Industrial brake systems are critical components of machinery and equipment used in various industries, including manufacturing, construction, mining, and transportation. These systems are responsible for safely controlling the movement and stopping of heavy equipment and machinery, making their proper function essential for workplace safety and productivity. Recognizing signs of potential problems with industrial brake systems is crucial for preventing accidents, minimizing downtime, and ensuring the safety of workers. Here are three common signs of an industrial brake system problem to watch out for:

1. Unusual Noise or Vibration

One of the most common signs of a brake system problem is the presence of unusual noises or vibrations during braking. If you notice grinding, squealing, or screeching noises when applying the brakes, it could indicate worn brake pads, damaged brake rotors, or misaligned brake components. Similarly, excessive vibration or pulsation felt through the brake pedal or steering wheel may indicate issues with brake discs, calipers, or hydraulic components. Ignoring these warning signs can lead to further damage to the brake system and compromised braking performance, increasing the risk of accidents and injuries.

2. Decreased Braking Performance

Another telltale sign of a brake system problem is a noticeable decrease in performance or effectiveness. If you experience longer stopping distances, delayed response times, or reduced braking power when applying the brakes, it could indicate issues such as worn brake pads, contaminated brake fluid, air in the brake lines, or hydraulic leaks. Inadequate braking performance poses a significant safety risk, especially in industrial settings with heavy equipment and machinery. It’s essential to address any issues affecting braking performance promptly to prevent accidents and ensure the safety of workers and equipment.

3. Fluid Leaks or Loss of Brake Fluid

Fluid leaks clearly indicate a brake system problem that requires immediate attention. Check for signs of brake fluid leaks around brake calipers, wheel cylinders, brake lines, and master cylinder reservoirs. Brake fluid leaks can result from damaged seals, corroded brake lines, or worn components, compromising the integrity of the brake system and leading to brake failure if left unaddressed. Additionally, a sudden loss of brake fluid or a significant decrease in the brake fluid level in the master cylinder reservoir may indicate a leak or another issue that needs to be investigated and repaired promptly.

If you observe any signs of an industrial brake system problem, it’s essential to address the issue promptly to prevent accidents, injuries, and equipment damage. Conduct regular inspections and maintenance of industrial brake systems to identify potential problems early and ensure their safe and reliable operation. Follow manufacturer recommendations for brake system maintenance, including brake pad replacement, brake fluid flushes, and component inspections, to prolong the lifespan of the brake system and maintain optimal performance. Prioritize workplace safety by training equipment operators and implementing safety protocols and procedures for brake system maintenance and operation.

How to Identify an Industrial Brake System Problem

A brake system problem, whether industrial or not, can lead to severe issues.

You can learn more by reading our blog. If you need an industrial parts supplier, we at Kor-Pak can help. We supply parts for several different industries, so check us out and see if we can help you.

Mining is one of the most dangerous yet relied-upon industries, so all equipment must be safe and reliable. The braking systems, especially, must be in top condition to ensure safety and reliability.

Properly working coal mining equipment is required for a smooth delivery when running in the mines. They also need to work despite challenges such as power outages.

Industrial braking systems control machinery and equipment that hauls and hoists materials. In this guide, learn about the type of brakes used in the mining industry.

Dynamic Wheel Brakes

Dynamic wheel brakes harness the kinetic energy generated by wheel rotation to produce electricity. This electricity is then used to decelerate and stop the car.

These types of brakes have a better response time and are more resistant to wear and tear. Their use of self-generated electricity also makes them an efficient way to control railcars.

Wheel Gripper

As the name suggests, this type of brake system grips the tracks. This braking system holds the rail car in place.

These brakes are mounted on the rails either inside or outside. They’re held by springs or pressure, meaning they can maintain their position even during a power failure.

Tripper Rail Clamps

Use tripper rail clamps for mining equipment that must be locked in place. These types of industrial brakes are spring-set and are released hydraulically. When power is removed, the brakes grip the rail to stop the railcar.

