SELECTION AND CONNECTION OF SPRING APPLIED FAILSAFE AND PERMENANT MAGNET BRAKES

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1 Ck85/06/ 70 Samatha Str SELECTION AND CONNECTION OF SPRING APPLIED FAILSAFE AND PERMENANT MAGNET BRAKES. OPERATING CONDITIONS. Normal Operatig Coditios The ambiet temperature must ot exceed 40 C ad its average value must ot be over 5 C over a period of 4 hours. The lower limit for the ambiet temperature is -5 C. The altitude of the locatio where the equipmet is to be used must ot be more tha 000 metres above sea level. The relative humidity of the ambiet air must ot exceed 50% at 40 C. Higher air humidity values are permissible at lower temperatures, e.g. 90 % at 0 C. The moderate amout of codesate which may occasioally form must be take ito cosideratio. The ambiet air must ot be cosiderably cotamiated by dust, smoke, aggressive gases as well as vapours or salt cotet. The ormal istalled positio of the brake is specified i operatio with horizotal shaft. Normally, the brakes are suitable oly for dry ruig.. ELECTRICAL CONNECTION. Voltage ad Curret Specificatios The uit must be coected to the correspodig type of curret depedig o the versio of the brake, i.e. direct curret, alteratig curret or three-phase brake. The detailed regulatios with regard to the electrical coectio must be observed i the operatig istructios for the correspodig device. Refer to the relevat equipmet sheets for the stadard voltage. The costatly permissible voltage chage at the termials of the uit whe actuated is +5 to -0 % of the omial voltage.. Rectifier.. Trasformer Rectifier Uit Trasformer rectifier uits for direct mais coectio are available for supplyig the brake with a low protective voltage of 4 V D.C. Rectificatio takes place i a bridge circuit. I order to protect the rectifier agaist switch-off voltage peaks durig D.C. switchig, the castig ecapsulated devices are equipped with a Z-diode at the output ad coected o a sheetmetal base up to size with a varistor... Trasformer Rectifier Uit with Overexcitatio. This trasformer rectifier uit shortes the switch-o time or D.C. brakes by approx. 60 %. Durig the fixed overexcitatio time of 50 ms, the trasformer rectifier uit supplies the brake iitially with 48 V ad the switches over to 4 V omial D.C. voltage. The cotact K must also be switched at the same time as switchig the D.C. side. I order to protect the rectifier agaist switch-off voltage peaks durig D.C. switchig, the output is coected to a varistor. The brake ad D.C. switchover cotact must be protected i all types of trasformer rectifiers by the user by coectig this cotact to adequately dimesioed varistors or RC elemets. 0.. Half-Wave Silico Rectifier This rectifier is icorporated i the coectio housig of the brake, it ca also be istalled i the termial box of a motor for example. The rectifier makes it possible to directly coect the brake to the mais alteratig voltage. Due to the high stadig wave ratio of the curret, the permaet maget brake caot be operated with a half-wave silico rectifier. The average D.C,. voltage value is 0.45 times ad effective value of the A.C. voltage. I order to protect the rectifier, brake ad switchover cotact agaist switch-off voltage peaks durig switchig o the D.C. side, a varistor is coected to each liear diode, retur diode ad switchover cotact coectio A - A...4 Silico Bridge Rectifier This rectifier is istalled i the same way as the half-wave silico rectifier ad it also eables direct coectio of the brake to the mais A.C. voltage. The average D.C. voltage value is 0.9 times the effective value of the A.C. voltage. I order to protect the rectifier, brake ad switchover cotact agaist switch-off voltage peaks durig switchig o the D.C. side, a varistor is coected over the rectifier output ad switchover cotact coectio A - A...5 Silico Overexcitatio Rectifier This rectifier is mouted i the coectio housig of the brake ad coected to the mais A.C. voltage. Durig the switch-o phase, the rectifier supplies the brake iitially with double the value of the omial D.C. voltage ad after the time of overexcitatio has elapsed, with the stadard D.C. voltage ratig. I additio to shorteig the switch-o time, the overexcitatio rectifier ca also be used to icrease the magetic force (icreasig the wear reserve i closed-circuit curret operated brakes). The brake is desiged for a average D.C. voltage value of 0.45 times the effective value of the A.C. voltage. This rectifier is ot suitable for permaet maget brakes. The A.C. side must be switched simultaeously with the A.C. side. I order to protect the rectifier, brake ad switchover cotact agaist switch-off voltage peaks durig switchig o the D.C. side, a varistor is coected over the rectifier output, feedback diode ad switchover cotact coectio A A.. Electrical Circuit.. Circuit of the Three-Phase A.C. Brake (Three-Phase Brake) Fig. Coectio of the Brake to the Motor Termials.. Circuit of the Sigle-Phase A.C. Brake Fig. Coectio of the brake to Auxiliary Cotacts*

