in the industrial brakes and clutches market place. Amongst other highlights, the report forecasts a 40% growth in the global market for industrial automation equipment from 2013 to 2018. This in turn will likely set a very strong demand for industrial brakes and clutches.

Kor-Pak Corporation is a proud distributor of GKN Stromag brakes and clutches. GKN Stromag produces hydraulically, pneumatically, and electrical spring applied brakes. These are amongst the most highly developed and reliable components for modern and energy efficient drives and insure hoisting and driving safety.

GKN Stromag Brakes offer high degrees of protection, low maintenance as well as fast and simple high wear resistant brake lining replacements.

Learn more about GKN Stromag brakes, brake systems,brake calipers and more at GKN Stromag Brakes product page, or the Stromag Clutches page for clutchesm or contact us for a quote. And always, please remember: Your ‘Special Orders’ don’t upset us! We’re experts at finding solutions to your emergencies, unusual challenges and even odd-ball requests.

Other key takeways from the GIA report include a rising trend in industrial activity and the adoption of automation solutions. They also report an increasing popularity of electromagnetic caliper brakes and rugged brakes in hazardous environments.

The United States portion of the global market should approach one billion dollars by 2020. Future growth will be centered in Asia-Pacific, Latin America as well the Middle East and Africa

GIA publishes and sells market research materials on off the shelf market industries ranging from baby toiletries to nuclear power. Headquartered in San Jose, CA, the company was founded in 1987. Learn more details about and how to purchase a copy of the entire report on the GIA Website.

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Finding The Missing Link In The Heavy Industry OEM Process

Heavy Industry Construction Crane

Heavy Industry Construction Crane

An OEM (original equipment manufacturer) manufactures a large piece of equipment for you, the end user. This may be an overhead crane or a gantry crane, a conveyor, stacker/reclaimer or “any equipment used for (non-automotive) heavy industry.

The OEM sells this piece of equipment to an end user. These could be a steel mill, mine, food processing plant, airport, container port, or literally any type of manufacturing entity within an industrial application.

This piece of equipment must do its job regularly and reliably for the end to profit. For example, a steel mill needs an overhead crane to help move material and process in the manufacturing of steel. Without this crane, the process comes to a halt and the job can not be done due to downtime.

An efficiently operating crane is part of the life blood surging through the veins of a successful steel making plant. So it’s only natural for end user companies to want to ensure their equipment runs at optimal capacity ensuring maximum uptime. They also want to keep costs minimal to reduce operating expense and add to their profit margin.

Therefore you might ask: “Does the OEM provide parts and service for this equipment in the long run?”

Not the Core Competency of an OEM

The answer is simply yes. The OEM does provide parts and service. However, it is NOT their core competency.

There are several variables that come into play in this scenario which create the opportunity for a MRO distributor to enter into the scene.

OEMs primarily specialize in making the equipment. They are typically very expensive products that include multiple components such as electrical, mechanical, hydraulic, etc. Some of these OEM’s do not provide the individual components. They neither service nor repair them.

Retrofit and Modernize Good Heavy Industry Equipment

Furthermore, as the heavy industry’s capital equipment ages and depreciates, there comes a definite need to retrofit and/or modernize it. For instance, a crane might be 30-40 years old.

Although it is still fundamentally a good piece of equipment, technology has improved dramatically since it was first put into production throttling efficiency.

Their also might be issues trying to keep the crane in service. The original parts may be obsolete or the OEM no longer provides maintenance manuals or instructions.

At the other extreme replacing the crane is costly and time consuming. The capital investment for a new crane might be close to $2 million alone. Plus there’s the downtime of replacement.

MRO Companies Fill the OEM Void by:

  1. repairing or providing service to an existing piece of equipment at a more affordable price versus replacing it with new equipment.
  2. troubleshooting, providing replacement parts or even reverse engineering a new part (both the latter combined with educating the customer).
  3. analyzing the situation and modernizing the operation. Finding suitable replacements for existing parts and thus making the process more efficient while saving the end user time and money versus buying new.

