How Electric Brakes Work

Electric brakes are standard features on trailers, and they’re similar to the hydraulic brakes on cars. The only difference is that electric options use electromagnets while hydraulic pressure powers car brakes.

An electric braking system has several components, including a magnet, shaft, actuating arm, small front shoe, reactor spring, and larger rear shoe. All these parts work together seamlessly to support the overall function.

If you’re curious about the workings of an electric break, this post is going to help you to learn that.

Read on to learn more.

The Controller

An electric braking system requires the use of brake controller, which is usually connected to the battery and stop light switch. This component regulates the electric current sent to the brake once your press the pedal.

Your trailer can have the time delay or proportional brake controller. These are the two common types of controller. Proportional controllers work by determining how the tow vehicle is stopping and regulates the power to the brake proportionally.

Proportional controllers work by determining how the tow vehicle is stopping and controls the power to the brake proportionally. The use of this controller allows the trailer brakes to be applied at the same time and rate as the tow vehicle brake.

With a time delay controller, you have to adjust its controls to suit your trailer weight and the moment when you apply the trailer brake. This is important to avoid too little or too much stopping resistance when braking.

The Braking System

As you already know, electric brakes have a magnet, which is usually on the backing plate. The plate is usually bolted to a flange on the trailer axle, which is the passage of the hub and the bearings. This magnet has two conductor wires that are directly connected to the trailer spring.

So, when electric power is on, it activates the magnet, which is then attracted to the drum face. The contact of the magnet and the drum face results in friction that prompts a rotating action. This rotation causes the actuating arm to pivot, pushing the brakes shoes out against the inside of the drum.

When this happens, the hub stops, resulting in the stopping of the wheels.

Safety Features

Federal laws in most states require the use of a safety circuit for trailers that have electric brakes. This circuit is known as a breakaway system, which is designed to apply the brakes if the trailer disconnects from the tow vehicle.

The breakaway system features a battery and switch. The switch has a non-conductive plastic that separates its contacts. A lanyard connects the plastic to the tow vehicle. So, if the trailer disconnects from the trailer, the lanyard pulls the plastic, allowing the switch to close. This stops the brakes of the trailer.

Electric Brakes – The Bottom Line

Massive drawworks disc brakes can get insanely hot. Overheating can lead to slowdowns and breakdowns. You don’t want that.

Read on to learn how this type of cooling works, and what you need to know about it.

Disc Brakes 101

Disc brake of various types are used in virtually every industry. Their main purpose is to control the speed of rotation by turning rotational energy into heat energy. Obviously, the more a disc brake works, the hotter it gets.

Disc brake overheating is a serious problem. In fact, it’s the number one cause of brake failure. There are several ways to cool disc brakes, mainly through air flow. Cooling with air flow is called convective cooling. However, it’s somewhat hard to control.

The Four Phase of Disc Brake Cooling

Thankfully, disc brake cooling is often predictable. Breaking comes in four phases:

1. Braking
2. Slow cooling
3. Fast cooling
4. Slow cooling

During braking, heat is generated as the drawworks lower the load. Obviously, larger loads will generate more heat.

During the slow cooling phase, the disc stops and work is done at ground level. In that phase, cooling happens passively.

During fast cooling, the discs spin as the load is raised again. The brakes are not applied as the block is raised, which means zero heat generation while the system cools rapidly.

Maintenance Pressure Points

Brake heating and cooling means that your system will go through temperatures that span about 150 degrees Celsius.

Most of the cooling comes from air convection while the discs spin without brakes (fast cooling).

A well maintained drawworks is less prone to overheating. In addition to proper ventilation, sufficient lubrication is also crucial in ensuring the machine is not generating excessive heat.

All grease fittings must be regularly maintained. Additionally, any chain parts must be properly oiled.

Follow your manufacturer’s guidelines and conduct regular inspections. While you can’t measure air flow, you can at least make sure that all oil sumps are filled and all oil nozzles are operational. A plugged oiler means no lubrication, which can lead to problems.

While your drawworks can operate in a range of 150 degrees, you must take into account the local weather as well. Additionally, if yours has a water cooling system, it’s important to keep the cooling water tank full and ensure that water flows properly.

What to Do If Your Drawworks Malfunctions

Even the most well maintained machine breaks down sooner or later. If yours malfunctions, don’t panic!

In case the disc brakes fail, you must always ensure the auxiliary braking systems are in order.

