What is Sintered Friction Material?

In an industrial setting where heavy machinery is involved, the right type of brakes could save lives, prevent property losses, and allow your business to run more smoothly.

Whether you’re looking into manufacturing machinery or replacing parts on existing machinery, it’s essential to know about sintered friction material.

Keep reading to learn more about this type of brake, and it’s benefits and applications. As you’ll see, it’s a crucial part of several industries.

What are Sintered Friction Materials?

Sintered friction materials are created with a mixture of non-metallic and metallic powders.

Base

The base of sintered friction brakes typically consists of an iron or copper alloy. This is what the other materials are bonded to under pressure to create a strong brake that can withstand high heat.

Friction Agent

The other part of this braking material is the portion that provides friction. The materials used as friction agents vary depending on the application and offer a range of energy capacity, wear behavior, and costs.

Whatever materials are used, they are cold-compacted when in powder form between 12 and 18 psi. This bonds them to a steel backing along with any other wear-resistant agents and fillers the brakes may contain.

What Applications do Sintered Friction Materials Have?

Next, we’ll take a quick glance at some of the most common commercial applications for sintered friction materials.

Sintered brakes are also now standard on motorcycles and ATV’s.

Benefits of Sintered Friction Material

Now let’s jump into some of the benefits you can gain from using sintered friction material in brakes for industrial equipment and machinery. Knowing what they’re commonly used for, it’s easy to see why they’re used in those applications.

Stable Under Various Conditions

When using heavy machinery, it’s crucial to have a brake pad that’s stable under various temperatures. Braking materials that are unreliable under temperature changes can be dangerous.

For outdoor applications such as locomotives or wind turbines, it’s even more critical to have brakes that work in wet or dry conditions.

Handle High-Heat

The metallic properties of sintered friction materials allow it to withstand a much higher temperature than organic options.

Large pieces of machinery generate more heat when slowing down than smaller ones, which is why it’s essential to have materials that can handle the heat generated by friction.

No Warm-Up Time

Some types of brakes require some time to warm up before they start producing results. When you’re in a situation where you need to stop something large quickly, there’s no time for brakes to warm up.

This is the third significant benefit to sintered friction materials. They don’t require any time to warm up so you can expect them to act as soon as you need them to, making them safer and more effective.

Ready to Place an Order?

Now you know what sintered friction material is and how it’s used in a variety of industrial and other applications.

If your business needs a high-quality brake material that can withstand high temperatures, contact us today. We would love to provide you with a quote and help you get what you need to keep your business moving forward.

 

3 Reasons Why the Industrial Clutch is Essential

When working with massive industrial machines, even the smallest piece can be a vital part of the overall work process.

A solid and reliable industrial clutch can be a core factor in a well-run setup. Working with industrial equipment without one can be detrimental.

The 3 Core Reasons for an Industrial Clutch

An excellent industrial clutch can come in a wide variety of forms and can work with all manners of machines. The prime purpose of an industrial clutch is to bridge connected machines and shape and control their power and motion.

When operating a large industrial complex, each industrial clutch can and should be providing all 3 of the below core factors.

While not useful all at the same time, each of them provides an efficiency boost and safety net for your employees and hardworking machines.

1. Higher Rates of Control and Speed

Industrial clutches are the lynchpin between machines. They allow for softer stops, smoother transitions of motion and power, and you can tune them for automatic reactions during emergency shifts.

All of these uses allow your industrial setup to run at higher speeds and efficiencies. Clutches act as a proper safety net that keeps your machines protected and operational. 

2. Better Motor Life with Less Pressure

There are a large variety of motors that get used in industrial equipment. No matter the type of motor, powering up a motor takes a bit of energy and strain. This gets worse when you need to build up to rapid cycling conditions.

In a system without an industrial clutch, the motor is in danger. The only way to control the motion of the load, then, is to start and stop the motor. While the motor can work to do this, doing it at a constant rate will wear it down fast.

With an industrial clutch, the motor does not need a constant shifting off and on to control anything. This takes away a lot of pressure on the motor.

3. Protection Within a Power Loss

When working with expensive equipment and high-value loads, you want to make sure you protect yourself at all times in case of emergency. A power loss can cause havoc if you are not prepared.