That is precisely where Kor-Pak Corporation excels if and when you find yourself in one of these situations. Kor-Pak is a service company that fills the void. We can furnish parts no longer available in standard catalogs or provide assistance with technical solutions and problem solving.

If you are looking for solutions, not merely line-card parts (what we call commodities), Kor-Pak is available. We:

  • bring product expertise, project management and problem solving capabilities to the table.
  • will spend the time and invest the resources to solve your problem.
  • simply get the job done for you.

Call us today at (847) 680-0999 or toll-free (888) 2KORPAK (888-256-7725) and find out how easy it is to partner with Kor-Pak.

Container Crane Brake

Hoist Crane Brakes, Hoist Disc Brakes, Crane Hoist Braking Systems

Hoist Crane Brakes, Hoist Disc Brakes, Crane Hoist Braking Systems

Hoist Crane Brakes, Hoist Disc Brakes, Crane Hoist Braking Systems for cranes are imperative for the safety and performance of your crane application.  Whether it be a Ship-To-Shore Crane, Gantry Crane, Overhead Crane, or another crane type, Hoist

Hoist Brake Setup

Hoist Brake Setup

Brakes are vital components of the industrial ecosystem that should be taken seriously and be properly specified and maintain.

To insure best practices for Hoist Brakes for Crane Application, it’s good to get back to the basics.

Hoist Brakes consist of shoe or disc brakes on the high speed side of the motor which are typically Thruster Disc Brakes, Thruster Drum  Brakes, or Magnetic Drum Brakes.  On the low speed side, it is important to have a Emergency Disc Brake system to prevent a load from falling in the event of a low-speed failure, such as gearbox or coupling failure or shaft breaking.

Specifying Hoist Crane Brakes, Hoist Disc Brakes, Crane Hoist Braking Systems

Low-speed brakes for hoist crane brakes applications are specified according to full motor torque plus a service factor.  In the USA this is called out in AISE standards.  The low-speed brakes are either used as dynamic stopping or static holding brakes, depending on whether there is a VFD controlling the motor as a primary brake.  There are several variables that are involved when specifying these brakes such as:

  • Environmental Factors (i.e. ambient temperature, dust/grime, saltwater exposure, etc.)
  • Required torque
  • Friction coefficient
  • Duty Cycle
    Thruster Disc Brake

    Thruster Disc Brake

    Thruster Drum Brake

    Thruster Drum Brake

    Magnetic Drum Brakes

    Magnetic Drum Brakes

  • Controls Integration/PLC
  • Several more

Emergency Disc Brakes

For the low-speed brakes, the brake(s) typically interface with a disc that is mounted on a flange on the drum.  If this is not possible then the shaft can be extended or other alternatives are available.  The emergency brake system is typically a caliper brake that is magnetic, hydraulic, or pneumatically released.  An encoder can be mounted on the shaft that counts the pulses of the drum to measure the RPM and when a predetermined speed is reached, and “Overspeed Condition” is detected which triggers the E-Brakes to apply via a proportional controlled power unit so the brakes will not come to an “immediate stop” and the brakes will stop the load from falling without creating a “shock load.”

Magnetic Emergency Disc Brakes

Magnetic Emergency Brakes

Hoist Crane Brakes, Hoist Disc Brakes, Crane Hoist Braking Systems

Hoist Crane Brakes, Hoist Disc Brakes, Crane Hoist Braking Systems

More detailed information regarding Crane Brakes, and specifically hoist brakes for cranes and emergency crane brake can be found in this Technical Paper.  In this paper you will see that Europe has implemented strict standards on the requirement for emergency brakes for hot metal cranes and certain hoist applications, but this is still not a requirement in the USA.  There have been numerous reported incidents of low-speed failures which have resulted in catastrophic failures that are extremely costly and some have caused fatalities.  It is imperative that the USA adopts the same standards as Europe to create safer operating environments.  While there is a cost to Emergency Crane Brake Systems, the benefits unequivocally exceed the costs when it comes to equipment protection, downtime, and most importantly, human lives.