Keep in mind that the auxiliary systems must be considered a temporary solution until you fix the main braking system ASAP. Auxiliary brakes are not designed for long-term use.

Even if you’re using an old, unusual model, there are reputable companies out there that specialize on sourcing unusual or hard-to-find machine parts.

From finding the right part for your custom solution, to sourcing rare parts for your disc brakes, help is available. You just need to reach out and ask.

Heavy industry parts are complicated. There are many different types of parts that are used on many different types of machines and equipment. But knowing the role of each one is the difference between carelessness and safety.

The sprag clutch plays an important role in heavy machinery. They have very specific use cases and can seem difficult to understand.

Understanding these clutches and nurturing an interest in this sort of subject matter may prove to be wise in the coming years, as manufacturing jobs are back on the rise in the United States.

After this quick read, we assure you that you will have a better understanding of exactly how sprag clutches work.

What Is A Sprag Clutch?

A sprag clutch consists of an inner and outer ring. Unlike other types of clutches, however, sprag clutches are perfectly smooth inside. There are no rims or ridges in this specific clutch.

The inner and outer rings are connected by small parts like steel wedges, which are referred to as sprags or sprag elements. Sprag elements are permanently in contact with both the inner and outer ring of a sprag clutch. They are placed at a specific angle that helps to create torque.

Sprag clutches are an important part of the smooth flow of heavy machinery. They are used across many different industries. However, this equipment isn’t just used for heavy labor, parts like this are also used in the creation of fun things like roller coasters!

How Does a Sprag Clutch Work?

The inner and outer parts in a sprag clutch are held together by individual elements called sprags, as mentioned above. When the inner part rotates in one direction, the sprags flow along with the spinning, and the part turns freely.

When the direction of rotation changes to rotate the other way, however, the sprag elements shift and hold the inner and outer parts together. This seems to lock into place and turn the entire sprag, once the sprag clutch rotates in that specific direction.

This works because the sprag elements are arranged in such a way that when the sprag clutch turns in one direction, rotation goes smoothly. In the other direction, because of their angle, they create a force that stops the rotation and holds the wheel of the sprag clutch in place. This force is called backstopping.

Want to Know More About Sprag Clutches?

Though a sprag clutch is different from other types of clutches used in industry, the result is the same as other types of clutches. The inner and outer parts are forced to hold, drive, or freewheel (or spin), depending on the direction the sprag clutch is rotating.

If you are more of a visual learner, check out this short video animation to see a sprag clutch in action.

Of course, for the safety of everything affected by heavy machinery, parts like sprag clutches must be engineered with the utmost care given to precision and quality. Contact us for help sourcing clutches and other parts when you need reliable quality.

Semi-metallic Brake Pads Vs. Sintered Brake Pads. What’s The Difference?

Every part of a machine is crucial to the safety of its operation. In the case of brake pads, failing to have the right ones could be catastrophic. Two commonly mentioned options include the semi-metallic brake pads and the sintered ones.

Aside from those two, there are ceramic and organic brake pads. Ceramic pads are composites of ceramic fibers and copper. They are very expensive but operate well.

Organic pads are from fiber materials mixed with resins. Though they are cheap, they function well. Unfortunately, they do not last.

This brings us to the two common ones. What is the difference between semi-metallic and sintered brake pads? Read on to learn more.

Features of Sintered and Semi-Metallic Brake Pads

When parts of your machine don’t work, you start poring over the maintenance manual to find solutions. A better solution would be to call a professional service provider to fix it for you. They know how to solve machine issues.

Brake pads can be frustrating depending on the one you have. Choosing the right one is not easy. Here are some details to help you sort out between sintered and semi-metallic brake pads.

Sintered Brake Pads

Manufacturers make sintered brakes by fusing metal particles and other materials. They bind together due to heat and pressure. They can use metals like copper or bronze.

These brake pads have the following features:

• the mixture of elements gives it a lot of friction
• functions well under high temperatures
• performs well in various weather conditions
• it is long-lasting
• withstands high speeds
• takes long to start operating smoothly
• make a lot of noise
• they don’t glaze
• wear down the rotors
• can be expensive due to the manufacturing process and materials.

Semi-Metallic Brake Pads

Semi-metallic brake pads contain metals such as copper, graphite, and iron. They also mix composite alloys and fillers to complete its manufacture. These brake pads are popular among race drivers.