Industrial clutches are a perfect tool towards ensuring that preparation. In the event of a sudden power loss, your clutch's design allows it to mechanically activate to ensure a slow and safe stop of machinery.

Without this, there can be grinding halts and nasty breaks when things go south.

Safe and Secure Machinery, When You Need It

An industrial clutch is a simple but powerful piece of equipment that turns a running setup from functional to practical. The protection and efficiency they can provide are critical to a well-run setup.

When you need equipment, maintenance, and information on all things industrial, you can turn to Kor-Pak. Contact us today for more details. 

How To Check Industrial Brakes

The industrial brakes on any machine are easily one of the most critical parts of your equipment. You need the brakes to make sure the machine slows down or stops when those commands are required.

That being the case, if you don’t know when or how to check your brakes, you could end up experiencing a lot of problems in your place of work. It may even cost you a lot of money on repairs.

Obviously, you don’t want to have to go through all of that. The good news is that you don’t have to. With these simple techniques, you can learn how to check industrial brakes and keep your machines in pristine condition.

Read on to learn what it takes.

1. How to Check Industrial Brakes: Safety First

Before you check your brakes, you need to make sure your own safety is good to go. Otherwise, your machine won’t be the only thing that needs to be fixed.

Make sure that anything that powers the system is locked down or powered off. With electrical systems, that means you need to cut off the current that powers the machine to eliminate the chances of starting it up on accident.

All holds and fastenings should also be in place before you begin. Each machine works differently, so check with the user manual, so you know where to go.

2. Check the Hydraulic Oil

Everyone knows that when it comes to heavy-duty machines, the hydraulic oil is its lifeblood. That said, one of the first things you should check is the oil that powers the brakes.

If you believe that you’re experiencing problems with the brakes, take a look at the hydraulic oil levels in the machine. There’s an excellent chance that they may be low and need to be refilled.

The good news is that it doesn’t take much to make it happen. Buy the correct grade of hydraulic fluid (each machine has its own grade) and add the oil you need. Your equipment should be back up and running in no time.

3. Check Through the Mechanical Things

If the hydraulic oil didn’t do the job, it’s got to be a hardware problem. These aren’t as quick of a fix, but by finding out where the problem lies, you can make it a lot faster to get to the bottom of things.

Start your troubleshooting by knowing all the hardware parts of the brakes. Piston bolts, chain sprockets, and guides are just a few of the parts that you’ll find on generally any industrial machine and are the most likely to be the problem.

Once you locate the problem, most repairs are pretty straightforward when working on the brakes. Buy your part(s) and have them installed so that your machine can get back to work!

For All Your Industrial Needs

Now that you know how to check industrial brakes, you’ll want to know where to go if it’s time to replace them. Luckily for you, you won’t have to look any further.

Kor-Pak Corporation is dedicated to giving you and your company the best tools and services for the best price. We work in several different industries and sell industrial brakes, crane wheels, oil rig equipment, rail parts, and much more.

Give us a call whenever you’re ready to get the tools that you need. We look forward to serving you!

 

Your Guide To Industrial Brake Parts

The history of brakes is long. Over the decades, brake systems have been upgraded and changed many times to meet the new and demanding requirements of ever-evolving vehicles and road systems. 

Industrial brake parts and systems can be slightly more complicated than your regular old car system, but the necessary components remain the same across the board.

If you’re looking to educate yourself on essential industrial brake parts, keep reading! 

Industrial Brake Parts

Regardless of the type of brake system you have – industrial vs. standard, disk vs. drum – some components span the differences. Here’s a quick and easy break down of the individual parts that make up your industrial brake system: 

The Brake Pedal

The pedal is the portion of the brake system that is located inside the vehicle. 

When you apply the brake pedal, you activate the master cylinder.

The Master Cylinder

The master cylinder is a plunger. When you press the brake lever, you force brake fluid from the master cylinder into the brake line. 

When you release the brake pedal, the cylinder deactivates and returns to simply storing brake fluid until you press the pedal again. 

The Brake Lines

Your brake lines are usually made out of metal. They carry the brake fluid from the master cylinder down to your wheels.