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3 Ck85/06/ 70 Samatha Str.. Circuit of the Sigle-Phase A.C. Brake sprig applied brake systems. This switch is force switch by the movemet of the brake armature, i.e. the correspodig switchig positio of the microswitch is implemeted whe the brake is applied ad released. After the armature is held off, the microswitch closes the cotrol curret circuit ad i tur, the motor cotactor for motor coectio. The use of the microswitch is ot permitted for hoists ad elevators..4 Switchig Cycles Brake momet ad curret cycles as a fuctio of time (Fig.9) Fig. Coectio of the Brake to the Motor Termials Fig. 4 Coectio of the Brake to Auxiliary Cotacts* * Please equire with supplier... D.C. Brake Circuit with Trasformer Rectifier Uit Fig. 9 Brake momet ad Curret Cycle as a Fuctio of Time Fig. 5 Circuit o A.C. Side Fig. 6 Circuit o D.c. Side with Wired Output..4 D.C. Brake Circuit with Half-Wave Silico Rectifier The switch-off delay durig deactivatio must be observed i the A.C. circuit of the brake (Fig. 5 ad 7). Oly a slight switch-off delay occursi the D.C. circuit (Fig. 6 ad 8). M f_ t i ad l f_ t i M N dyamic torque t switch-off delay M residual torque t rise time t switch-o time t switch-off time The switch-off delay t the time from iterruptig the curret supply to the begiig of the icrease i torque. The rise time t the time from the begiig of the icrease i torque to achievig the dyamic torque ratig. The differet switch-off characteristics of torque ad curret as a fuctio of time for D.C. ad A.C. circuit (Fig. 0a ad 0b). Fig. 7 Circuit o A.C. Side Fig. 8 Circuit o D.C. Side..5 Load Capacities of Protective Elemets The protective elemets used i the wirig of the rectifiers ad switchover cotacts must ot be overloaded durig cotiuous operatio. Varistors are adequately sized oly whe their surface temperature is at o time more tha 0 C above the ambiet temperature. Please equire i case of doubt.. Microswitch Attachmet The egagemet time of the D.C. brake is greater that the respose delay, e.g., of the three-phase squirrel-cage (iductio) motor. For this reaso, the motor rus agaist the brake which is still closed, leadig to higher power cosumptio tha whe startig up the motor with the brake ot applied. IF the start-up momet of the motor is greater tha the brakig momet of the brake, frictioal work occurs at the brake, thereby havig a adverse effect o the service life of the uit. As a reliable corrective measure, we therefore recommed that a microswitch is istalled i D.C. Fig. 0a Switch-O ad Off Characteristics i D.C. Brake Circuit Fig. 0b Switch-O ad Off Characteristics i A.C. Brake Circuit 05

4 Ck85/06/ 70 Samatha Str.5 Fact Excitatio ad Overexcitatio I order to shorte the switch-o time of the D.C. brake, either the time costat which dictates the curret rise must be reduced, T R R + R (fast excitatio) V Or at the same time costat, the quotiet; U R (overexcitatio) must be icreased. I the formula, L stads for iductivity ad R for ohmic resistace. I the case of fast excitatio, the total resistace is icreased ad the time costat reduced by coectig a series resistor R V. A higher voltage is the requires as the result of the series resistor R V. I the case of overexcitatio, a multiple of the omial voltage is applied to the termials of the uit, thereby decreasig the switcho time at the same time costat t as for coectio to omial voltage. Fig. illustrates the effect of fast ad overexcitatio o the switch-o time. The specified values are referece values. U N omial voltage of device Fig. Shorteig the Switch-O Time by Fast Excitatio a ad Overexcitatio b t N switch-o time without shorteig iflueces.. CONFIGURATION OF BRAKES, DETERMINING BRAKE TIME AND BRAKE PATH Brakes are subject to static load i the form of the load momet M 4 for holdig loads ad to prevet the acceleratio of movable masses. The brake is subject to a dyamic load whe movig masses are to be braked with or without the ifluece of a load momet M 4. I this way, kietic eergy i the brake is coverted to heat. Takig the static ad dyamic load ito cosideratio, the followig requiremets result which the brake must meet: Requiremet : MN M4 SL Requiremet : Wmax W Requiremet : PN W Z Sth Requiremet 4 : max. Brake Cofiguratio Correspodig to Load Momet Load momet M 4 must be used to idicate the reductio of the total load actig o the brake shaft. As a safeguard agaist static overload, the safety factor SL is used as specified i appropriate literature ad various regulatios. While takig ito cosideratio the safety factor, the static torque of the brake specified i the data sheet must ot bee exceeded. If o load momet is specified, the motor power ratig must be used as the desig factor for the brake as follows: M N F MMot SL Equatio () M P Mot 9550 M Mot P omial motor torque i Nm omial motor power i kw omial motor speed i rpm. Brake Cofiguratio Correspodig to the Frictioal Work W The dyamic load of the brake results i eergy coversio (work) from kietic eergy to heat. The followig formulae apply for: Rotatio: W J 85. (a) Traslatio: W m v (b) J sum of all momets of iertia referred to the brake shaft speed of brake shaft m mass v velocity of the mass While takig ito cosideratio the effect of the load momet M 4, the followig work is derived which the brake must perform: M W J M! M (c) M 4 brakig (+) or drivig (-) load momet. Brake Cofiguratio Correspodig to Frictioal Work per Hour I accordace with the cofiguratio described i., it is still ecessary to examie the brake with regard to maitaiig the omial switchig capacity P N. The followig applies: P F W Z S () N S th Z th Safety factor agaist thermal overload for takig ito accout the degree of ucertaity i the assumptio regardig the brake operatios per hour or their ueve distributio. brakig/hour evely distributed..4 Determiig the Brake Time t (without Switch-off Delay t ) I additio to brake cofiguratio i accordace with torque, frictioal work ad speed, it is ofte ecessary to cosider the brake time. Assumig that the brake time t is a multiple of the switch-off delay t, ad ca be calculated with a approximately costat torque M N, the followig is derived: J t (4a) 955. MN Takig the ifluece of the load momet ito cosideratio M 4 : J t (4b) 955. _ MN! M4i M 4 brakig (+) or drivig (-) load momet 06