Tripper rail clamps are a good option for emergency stops and lockdowns. However, they’re most often used for holding positions.

Drum Brake

Drum brakes are a type of dynamic brake. These types of brakes are more cost-efficient, as well as, requiring less space. The compact brake system is ideal in tight or small mining environments.

These brakes work by a drum pushing against the wheel. This will lead to a safe and gradual stop. 

Disc Brakes

Another dynamic brake system, disc brakes, is one of the top choices for braking systems. However, they require more space than their counterparts.

A metal disc is installed on the front wheels. When the brakes are applied, a pad presses against the disc and slows down the equipment. These types of brakes work well with high-torque equipment.

Hydraulic Brakes

Hydraulic brakes are another type commonly used for coal mining equipment. These brakes are spring-loaded and work by adding pressure against the drum, which slows the equipment down.

This system allows hydraulic brakes to have adjustable torque. These types of brakes are also long-lasting, even under challenging environments.

Brakes Are Essential Coal Mining Equipment

Many facets of life rely on the coal mining industry. That means that coal mining equipment must be dependable and secure. Brakes are one piece of equipment that has to be in proper working order.

Understanding the different types of brakes and when they’re needed will ensure the coal mining operation runs smoothly. It will also help with the maintenance of your equipment.

Kor-Pak is a leader in the industry for providing quality industrial equipment. Request a free quote for parts and service today!

In the world of heavy machinery, reliable braking keeps things moving safely. At the heart of industrial braking systems lies the brake lining.

This is a critical component that deserves a closer look. Business owners should understand the landscape of friction materials. You can make better purchasing decisions if you know about the brake clamp, brake pad, and brake rotor.

It’s imperative to focus on the material for the brake lining that powers industrial machines. That includes everything from wind turbines and ski lifts to steel mills. Here are five materials for safe industrial operations:

1. Asbestos-Free Organic Friction Material

Think of this material as an eco-friendly option. It skips asbestos and instead uses aramid and glass fibers with synthetic resins. Great for elevators and escalators, it keeps things quiet and engages smoothly.

Additionally, it has excellent thermal energy dissipation and stability. This makes it a reliable choice. The material ensures optimal performance in different conditions.

2. Sintered Metallic Friction Material

If your machinery deals with high heat and heavy loads, sintered metallic is the go-to. Made from metal powders, it’s a tough player, efficiently handling extreme brake rotor conditions.

Its robust nature ensures a prolonged service life. This makes it a preferred choice for industries that demand durability and resilience in brake pad materials.

3. Carbon Composite Friction Material

Carbon composite friction material is a top choice in the industrial brake world. Blending carbon fibers and graphite, they stand up to high temperatures and heavy use.

Trains use them, as they can handle the frequent and intense braking. Their durability and resistance give them longevity and reliability. 

This brake material is an excellent choice for those who want to avoid buying brakes every few years. The material lasts, so business owners don’t have to make repeat purchases. 

4. Woven Metallic Friction Material

Woven metallic friction material has the strength of metal wires combined with heat-resistant binders. It’s the balanced choice for brake pad materials, seen in conveyors and moveable bridges. 

The woven pattern ensures even wear, keeping maintenance low. This material allows for seamless engagement and disengagement of the braking system. This makes it a reliable option for various industrial applications.

5. Ceramic Friction Material

Ceramic friction materials can handle extreme temperatures. Used in amusement park rides and ski lifts, they excel in high-performance situations.

The ceramic fibers and fillers keep wear rates low. This ensures a smooth and reliable operation. They also can resist fading. Ceramic friction material continues to look new for a long time after it’s purchased.

This makes them indispensable in applications where precision and consistent braking are non-negotiable. 

Material for Brake Lining

Choosing the material for brake lining is vital. Each type caters to specific needs, ensuring optimal performance in various applications.

As technology evolves, so does innovation in friction materials. This innovation contributes to the efficiency and safety of industrial brake systems.

Kor-Pak has the experience to keep businesses moving. Our professional team has been helping business owners for years, with hundreds of satisfied customers. Click here to learn more about the selection of Kor-Pak brake materials.