The Rotors or Drums

Depending on whether your industrial equipment has disc or drum brakes, you will have either rotors or drums behind your wheels.

The rotors or drums are the part that the brake pad is one half of the friction interaction that stops your car. The brake pads rub against either the rotors or the drum to create enough friction to slow and stop your equipment.

The Brake Pads

The brake pads are the other side of the friction equation. The pads rub against the drums or rotors. They are made of composite materials, which gives them longevity over thousands of miles of driving. 

The Wheel Cylinders

As the brake fluid flows into the wheel portion of the brake system, the wheel cylinders are filled with fluid. The fluid either squeezes the disc brake pads inward or pushes the drum brake pads apart, depending on your system.

As the pads are pushed together or apart, they rub against either the rotors or drums, causing the industrial equipment to stop. 

Know Your Industrial Brake Parts

Although most industrial brake systems are either drum or disc brakes, other system types may have slightly more nuanced industrial brake parts. For instance, your crane may have storm or rail brakes

Now that you know all the parts of your brake system, you can more easily describe maintenance issues or pick repair parts. 

If you’re looking for more information on brake systems, or need to talk to a professional about repairs, contact us today!

 

How Water-Cooled Brakes Work in Your Industrial Equipment

You need brakes that work for your machine.

The problem is that traditional disc brakes experience a great deal of pressure which can overwhelm the system.

This is where water-cooled brakes can make all the difference between a job done right and a bevy of technical difficulties.

Here’s what water-cooled brakes are, how they work, and when you need to use them in your industrial machinery.

What are Water-Cooled Brakes?

Water-cooled brakes consist of a central and stationary cooling plate. This plate has an internal chamber responsible for circulating coolant. There are also multiple cast-iron sectors mounted on opposite sides of the disc. The plate and iron sectors are typically divided by insulation layers.

They’re similar in principle to wet brakes, which use oil to keep the machine cool (especially in heaving braking applications).

The alternative is dry brakes, which are typically a single drum system which heats up once put under pressure.

How Do They Work?

Let’s say you’re using a machine and press down on the brake. There are different cooling systems your machine might use, but it generally works like this.

When you press down on the brake, this generates heat from friction. If left alone, the heat buildup from friction could put the whole system under extreme pressure and cause a mechanical breakdown.

The cast-iron sectors have enough thermal capacity to retain some of the heat generated by braking for a while. The task of conducting it out of the brake system lies with the water, which is used as a coolant liquid.

The heat is transferred to the water at a rate determined by the thermal conductivity of the insulative layers.

When Water-Cooled Brakes are Necessary

Knowing how brakes work, the question becomes when you might need water-cooled brakes over dry brakes.

Water-cooled brakes are most helpful when there isn’t enough space to create sufficient airflow needed for dry brakes to function optimally. They’re also useful in machinery that needs better heat conduction than air can offer.

This is most often seen in industrial machinery.

Within heavy machinery, these brakes are used in a variety of industries, such as drillers, tensioners for unwind stands, winches and mooring systems, and in yarders in the forestry industry.

Do You Need Water-Cooled Brakes?

The advantage of water-cooled brakes comes down to physics.

Air is ultimately a poor cooling medium–its density is too low, and the rate of heat transfer is too slow to work for heavy machinery, which generates too much heat and force in the course of normal use to make dry brakes practical.

Water-cooled brakes overcome this limitation. This way, you can stop worrying about mechanical failures and focus on the job at hand with a fully functional machine.

If you need to upgrade your machinery to make the most of your work time, we can help. We offer comprehensive services for industrial machinery, including modernizations, upgrades, repairs, and custom machining and fabrication.

If you need to request a quote, use our contact page to get in touch.

An Engineer’s Conundrum: Do You Use Drum Brakes, Disc Brakes, or Storm and Rail Brakes?

When choosing which types of drum brakes to use, you want to be informed. Your safety and investments depend on it. The importance of brakes doesn’t need to be overstated.

From storm and rail to disc and drum brakes, read on to learn which set of brakes fit your current situation. You’ll thank yourself later.