5 Ck85/06/ 70 Samatha Str The total time from the commad STOP to actual stadstill of the system is approximately the sum of t ad t.5 Determiig the Slow-Dow Path S 4 The slow-dow path S 4 comprises two compoets. I the switchoff delay phase t, the brake shaft still rus ubraked, while the actual brakig procedure takes place i the secod phase. Both compoets ca be expressed i the equatio: t V0 S4 t V0+ (traslatio) (5a) S 4 brake i m velocity at begiig of brakig i m/s V 0 { _ t + t i (rotatio) (5b) speed at begiig of brakig { slow-dow path i Reductio of Paths, Torques ad Momets of Iertia It is ecessary to reduce the specified values o the brake shaft with respect to brake cofiguratio ad determiig the brake time ad brake path. The followig is true with regard to the slowdow path i degrees: { 4B B { i (6a) 4A A Idex A drive shaft Idex B brake shaft i reductio ratio for torque: MB A M (6b) A B i for momet of iertia J (flywheel effect GD ): J J B A GDB A (6c) GD A B 5. PERMISSIBLE FRICTIONAL WORK PER ENGAGEMENT W max IN RELATIONSHIP TO THE NUMBER OF OPERATIONS PER HOUR Z The maximum permissible frictioal work W max is the frictioal work i relatioship to the umber of operatios per hour, at which the after-ruig costat ad where factor are withi certai specified limits. The diagrams Wmax f_ Ziare show i the data sheets. The specified values of W max are based o the permissible limit data at the frictio surface o the oe had ad the limit data of the exciter widig (whe mouted as motor brake) o the other. Depedig o the type of brake, differet values are obtaied for W max (Fig. ) for brakes of the same torque. 6. BRAKE SELECTION After completig determiatio of the brake requiremets i accordace with the specificatios stipulated i Part, a iitial rough determiatio of the type of brake ca ow be carried out with the aid of Table. I additio, the techical data of the pre-specified type of brake are also available so that a decisio ca also be made with respect to the brake size. If is foud that the performace requiremets of the brake are i the viciity of margial values, more emphasis should the be placed o the type of brake moutig ad the resultig value for the omial switchig capacity P N (Fig. 4).7 Relatioship of Momet of Iertia J to Flywheel Effect GD Normally, the momet of iertia J applies i the Sl system. The followig applies for the still commoly used term flywheel effect: J GD 4 D (7) GD flywheel effect i kpm.8 Coversio of Mass Actio from Traslatio to Rotatio The followig applies for covertig a mass m at velocity v ito a adequate momet of iertia J at the speed : J v 9. m (8) 4. DETERMINING THE MOMENT OF INERTIA J The geerally applicable formulae for momet of iertia should be used for geometrically simple bodies with eve mass distributios. I the case of more complex bodies, the momet of iertia is determied either by dividig the body ito geometrically simple parts or by meas of trials. Fig. Maximum permissable frictioal work per egagemet W max i relatioship to the umber of operatios per hour Z for differet types of brakes 07

6 MAGNET SERVICE BINDER (South Africa) cc Ck85/06/ 70 Samatha Str Fig. 4 - The effect of the type of moutig o the omial switchig capacity. Geeral idustrial applicatio Brake attached to motor Fa withi motor Brake icorporated i motor Fa behid brake Brake without heat geeratio through exteral paths Brake with heat geeratio of motor ad fa Brake with heat geeratio of motor ad fa ~0.7 PN ~0.85 PN PN Table Type of brake Performace requiremets of brake Dyamic torque Number of Nomial operatios switchig capacity Maximum frictioal work per egagemet Wmax High Medium Low Number of operatos MN - Nm Z - h- PN * E 500 Three-phase sprig applied sigle disc brake 7/ E 0000 A.C. sprig applied shoe brake E x PN D.C. sprig applied sigle-disc brake E 500 D.C. sprig applied double-disc brake E 750 D.C. permaet maget sigle-disc brake E x PN D.C. sprig applied brake 7/7 ** Z * PN equal momet brakig (D.C. sprig applied disc brake ** high; medium; low Brake motor Electomagetic operated clutches ad brakes 08 Brake path cosistecy requiremet

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