Electromagnetism is a fascinating scientific principle. It describes a two-way link between electricity and magnetic fields, which changes to create a voltage. This bond has several industrial applications, including braking equipment and heavy machinery.

Read on to learn why magnetic brakes are ideal brake options for commercial use.

1. There Are Multiple Options for Magnetic Brakes

Magnetic brakes slow and stop the movement of machinery using electromagnetic principles. The induction of an electromagnetic field stops the machine without any physical contact with other parts.

Nothing touches the wheels, but the eddy current produced within the metal creates a magnetic field that opposes the initial external one. They repel each other like magnets might, creating a braking force that stops the metallic wheel from moving.

There are two options for these brakes. Passive magnetic brakes have permanently attached magnets that create the necessary magnetic force. They’re used in machines that move at a reasonably consistent speed because they always use the same braking force.

Active magnetic brakes are another option. They use electromagnets to create the field when necessary, and the strength is adjustable. All the operator needs to do is change the current strength, and this high-level control makes active brakes ideal for most industrial machines.

The bottom line is that magnetic brake users have multiple options. The core benefit is that something will always be perfectly tailored to the operator’s needs. You can find an efficient, effective, and economical way to stop equipment motion.

2. Fewer Parts

There’s no need for a brake pad or disc because nothing touches the wheel or brake when one uses magnetic industrial brakes. These parts wear out over time, so not requiring them means saving money on future replacements.

Lower maintenance fees allow you to focus on the upkeep of other machine parts and increase its efficiency. This prolongs the lifespan of machinery parts.

Additionally, you don’t need to worry about periods of low-quality production. When brake pads and discs begin to wear out, machines take longer to stop. You may not immediately notice it, which results in an overuse of electricity and machines that stop slowly.

You don’t need to worry about this with eddy fields. They’re produced consistently.

3. No Sudden Stops

Magnetic brakes are incredibly reliable, but they also move smoothly. You can reliably control the braking force to ensure consistency and even. This means that machinery parts won’t make jerky or sudden stops that lead to unreliable braking.

You won’t need to worry about equipment stopping too fast and using too much power. You also won’t need to worry that the movement will damage whatever the equipment is producing. It is also ideal for machinery with a human operator driving it because the person won’t have to worry about whiplash or other injuries from jarring stops and lunging movements.

Upgrade Your Industrial Equipment Today

While there are several types of brakes, magnetic ones work well for many industrial machinery. Now that you know why you should use them whenever possible, it’s time to begin browsing products and selecting the appropriate options for your manufacturing and warehousing needs.

Contact Kor-Pak to request a quote and discuss the parts, products, and services we offer.

Unscheduled downtime wastes time and money. In the current competitive climate, you must give your business every possible advantage. Regular equipment maintenance helps prevent breakdowns and other incidents.

Brakes are an essential component to inspect. Mechanical disc brakes have a simple design. They’re an excellent industrial option when power for other brakes isn’t available.

Mechanical disc brakes are relatively low-maintenance. However, periodic inspections and repairs are still essential for safety and performance. Learn more about how to maintain mechanical disc brakes in industrial applications properly.

Check the Brake Positioning

Brakes that wear unevenly will have poor performance and a shorter life. Several common-sense steps will promote more even brake wear.

Machinery should be level. Loads should be as evenly distributed as possible. The size and weight of loads should fall within the tolerances of the equipment.

Verify the Air Gaps

The brake disc’s air gap on both sides is essential to the braking system. The gap should be the same on both sides of the disc.

Some industrial brakes have an automatic wear adjustment for the air gap. Checking the gap during routine brake maintenance is still a good idea.

Clean and Lubricate the Brake Linkage

Mechanical brakes use a cable or linkage system to transfer force to the calipers. Cleaning the linkage helps ensure the brakes are giving the best possible performance.

Debris or dirt on the linkage can reduce the brake torque. The brakes may not work correctly.

Lubricating the linkage after cleaning is also an essential part of brake services. Lubrication helps the brakes give their full clamping force.