The Difference Between Types of Drum Brakes, Disc Brakes, and Storm and Rail Brakes

When trying to stop a train, truck, or other forms of heavy machinery, you want to be sure that your brakes are dependable. I mean, think of the sort of friction created by a 7000 horsepower piece of machinery trying to stop.

  • Drum Brakes- Brakes that utilize friction by pressing a group of pads outwardly against a cylindrical rotating part called a brake drum.
  • Disc Brakes-Similar to a bike brake except brake pads squeeze rotating disc inside wheel. Force is transmitted hydraulically instead of through a cable.
  • Storm and Rail Brakes-Similar to drum and disc brakes, only these brakes are not usually used for stopping or slowing down. They are primarily used for locking things.

Industrial brakes should be tailored to your specific application.

Why Choose Drum Brakes?

I know what you may be thinking, why wouldn’t I just go with disc brakes? They’re better. You wouldn’t be wrong in stating that disc brakes perform better and last longer on average.

However, in the case of industrial brakes for heavy machinery, you don’t need the most hi-tech option. You need something dependable and cost-efficient. Different types of drum brakes offer you just that.

After all, you’re already spending a ton of money on the machinery itself.

You’re not cutting corners with drum brakes, either. Five years, ago federal authorities updated stopping-distance restrictions for heavy tractors. There was talk that this would finally initiate the conversion from drum brakes to disc.

Not the case.

Drum brakes have drastically improved their performance and dependability by expanding their size.

In 2015, 90% of heavy truck buyers opted for drum brakes.

There’s also an added expense to disc brake maintenance that adds to the appeal of drum brakes.

If you’re looking at a standard operation, drum brakes are your best bet. But you have to buy the right set. If you are dealing with operations that require higher safety precautions, I would consider disc brakes.

Why Choose Disc Brakes?  

Drum brakes are great for the average operation because of their cost-effectiveness. Disc brakes are still superior in performance and maintenance.

Disc brakes last longer than drum brakes. They are also easier to repair. Because of this, they offer a viable option for companies who know they are transporting large amounts of goods over long periods.

They are perfect for tankers, freighters, and heavy-duty vehicles transporting hazardous materials.   

Certain industrial applications require a little more assurance and thus, a bit more expense than drum brakes.

Why Choose Storm and Rail Brakes?

While drum brakes and disc brakes are industry standards and have a wide range of applicability, storm, and rail brakes have a niche position. Their place is just as important.

These brakes are ideal for large cranes and other equipment that needs to be locked in position for long periods.

The Type of Brake You Use Depends on the Job you Do

Choosing a brake system is no easy task. You have to weigh in the potential long term and short term effects of your decision.

Certain types of drum brakes are great if you’re dealing with a standard operation in which the risks aren’t too high. Disc brakes are great for the long haul. Storm and rail breaks have a specific job.

Make sure your decision is an informed one!

 

Hydraulic vs Mechanical Disc Brakes: Your Questions Answered

Brakes come in many varieties and sizes, each with its own purpose. Out of the two most common brake types, hydraulic vs. mechanical disc brakes, which one is best? What is the difference between the two, and what purpose do they serve?

If you’ve come to this article seeking answers to these questions, then you’ve come to the right place. All of these questions (and more) are answered in the below.

Hydraulic vs. Mechanical Disc Brakes

In this section, you’ll find out the difference between hydraulic and mechanical brakes. Read on to find out more.

What’s the Difference?

Hydraulic brakes are better at coming to a complete stop than mechanical brakes, are cheaper, and save more space than other brake types.

Efficiency means that hydraulic discs dissipate heat well. This translates into a long life span for hydraulic brakes. When all of this comes together, it means that hydraulic brakes end up being safer than other brakes.

Hydraulic brakes are easy to repair because of readily available parts and because of their sealed-off closed system. This means that hydraulic brakes only lose brake fluid when the brake is malfunctioning.

Hydraulic brakes are also easier to inspect than mechanical brakes because there is no need to remove the wheels.

Mechanical brakes are significantly less durable than hydraulic brakes because they rely on fiction alone to stop vehicles. The durability of mechanical brakes depends on the strength of the friction-like material used in the pad or shoe of the brake.

Hydraulic brakes may be easy to fix, but that doesn’t mean that mechanical brakes aren’t easy to fix as well. Mechanical brakes are easier to set up and maintain and are more cost-effective than hydraulic brakes.