They have the following features:

• they tolerate high temperatures
• have high friction levels and great grip
• they are affordable
• they are durable
• different brands use different metal mixtures and ratios
• don’t make as much noise as the sintered pads
• don’t cause the same level of rotor wear and tear as the sintered pads
• function well in cold conditions
• tend to glaze due to producing brake dust.
• work well in light or heavy-duty usage.
• they need a bedding-in period
• pedals are firmer
• are great for everyday use in different environments.

As you can see, both of these brake pads offer you different options. The choice you make depends on the performance you want, the compounds you prefer, the environment you are in, and your budget.

Of the two, the best choice is the semi-metallic pads. These offer a combination of two worlds: the organic and the sintered versions. Thus, you get pads that operate at high temperatures, are durable, and easier on your wallet.

Learn More About Our Products and Services

You can get more information on brakes and other industrial parts. Some machines need very specific parts.  Contact us and we will help you find the solution you want.

Twiflex Brakes present industrial operations with a strong, reliable heavy-duty braking system. There are times though, with repeated usage, when they need to be replaced.

Let’s take a look at what you’ll need to do in order to correctly, and safely, replace your Twiflex Brakes.

Maintenance = Longevity and Safety

Twiflex Brakes are a drum braking system. With proper care and maintenance, they should last for years.

Maintenance can be broken into three key parts. Each part has equal weight in its importance to the braking system and to your company as a whole.

Constant upkeep will not only keep brakes functioning, it will also help maintain the safety of the equipment. When the brakes do need to be replaced though, keep that idea of safety going by using the proper equipment and protective gear.

The third leg of the maintenance stand is monetary. There is an investment to be made for regular maintenance of your Twiflex Breaking system.

Over the course of time though that investment will pay itself back with less downtime for your machines and fewer man hours spent on a machine that’s not functioning properly.

Replacement, Is It Time?

Do your breaks squeal? Is there reaction time low? Do they vibrate when being used? Do they feel like they pull? is there a grinding sound when they are engaged?

If the answer to any of these is yes then replacement is the best option. (Of course, you should also keep an eye on your instrument panel for an indication when things are not working at 100%)

The Replacement Process for Twiflex Brakes

Of course, the first step is to take the old brake system apart. First take the system off-line and disconnect it from any available power sources.

It’s a good idea to take images of the process as you go. Those pictures can be a helpful reminder of how the system needs to go back together.

If you’ll be replacing cylinders during this maintenance repair, you’ll also need to bleed the brake lines. This will make the entire process go smoother and ultimately safer.

You’ll first need to remove the brake adjuster. Remember at each step of the process, DO NOT force any of the parts to come off or apart.

If parts do not want to separate, use an appropriate solvent to loosen them. You can also try to use a lever or similar device to change your position and gently apply additional force.

With the brake adjuster off, you can access the rotors. Loosen and remove those.

Dismantle the brake components and then rebuild the system with the new Twiflex brake parts.

Performance

It’s very important that you follow all of the suggested steps when installing your Twiflex Brakes. Not only for safety’s sake but to optimize performance also.

As you have seen, Twiflex Brakes provide a safe, secure breaking option for industrial machines. Installation is easy and with proper maintenance, they will last you for many years.

When you’re ready to explore Twiflex Brakes for your machines or if you need some help with maintenance of your existing system, just contact us. We’re happy to help.

Friction material is used in a variety of applications that need to control speed. In layman’s terms: brakes.

These materials are often first in consideration during the design phase of building machinery and other industrial applications. Many materials are available to choose from with each having their benefits and drawbacks.

Read on to understand the options and factors in choosing the materials.

Types of Friction Material

The materials used in the final product will range due to many factors. The materials are combined, woven, and bonded to handle heavy use and heat. Some materials work better than others depending on the application.

You must first understand the types of friction material to suit your needs.

• Metallic & Semi-Metallic – Tin and copper powders fuse to create durable pads, clutches, and hydraulic parts. This mixture may include hard resin to aid with heat dissipation.

• Ceramic & Carbon Ceramic – Copper and a mix of carbon fiber or Kevlar are often found in these types of friction parts. Ceramic has a good balance of heat dissipation, reduced dusting, and vibration absorption.

• Organic – Cork, cellulose paper, Kevlar paper are used. Synthetic Benzoxazine compounds are now commonplace in the development. These materials are often married to ceramic parts.

The new standard in the part lining is organic these days due to the shift away from the use of asbestos-based materials due to health concerns. The exact composition differs between manufacturers for trade secret purposes.

The application of the materials is next once you have set your mind to the type.