Look at the Brake Pads

The brake lining is the part of the brake pad that comes into contact with the disc. It protects the brakes from rubbing metal on metal, which could cause significant damage.

Brake pads were traditionally made from asbestos. Asbestos poses serious health hazards, and its use is declining. Other friction materials are being developed.

These materials are increasingly practical and durable. Brake maintenance should include an inspection of the thickness of the lining. Brake pad lining that has become too thin will need replacement.

Watch for Wear on the Rotors

Brake rotors turn kinetic energy into heat. When the brake engages, the calipers squeeze the brake pads against the rotors. This creates friction, which slows and stops the equipment.

Rotors often wear out at the same time as the brake pads. Their lifespan depends on factors such as:

• Rotor quality
• Heat dissipation
• Type of brake pad
• Climate
• Operating conditions

Checking the rotors for wear during routine maintenance will help identify issues before they cause brake failure.

Maintaining Mechanical Disc Brakes

Mechanical disc brakes are an essential part of your operations. Regular maintenance will help ensure they perform reliably for as long as possible. You can identify potential issues before they cause unscheduled downtime.

If a maintenance inspection shows a problem, Kor-Pak has the replacement components you need. We’re a leading distributor of OEM and aftermarket products. Our experienced team will help you find a solution that optimizes your system performance at the most competitive price.

Request a quote from Kor-Pak today and take control of maintaining your brakes.

Investigate Sizes for Caliper Disc Brakes

Caliper disc brakes come in a wide range of sizes. The first consideration when selecting brakes will be the size of your machinery. You need something that fits seamlessly into the body of the equipment on which you plan to install the brake.

It’s also important to note that brake disc sizing impacts the power of said brakes. Most machinery will have the potential for multiple brake sizes.

Small disc diameters are ideal for those who want to stop motion over a longer period gradually. They have a smaller surface area and fewer calipers squeezing onto the brake pad rotors. In some cases, people may use them to supplement larger-diameter brakes.

A larger disc diameter means more grip. They generate more friction, but it’s distributed over a bigger surface area to prevent overheating. Plus, big brakes generate more torque, so motion stops quickly on very heavy machinery.

Choose Quality Brake Material

Applying brakes on industrial machinery generates a lot of friction. The friction causes the machinery to slow and stop. Friction naturally generates heat, so stopping industrial machinery with caliper disc brakes generates much heat.

It’s critical to choose brakes with a high thermal tolerance. Cast iron is one of the best disc brake materials on the market because of its conductivity. It also is extraordinarily durable and can withstand frequent friction with little corrosion.

Understand Floating vs. Fixed Calipers

There are two general kinds of caliper disc brakes: floating and fixed.

Floating brakes are movable, while the caliper/piston is moveable. There only is a piston on one side of the brake, and it moves forward to create friction against the brake. Floating brakes are structurally simple, easy to disassemble and move, portable, and lightweight.

Fixed brakes are stationary and have caliper pistons on both sides of them. Pressing the brake does not move the caliper. Instead, the opposite caliper pistons use hydraulic pressure to move forward and press against the brake disc from both sides.

The brake oil enters from the inlet of the caliper. It stops by acting on the stationary pistons.

Most brakes are floating because fixed brakes are large and clunky. The air circulation is low, and it’s challenging for them to cool down. Still, they do have some industrial applications, such as assembling very large products in bulk.

Get the Right Industrial Brakes

Now that you know some tips for selecting caliper disc brakes, it’s time to invest in high-quality industrial equipment. Our team is committed to providing you with top-of-the-line manufacturing products from trusted providers.

We offer various industrial braking equipment and accessories for diverse applications. Contact Kor-Pak to request a quote for your individual needs.

You need industrial brakes. Which type will be best suited for your application?

Do you need pneumatic, hydraulic, or electric actuation? Will disc or drum brakes be a better choice?

Hydraulic disc brakes offer an advantage in many situations. A hydraulic disc brake can handle applications that need higher torque. It distributes heat more evenly and is less likely to overheat.