Also known as drum brakes, these brakes are known to brake fade, which is when you lose braking power due to the heating up of the brake system. Modern vehicles still utilize this older braking system, although they are (for the most part) found in the rear wheels.

Which Brake is Better?

Each brake serves its purpose in the real world.

Hydraulic brakes are most commonly found in vehicles, which often require a specific fluid to allow them to run correctly. High-pressure breaking is where hydraulic brakes excel, assuming the hydraulic system that powers them is operating correctly.

Mechanical brakes, on the other hand, do not require a power supply or system to run. A simple lever is usually what powers a mechanical brake, meaning they are quite basic. Parking brakes are an excellent example of a mechanical brake.

You Decide…

Hydraulic vs. mechanical disc brakes may sound complicated, but hopefully, this article has made it easier to understand what they are and what they do.

If you’d like a one-stop place for all the industrial solutions that you or your company require, then make sure to check us out.

How to Choose a Clutch That’s Right for Your Machine

In simple terms, a clutch is a mechanical device connected to two or more rotational shafts. When the clutch is engaged, power is transferred from the engine to the wheels.

Choosing the right clutch for your machine is essential in terms of saving you time and money. You cannot afford to have your heavy machinery break down because the clutch isn’t up to the job.

To make the right choice, it helps to know what the different components are and how they work together to affect performance. Keep reading to learn more.

Components of a Clutch

There are several clutch components, the largest parts being:

  • Flywheel
  • Clutch disc
  • Pressure plate

Springs, release levers, covers, bearings, and pins are also used to make up the complete clutch assembly.

The Flywheel

The flywheel stores rotational energy and when the clutch pedal is pressed it provides inertia to allow continuous rotation.

Clutch Disc

This is the part that gets the most wear and tear because it absorbs the load when engaged. There are two types of clutch disc; sprung hub and solid hub.

Pressure Plate

The pressure plate is another hard working part. It forces the clutch disc against the flywheel via springs when the clutch pedal is engaged.

Clutch Disc Material

This part is more likely to wear first, so it makes sense to choose the correct material for the application.

A solid hub clutch disc is primarily used for high capacity engines, such as racing. These hi-performance clutches have heavy-duty springs to absorb the load caused by the higher engine capacity.

Most other applications use a sprung hub clutch disc. It is designed to absorb and spread shock on initial engagement and throughout its use.

Materials used for discs include, organic, Sintered iron and Kevlar. Organic materials are present in most stock clutch discs.

Sintered iron is used for its non-slippage ability.  It can withstand extremely high temperatures, so it’s good for applications that require dynamic stopping. It can also be resurfaced if slippage becomes a problem.

A Kevlar clutch has a higher friction force, but this can result in rougher engagement and some vibration in low gears. That said, it is an incredibly hard-wearing material.

Torque and Response Time

The job of a clutch is to transmit torque without slippage. The heavier the load, the more likely slippage can occur. This is what causes wear and tear.

Response time is how long it takes the load to reach a specified time.

There are several factors affecting torque and response time.

Depending on the application, full torque during acceleration may or may not be needed.

The ability to disperse heat is also crucial and affects every instance of clutch engagement.

Buying a Clutch

Now you know what goes into choosing the right clutch for your machinery. Of course, you want to get it right the very first time.

That’s where we can help. We’re experts in all kinds of industrial clutches. We can advise you on size, torque, style, and application.

If you need to buy a clutch, get in contact today.

Your Guide To Dynamic Resistors

Trains and the locomotives pulling them can weigh anywhere from 40 tons to 500 tons depending on the number of axles. And, as you can imagine, the heavier the train, the harder it is to slow it down.

It takes massive amounts of energy to slow down a heavy mechanical system.

Before dynamic braking systems, we used to apply mechanical force manually. Someone would run down to the end of each car and turn a wheel applying the brakes. This often didn’t work fast enough, and trains crashed.

Primarily since the advent of the diesel engine, we use more reliable systems to slow down mechanical systems.

Trains might be the most common example, but you’ll find dynamic braking systems in elevators and cranes too.