Hoist Crane Brake Experts

Kor-Pak Corporation provides complete turkey systems for crane hoist brake systems including brakes, controls, installation, engineering, commissioning, and after-sales support.  As subject matter experts, Kor-Pak will provide you with the quality, service, and engineering support you need to insure that your crane is operating as safely and efficiently as possible.  For more information please contact a Kor-Pak representative today.

Kor-Pak ISO Certified

Kor-Pak Corporation is ISO 9001:2008 Certified

Kor-Pak ISO CertifiedKor-Pak is proud to announce that they are now ISO 9001:2008 certified which is another step that will take Kor-Pak to the next level as they are seeking aggressive growth strategies.

Jesse Izaguirre, Operations and Quality manager was the key agent who spearheaded and accomplished this initiative.  According to Mr. Izaguirre, “It was a long and challenging process but I believe it was worth it in every respect.  Kor-Pak is determined to grow at a fast pace and my job is to insure that we can remain scalable and not compromise quality.  You often time see businesses grow and subsequently their level of service and/or quality goes down.  Since I worked at Kor-Pak, the tone at the top has always espoused the philosophy “put the customer first and we pride ourselves on first-class service.  So my job is to make sure that there is a positive correlation with revenue growth and quality control.”

To view Kor-Pak’s ISO Certificate, please click on this LINK.  For more information about Kor-Pak’s quality control processes or anything or a similar nature, feel free to contact Mr. Jesse Izaguirre at jesse.izaguirre@kor-pak.idatatools.com

Kor-Pak Featured in Hoist Magazine and Iron and Steel Technology

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Kor-Pak Featured in Hoist Magazine and Iron and Steel Technology

Kor-Pak’s technical papers about Industrial Braking Systems are proudly featured in this month’s edition FotoFlexer_Photoof Iron & Steel Technology (Affirmative Abrasion: Advancements and Innovations in Industrial Braking Systems) and Hoist Magazine  (Braking Bad: Avoiding Improper Brake Selection).  These papers were written with the help of several highly experienced professionals from varying backgrounds including brake manufacturers as well as end users and the paper’s objective is to provide the reader with an extensive overview and analysis of industrial brakes and the selection process, engineering, various types of brakes and how they relate to different applications, and highlights ways to boost safety and performance.  Additionally, this paper explains ways in which safety can be substantially enhanced through the use of emergency caliper disc brakes and storm/parking brakes whichds1 prevent a falling load or runaway crane from occurring.  Ultimately, the brake selection process is both an art and a science and requires a cohesive blend of hard data analysis as well as intangible expertise and understanding of application-specific variables that can materially impact braking performance as well as safety.

Kor-Pak always strives to be on the leading edge of innovation and safety and we hope that this paper will help end users, engineers, and any other stakeholders who may benefit from a greater understanding of brakes and how they function in the industrial world.   Contact a Kor-Pak representative today to receive a copy of the technical paper and for all other inquiries.

Demag Logo

Kor-Pak Corporation is an Authorized Demag Dealer

Kor-Pak Corporation is an Authorized Demag DealerDemag Logo

 

At Kor-Pak Corporation we are proud to announce that we are now an Authorized Dealer for Demag products.  Demag is an internationally recognized name brand and has a reputation for offering the highest quality lifting products in the marketplace.  Being that Kor-Pak is now a full-service crane provider, the Demag brand will complement it’s existing product and service portfolio and enable Kor-Pak to be a complete provider for cranes, hoists, and other Demag parts, as well as offering a complete service mix including inspections, load testing, training, modernizations, repairs, and engineering.  We invite you to contact a Kor-Pak representative today to learn more about the Demag brand and allow us to demonstrate it’s unparalleled excellence for Crane and Hoist applications

About Demag:Demag Crane

With its Material Handling business group Terex MHPS GmbH is one of the world’s leading suppliers of industrial cranes, crane components and services of the Demag brand.

We offer our customers a complete range of cranes, drives and handling equipment for every application – optimised by comprehensive sales and service support. These solutions provide our customers with valuable quality and efficiency benefits. In small workshops as well as in major industrial enterprises.

Our extensive product range includes a wide range of solutions for specific industries for travel applications, load handling at the workplace and material flow in production and storage. The Demag crane experts always focus on the benefits for our customers – the greatest possible efficiency and reliability, optimum availability and maximum performance.