Hydraulic disc brakes are less prone to brake fade compared to other types of brakes. They use fluid pressure instead of friction. The brake pads don’t wear as quickly.

Learn more about hydraulic disc brakes, their advantages, and their common industrial uses.

Dynamic Braking

The most apparent use for industrial brakes is to bring a moving part to a complete stop. This is known as dynamic or active braking.

Many types of industrial vehicles can use hydraulic disc brakes for this purpose. Construction equipment and agricultural machinery are some examples. Wind turbines are another application for hydraulic brakes.

Holding

Hydraulic disc brakes can stop and hold industrial machinery parts during an action. Holding brakes are common on rotating equipment, like winches and cable wheels. Holding brakes have many applications, such as:

• Factory automation
• Medical equipment
• Elevators and escalators
• Construction equipment
• Robotics

Hydraulic brakes can stop the load before holding it, as well as simply holding it. They’re a good option for high-inertia loads. They give the operator more control, which makes them well-suited for high-load applications like amusement park rides.

Tensioning

Tensioning controls the speed of a moving part. It creates drag to control movement instead of stopping the movement altogether. The most common uses for tensioning brakes are web systems that handle rolls of material like tape, wire, or paper.

Electric friction brakes are a common choice for tensioning. They aren’t well-suited for high-torque applications, though. Hydraulic brakes are better when high torque, high speed, or wide tension strength are necessary.

Fail-Safe

Hydraulic spring-applied disc brakes are a good choice for emergency braking. They use hydraulic pressure to hold the brake open. If power is lost or the brake is turned off, the spring engages the brake.

Hydraulic brakes exert very high torque.

Disc brakes are capable of higher rubbing speeds than drum brakes. They can handle higher surface temperatures during an e-stop. They dissipate the heat generated by braking more efficiently.

Fail-safe brakes are a safety requirement for many types of industrial equipment, including:

• Mining and construction vehicles
• Rail cars
• Agricultural equipment
• Hoists and cranes
• Manufacturing equipment and conveyors

Hydraulic brakes can help you meet safety requirements and machinery directives.

Finding the Right Hydraulic Disc Brake

A hydraulic disc brake can serve many purposes. You can use it as a dynamic brake for holding or tensioning. Hydraulic brakes work well as fail-safe brakes.

Finding the right brakes for your application is essential for safety and performance.

Kor-Pak has a diverse catalog of industrial hydraulic disc brakes. We can also design custom brakes to meet your needs. We’ll help you find the right industrial machinery parts and keep them running efficiently.

Browse Kor-Pak’s selection of industrial disc brakes and reach out with any questions. We’re committed to exceeding your expectations with our parts and customer service.

The cost of unplanned downtime can be as high as $9,000 per minute.

Drum brakes are essential for the operations of businesses in many industries. The unexpected need for a drum brake replacement can cost significant time and money. You can minimize the damage by being prepared.

Learn more about drum brake replacement in heavy industry and how to get brakes back to optimal performance.

1. The Whole Brake Mechanism May Not Need Replacement

If you notice problems like unusual noise or vibration in your drum brakes, you may not need to replace the entire brake mechanism. Drum brakes include:

• Drum
• Backing plate
• Brake shoe
• Wheel cylinder
• Return springs
• Self-adjuster

Worn brake shoes can cause a range of noises, like squeaking, scraping, or grinding sounds. If you notice the problem soon enough, you can replace the brake shoes and prevent damage to other brake components.

A worn brake drum can cause vibrations when braking. A warped drum doesn’t make proper contact with the shoes. If other brake parts haven’t been compromised, you can replace the drum to fix the problem.

An inspection will show how many parts need replacement.

2. Choosing the Right Drum Brake Replacement Is Critical

Drum brakes come in many different types to match the application. Accidentally choosing the wrong type could result in catastrophic failure.