Matching Friction Material with Application

Friction material plays a central role in the friction systems’ application. The general need for the material is to cause a stoppage of operations.

Here are considerations to match the material with the intended application:

• Equipment – Fleet vehicle or crane? Train or motorcycle? The general rule of thumb is “heavier equipment, heavier material”.

• Noise – Metal-on-metal friction causes ear-piercing noise but is a compromise for the stoppage power. Ceramics and organics are less noisy though it’s a trade off in material durability.

• Durability – High heat and dissipation from heavy usage lead to warping in organic-based material though easily replaceable. The metallic material is best suited for heavy equipment but comes at higher costs.

• Type – Friction is resistance against another material and happens in various ways from static, kinetic, and rolling. The type of friction will determine the need for the correct material.

The need for the utmost quality is first to be desired when you’re considering its use in big machinery like cranes and trains. There is no margin for error when it comes to safety in heavy industries. It’s a reason we’ve partnered with Scan-Pac manufacturing and so you can rest assured you’re receiving quality materials.

Trust in Us

We place your needs first and foremost here at Kor-Pak Corp.

Whether you’re in search of the right crane hoist or need guidance on how to manage railroad friction materials — we have you covered. With over 40 years in business, servicing all heavy industries, you can trust us to help you realize (and accomplish) lofty goals.

Give us a call, today!

While air over hydraulic brakes might not be the most common technology anymore, they are still relevant and thus important to understand.

In fact, a good understanding of air over hydraulics is important not only because of the necessary maintenance and upkeep, ut also in case you’re thinking of a replacement.

In this article, we will go through what an air over hydraulic brake system is, and how the system works.

What is an air over hydraulic brake system?

As the name suggests, this type of braking system is a combination of parts of an air brake system and a hydraulic brake system.

It uses both air and hydraulic compression to operate the brakes.

This type of braking system was created with the hopes of increasing the braking power compared to the power in a hydraulic braking system.

This system is not the most common, but it can often found in trucks, trailers, cranes, and other industrial equipment.

Because of all of their parts and components, these systems must be inspected often and maintained by a professional.

How it works

Normal braking

As we learned earlier, this system works by combining elements of an air brake and a hydraulic brake.

It has a special type of power cylinder that contains a hydraulic cylinder and an air cylinder in tandem.

While both of these cylinders have pistons, the important thing to note is that the pistons are not the same size. the air piston is greater in diameter compared to the piston for the hydraulic cylinder.

The air piston is greater in diameter compared to the piston for the hydraulic cylinder.

What does this mean? This means that there is more hydraulic pressure compared to air pressure during normal breaking.

So when the pedal is pressed, the valve opens and releases the pressure, which a causes braking to occur.

Hard braking

The valve movement when is different depending on how hard the brake pedal is pressed.

When heavier pressure is applied to the brake, there is more valve movement.

Because of the increased valve movement, a greater amount of pressure is released into the power cylinder, causing stronger and faster braking.

What to look out for

As we mentioned earlier, the many parts of this type of system means there are more areas that could be faulty or need repair.

You’ll need to be on top of the maintenance of the many parts of the air over hydraulic braking system, as any issues could result in liabilities and expensive repairs.

Besides the system itself, the oil involved in this system needs to be maintained. Be aware of potential freezing during the winter months!

Bottom Line

Hopefully, this article answered any questions you had about how an air over hydraulic brake system works.

There are many types of brakes, but it is still important to understand how each system works, especially if you have machinery that uses certain systems.

We have a lot of experience with a variety of braking systems and machinery, so if you have any questions or need any advice, feel free to contact us.

You can also leave us a question or a comment in the comment section below!

At Kor-Park, we pride ourselves on providing our customers with the best products.

We supply tools like the Marland clutch because they are durable, versatile, and time-tested. With proper care and maintenance, your clutch will last a long time and serve multiple functions across your business.

Learning new applications will help you get the most out of tools you already love to use.

There are countless uses for a Marland Clutch. We’ve compiled this list to help you understand the functions that make the most sense for your business.

What is a Clutch For?

First, let’s review exactly what a clutch does.

In short, the clutch is a device that couples and uncouples moving parts in a mechanism.

For example, if you’ve ever driven a manual transmission vehicle, you’ve used a clutch. Here, the clutch’s job is to engage and disengage various gears.

Clutches transmit power between shafts, motors, gears, etc. This is what makes them such versatile tools.

