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MEROBEL brake is a connector that transmits torque from the driving side to the driven side. It can be freely engaged, disengaged, or braked as needed. It offers advantages such as compact structure, simple operation, sensitive response, long service life, reliable use, and ease of remote control. Electromagnetic brakes are ideal automation actuators in modern industry, mainly serving to transmit power and control motion in mechanical transmission systems.

MEROBEL Brake Introduction

Pneumatic brakes control the friction between the brake disc and friction plates by adjusting air pressure, thereby achieving the purpose of adjusting the braking force on the paper roll. The installation, structure, and tension control principle of the pneumatic brake are shown in the figure. The installation positions of the pneumatic brake and the paper roll mandrel are shown in (a) of the figure. The structure of the pneumatic brake is shown in (b) of the figure. The brake disc 5 is connected to the paper roll shaft. Fixed friction plates 8 and movable friction plates 7 are installed on both sides of the brake disc 5. Generally, there is a gap of 1 to 2mm between the fixed friction plate 8 and the brake disc 5 (the gap is adjustable). The movable friction plate 7 is installed on the piston shaft 4 of the cylinder. The compressed air interface 2 on the left side of the piston is connected to the air compressor, and the right side of the piston is connected to the atmosphere through the air hole 1. The friction force between the movable friction plate 7 and the brake disc 5 is controlled by the air pressure on the left side of the piston, thereby controlling the braking force on the paper roll. The initial air pressure for the movable friction plate 7 is set according to paper and printing tension requirements. During paper unwinding, if the tension changes, the position of the floating roller (see (c) in the figure) changes, causing the sensor 9 to rotate by an angle and send a feedback signal. This adjusts the air pressure on the movable friction plate 7, changing the friction force between the movable friction plate 7 and the brake disc 5, thereby changing the web tension to ensure stability. If greater braking force is required, the fixed friction plate 8 can be adjusted to contact the brake disc 5. In the event of paper breakage or emergency stop, the air pressure is rapidly increased, causing the friction plates to lock the brake disc 5, preventing the paper roll from bunching due to inertia.

MEROBEL Brake Working Principle

The working principle of a pneumatic brake involves inputting pressurized gas into the air chamber of the pneumatic brake, which pushes the piston to perform linear motion. This presses the brake friction blocks against the brake wheel to generate friction and achieve braking. Pneumatic brakes engage via air pressure and release via return springs. The disc slides along the axial direction under air pressure to contact the friction plate. Components such as the disc and friction plate are assembled onto the hub to form an integrated structure. The friction plate can be disassembled by unscrewing the adjustment nut, making replacement simple. Pneumatic brakes are mounted on the shaft using a tapered bushing with a wedge, allowing the friction plate to be replaced while keeping the mechanical equipment intact. Cooling fins installed on the disc with the hub dissipate heat generated by friction. The friction plate is split into two halves; it can be replaced by removing the countersunk screws through the holes in the disc with the hub using a screwdriver. Pneumatic brakes have good heat dissipation properties and are widely used in packaging machinery, wire and cable equipment, thin paper, and corrugated paper industries. Pneumatic brakes are also known as air brakes, meaning an air chamber applies pressure via ventilation to tightly close the jaws for braking effect; this is widely used in industry. Pneumatic brakes are further divided into normally closed and normally open types. A normally closed brake has its jaws open when not working; when operating, air is supplied to engage the brake, forming the braking action.

MEROBEL Brake Precautions for Use

1) Install a safety cover with good ventilation or other safety measures. 2) The pneumatic brake must be used within the permissible engagement and braking work load range. Exceeding the permissible engagement and braking work load during operation will cause increased heating, reddening and overheating of the friction surface, which may lead to fire. It will also directly affect the performance of the pneumatic brake, so please ensure use within the permissible engagement and braking work load. 3) Do not arbitrarily increase the rotational speed beyond the permissible limit. Exceeding the permissible rotational speed will increase vibration and, depending on the situation, may lead to dangerous conditions such as damage or flying debris. Please ensure use below the permissible rotational speed and install a protective cover. 4) The friction plates used must not come into contact with water or oils, as this will affect torque and operational performance. 5) Before installing the pneumatic brake, confirm the surrounding environment. Places with moisture, oil, dust, vibration, impact, or high humidity will directly affect the service life and performance of the pneumatic brake. 6) When assembling the brake, try to balance the braking force and driving force on the shaft. 7) The air port of the pneumatic/hydraulic brake should be located above the brake body to facilitate air exhaust. 8) The position of the booster and hydraulic source should be higher than the brake, and the closer to the brake, the better. 9) The brake disc should be installed at the center of the brake caliper; a deviation of less than 0.2mm is preferable, and the amplitude of the brake disc should be controlled within 0.1mm. 10) Before using the pneumatic/hydraulic brake, completely exhaust the air from the brake body, loosen the exhaust port bolt, and attach a transparent hose. Note: Operate the hydraulic source at low pressure until the brake fluid fills the hydraulic cylinder (avoid rapid entry of brake fluid into the hydraulic cylinder, as this may create foam and hinder air exhaust) and flows into the transparent hose. Ensure there are no air bubbles in the hose before tightening the exhaust bolt and removing the transparent hose. Maintain sufficient brake fluid volume at all times; do not mix with other mineral oils and replace regularly. When the brake lining wears down to a thickness of only 10mm, it should be replaced immediately to avoid affecting the braking performance of the pneumatic/hydraulic brake.

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