A drum brake must have enough braking torque. It must be a size and model that can dissipate the energy from braking without overheating. Other design factors include:

• Electro-hydraulic or magnetic actuator
• AC or DC power
• Shunt or series-wound coils
• AISE or DIN standards

In most cases, the drum brake replacement should be the same as the original brake. However, if you need a drum brake replacement due to unusual wear, the original brake may not have been the best for the application. An industrial brake specialist can help evaluate the best solution for different drum brake applications.

3. Quality Parts Are Worth the Cost

A drum brake replacement is not the place to cut costs. Drum brakes are essential for the safety of your operations. When a drum brake replacement is necessary, quality matters.

You can choose OEM or aftermarket brakes. Original OEM parts provide reliable quality. They’re usually more expensive, though.

Aftermarket drum brakes are typically more economical. You can find high-quality parts if you use the right manufacturer. In addition, aftermarket parts may help you meet the specific demands of your application.

Find the Best Industrial Drum Brakes and Parts for Every Application

Problems with your industrial drum brake can’t be ignored. Optimal brake performance is essential for your operations.

A detailed inspection will show whether a full drum brake replacement is necessary. High-quality parts from a reliable manufacturer will continue to meet your application’s demands.

Kor-Pak manufactures and supplies OEM and aftermarket parts. We specialize in industrial brakes. We can design a custom drum brake if our extensive catalog doesn’t have exactly what you need.

Contact Kor-Pak today for a quote or more information about our industrial drum brakes.

Equipment failure in industrial settings is the leading cause of accidents. Some of those failures were due to poorly manufactured industrial brakes. In such high-stakes environments, the quality of disc brake pads becomes paramount.

Poor quality or performance can result in problems or even serious accidents. That’s why choosing the proper manufacturer for disc brake pads is essential.

Keep reading to explore these critical considerations. The information will help professionals in the industrial machinery sector make better choices.

1. Industry Certifications: A Seal of Reliability

When sourcing disc brake pads for industrial use, certifications play a critical role. Labels like ISO 9001 are more than just industry jargon. They show a manufacturer’s dedication to quality.

These certifications come from rigorous testing and adherence to international standards. They assure that the product meets strict criteria for performance and safety.

In industrial settings, disc brake pads endure harsh conditions and heavy usage. A certified manufacturer guarantees that the pads can withstand these challenges. 

Certifications should be among the first criteria when selecting a manufacturer for industrial disc brakes. They offer confidence that the product will meet the specialized needs of industrial applications.

2. Customization Capabilities: One Size Doesn’t Fit All

Industrial applications for disc brake pads are diverse, covering everything from wind turbines to port cranes. Given this wide range of uses, the ability to customize is essential. A manufacturer that can tailor disc brake pads to specific needs is a valuable partner.

For instance, a brake pad suitable for a conveyor belt might not be fit for a high-speed train. A manufacturer with customization capabilities can adapt disc brake pads to various needs. It can enhance both safety and performance.

When assessing manufacturers, look for those that offer customization options. Whether it’s adjusting the material composition or the size and shape of the pads, these custom features make a big difference. A tailored disc brake pad will likely perform better and last longer in its specific setting.

3. Proven Track Record: Credibility Matters

A manufacturer’s history can speak volumes in an industry as critical as this. A proven track record isn’t just a bonus; it’s often a requirement when sourcing disc brake pads for industrial applications. After all, these components are part of systems where failure is not an option.

Manufacturers with years of experience have had the time to:

• Refine their products
• Correct issues
• Adapt to industry changes

This experience leads to more reliable disc brake pads that are suited for their intended purpose.

To assess a manufacturer’s credibility, consider looking at:

• Customer reviews
• Case studies
• Industry awards

These can give you an idea of the manufacturer’s standing in the market. It’s also wise to check if the company has a history of meeting delivery timelines and providing good customer service.

The Strategic Path to Sourcing High-Quality Disc Brake Pads

Ready to take the next step in securing high-quality disc brake pads? Kor-Pak offers a range of industrial braking solutions that meet stringent quality and performance criteria.

Don’t compromise; choose a partner that understands the intricate needs of industrial braking systems. Reach out today for more information.