To help these systems to operate quickly, smoothly, and efficiently, engineers created dynamic resistors. Without resistors, these systems would be clunky and possibly dangerous.

Here are the various features and specifications of this all-important braking component.

1. What Does a Dynamic Resistor Do?  

There are two kinds of dynamic resistors. One is rheostatic or dissipating, and the other is regenerative.

Dissipating braking resistors essentially recycle kinetic energy and turn it into electrical energy. The energy in the case of trains comes in the form of heat.

This energy returns to the supply line where it overloads the circuit and slows down the mechanical system. This is a lot like using your manual transmission to help slow your car down a steep grade.

If the resistor is rheostatic, its main function is to cool the braking system. But even these resistors can become overheated forcing operators to revert to mechanical systems.

Often dynamic braking systems use both kinds of resistors.

Unfortunately, dynamic braking isn’t sufficient on its own to slow down a massive train. Most systems combine dynamic brakes with air brakes.

2. What Are the Advantages of Dynamic Braking?

Friction braking systems do work. On their own, they can stop a train. But on a steep grade, they’re less reliable.

The other problem with friction systems: they wear down faster.

Just like car brakes, mechanical brakes on a train eventually wear down. When adding the extra force from dynamic motors, you extend the life of the friction braking system.

Speed. That’s the most significant advantage of adding electrical braking to your system.

You slow down faster. But this also means you can push your train to go faster.

The second most significant advantage is cost. Not only will you use less energy to slow down the train, but you also won’t have to replace components like brake shoes.

Lastly, because you’re converting heat energy into electrical energy or dissipating heat through resistors, there is less chance of fire or failure. Mechanical brake systems cause too much heat when not assisted. This means your brakes are more likely to fail.

Dynamic Resistors Are Important

Dynamic resistors are incredibly crucial in train operation. You won’t likely find a contemporary locomotive without this kind of braking system installed.

If you’re in the market for rail parts, check out our store.

What You Need To Know About Dynamic Braking

To say that trains are large is a bit of an understatement. Everyone knows this, but what most people don’t know is that the average train weighs between 100 and 200 tons and generates 6000 to 7000 horsepower. ‘Large’ doesn’t even begin to cover it!

Are you stumped when trying to purchase parts to resupply a train? Or are you renovating one of these metal beasts?

You probably want some tips on how to generate enough force to power it. That’s where dynamic braking comes in.

Here, we’re going to tell you about dynamic braking and how it can work for you!

What Is Dynamic Braking?

Before you can learn how dynamic braking helps the train work, it’s first essential to understand what it is. Even though trains have been improving over the decades, dynamic braking has been constant throughout time. That’s how you know it’s a tried-and-true method!

The traction motors in the train are what slow it down and bring it to a stop. It doesn’t use any additional electricity to make the train stop, which is excellent for both utility and simplicity. Plus, the train can stop this way—no matter what speed it’s going or traction it has!

How Does It Work?

Trains use electricity to move along the tracks, and the conductor controls how the electricity works. For dynamic braking, the conductor pulls a lever that makes the electricity in the train distribute into the traction motors more. This helps control the heavy train when it slows down.

Dynamic braking is really safe for this reason. There’s a lot of control in where the train goes and how slowly and safely its stops are. Because of this, the train will not stop so abruptly or quickly as to injure someone or destroy goods in transit.

Click here to check out great prices and variety on the parts that will make dynamic braking possible.

Braking And Your Engine

The main engine in the popular Diesel locomotive is a cylindrical two-stroke engine. These are 760 cubic inches in volume, so a lot is going on in these monstrosities.

This generates a ton of power, of course, but the thing that makes it even more significant than it sounds? This is only one small part of the full engine.

As you can imagine, these engines are powerhouses. With 3200 horsepower, you can’t go wrong. This makes dynamic braking even better. More energy output from the train leads to greater control over its brakes!

Hit The Brakes!

Dynamic braking is a safe and easy way to make a train slow down and stop at the pace it’s supposed to. It’s also efficient because it redistributes the electricity that’s already in the train.

Now that you know all about how dynamic braking works visit our contact page to learn how you can implement this knowledge effectively in locomotive renovations.

All aboard!