Clutches provide an important function industrial settings. They are crucial to controlling the speed and power with which machinery operates. Without a clutch, it is almost impossible to regulate these functions.

The Marland Clutch Difference

Of course, a Marland Clutch is designed to handle power transmissions in machines much bigger and more complex than a manual transmission car. Industrial-sized equipment calls for an industrial-sized clutch.

Marland has been producing clutches since 1931. These clutches help businesses keep their industrial equipment running smoothly.

Industries like mining, metals, power plants, and cement manufacturing all use the Marland Clutch on their heavy machinery. These clutches come in different sizes and designs. This helps to meet the unique needs of different industrial equipment.

The type of machinery you are looking to handle will help determine which type of clutch you will want to use.

The Right Clutch for your Business

Every industry’s machinery has unique needs and requires different kinds of clutches.

For instance, the machinery used by oil refineries cannot be stopped for routine maintenance. Marland’s CECON (Completely Enclosed for Continuous Operation) clutch is optimized for these needs. This clutch is also a great option for machinery that operates outdoors, or in wet conditions.

There are some industries where machines must remain functional during emergency shutdowns. Kiln drives use Marland’s One-Way CEBMAG clutch to keep their machines running slowly in these situations.

In addition to one-way clutches, Marland also produces backstops. These are important to protect against reverse torque on a conveyor or elevated installation.

Additionally, if your machinery needs require multiple clutches, Marland manufactures clutch couplings. These will help you use your clutch in the way that best works for your business.

At Kor-Pak, our goal is to provide you with equipment customized to meet your needs. Whatever the unique needs of your industrial equipment, there is a clutch that can help things run more smoothly.

If you have questions or need help determining which clutch is right for you or taking care of your Marland Clutch, contact us so we can work together on the bets solution.

Caring for your drum brakes means caring for your customers, employees, and your machinery.

With improper brake maintenance, you are risking safety and unnecessary expense

Remember, brakes don’t fail on their own. Brake failure is a result of improper maintenance.

Let’s make sure you are properly installing and maintaining your brakes.

Here we go:

Drum Brakes Installation Safety

You will want to have your employees wear an asbestos respirator when installing or changing your brakes. Also, make sure your employees are aware of all hazards before they begin.

You should also provide gloves and eyewear before starting.

Procedure

1. You’ll need to follow the directions to remove the tires first before installing or replacing brakes.
2. Check the brake adjuster and all screws. You may need to remove or adjust.
3. Pull the brake drum off, holding with two hands and wiggling.
4. Inspect the brake before replacing or installing.
5. Encourage your employees to take a digital photo before disassembly.
6. Use comparable brake shoes. They should be the same width.
7. Dismantle brake components.
8. Reassemble after replacing pads and any faulty springs.

Bleed The System

If you replaced any brake cylinders you will need to bleed the system before operations.

Watch The Signs

When brakes are failing, there are a number of common symptoms experts tell us to look out for. These include:

• Poor performance
• Squealing or grinding noises
• Grabbing or pulling to one side
• Brake pedal loss
• Pulsation of the brake pedal
• Clicking noises
• Drag during acceleration
• Warning lights on dashboard and system sensors

If any of these issues occurs, don’t wait for scheduled maintenance. Take your equipment offline immediately and perform a diagnostic.

But beyond troubleshooting issues, you should plan regular maintenance as well.

Perform Regular Maintenance

Even if your brakes are showing no sign of failure, it is important to maintain them regularly. Waiting for your brakes to fail before performing maintenance is waiting for disaster.

Plus, for personal users and industrial concerns alike, preventative maintenance is shown to save money. You will be extending the lifecycle of your machines, lowering capital improvement costs, and eliminating unplanned downtime.

With your brakes, performing preventative and predictive maintenance means scheduling work every 6 months.

Include in Your Overall Operations Plan

Your brake maintenance and troubleshooting efforts should be incorporated into standard operations. If your engineers and operators know what to look for you will save on accidents and cost.

But brakes are only a small part of an operations plan. Putting it all together means getting trusted support and advice.

Kor-Pak can help with all the systems and parts that keep your business running.
With knowledge and know how, you will also be keeping your operators, workers, and customers safe.

We serve numerous industries, including steel, rail, energy (wind), mining, and oil. At Kor-Pak, we keep industries productive. 

We understand your business needs.

Our customers are important to us. Don’t wait to see how we can help with every aspect of your operations plan.

Contact us now and discover how Kor-Pak can help bring value to your business today.