Our customer approach has a long tradition that dates back over the long history of our company. It began in 1819 with the establishment of Mechanische Werkstätten Harkort & Co. in Wetter an der Ruhr. In 1840, we started manufacturing overhead travelling cranes, concentrating on the production of cranes and crane components at an early date, also including hoist units with an electric drive since 1910.

Pastillas de frenos para turbinas eólicas

Pastillas de frenos para turbinas eólicas

Kor-Pak se especializa en frenos industriales y materiales de fricción, y las aplicaciones en turbinas eólicas no son bsak_300_ds_original_300x336la excepción. Kor-Pak ofrece productos de OEM y posventa a las siguientes marcas:

  • Svendborg;
  • Twiflex;
  • Brembo;
  • Sime;
  • FTL;
  • Pintsch-Bubenzer;
  • Sibre;
  • Twiflex;
  • Dellner;
  • y muchas más.

En Kor-Pak hemos suministrado con éxito pastillas de frenos de alta calidad para turbinas éolicas a OEM, usuarios

Yaw Brakes

Kor-Pak suministra pastillas de frenos de guiñada

finales y distribuidores utilizando nuestros materiales de fricción de moldeado rígido, semimetálicos y sinterizados, y avanzamos con prosperidad en el diseño o la ingeniería inversa de pastillas de frenos a fin de brindar la máxima vida útil a precios competitivos.

Pastillas de frenos sinterizadas para turbinas eólicas

Las pastillas de fricción sinterizadas resultan ideales para las aplicaciones con altas temperaturas, ya que permiten una mayor disipación de calor.  Kor-Pak brinda conjuntos completos de pastillas de frenos sinterizadas para todo tipo de aplicaciones de frenado de turbinas eólicas, y lo abastecerá con productos de alta calidad a precios competitivos.

Asociación estratégica para aplicaciones de turbinas eólicas19742898_m

Kor-Pak hará todo lo necesario para satisfacer sus necesidades.  Ya sea para disponer un programa de abastecimiento, realizar pruebas de varios materiales, a fin de garantizar características de desgaste óptimas, o colaborar en proyectos de investigación y desarrollo, Kor-Pak se esforzará por brindar innovación y un servicio destacado de atención al cliente.

 

AIST Technical Paper About Emergency Brakes on Cranes

AIST Technical Paper About Emergency Brakes on Cranes

You can read the technical paper written by Chris Koralik by visiting this link: http://digital.library.aist.org/pages/PR-366-383.htm

The title of the paper is “Affirmative Abrasion: Advancements and Innovations in Industrial Braking Systems” and it was written with the help of several experts with varying backrounds and fields of expertise including application engineering and brake design.

Emergency Brakes for Cranes

One of the main highlights of this technical paper pertains to Emergency Disc Brakes used for EOT cranes.  These brakes are designed to prevent a load from falling which could potentially result from a transmission failure on the low-speed side of the crane, such as a gearbox failure or shaft breaking.  There have been catastrophic failures of this type in recent past at Port Terminals, Iron and Steel Producing Plants, and other industrial crane applications, and emergency disc brakes would have prevented these disasters from occurring.

AIST Crane Symposium Emergency Brake Presentation

Click HERE to view the PowerPoint of the presentation given at the 2014 AIST Crane Syposium.  This presentation evoked a great deal of thought and curiosity from the audience and there is no doubt that end users, application engineers, and brake designers will continue to explore options to retrofit cranes with e-brake packages and specify them in new crane designs as well.

Selecting Emergency Brake Package For Your Crane

In  order to select the optimal emergency brake package for your crane, it is imperative that you partner with a company that possesses an intimate knowledge of the application and can identify various packages to meet the industry and application-specific conventions to provide a system that will work.  Kor-Pak possesses the requsite expertise and experience to provide a robust and efficient emergency braking system for your crane.

Kor-Pak on the Cutting Edge

Kor-Pak is an industry-leader and has a forward-thinking approach that focuses on helping customers reach the next level and finding bettter solutions.