Selecting a Caliper Disc Brake for Your Industrial Application

Nov. 27, 2024

Selecting a Caliper Disc Brake for Your Industrial Application

Caliper disc brakes are incredibly versatile. They can slow, hold, and stop very heavy and/or fast-moving units quickly. For this reason, they are well-suited to applications that require high torque, high energy stopping, and/or tensioning. Caliper disc brakes absorb the generated energy of the braking process, then dissipate that energy as heat. Here is an overview of each type of brake and what it does best, to help you in selecting the right kind for your application.

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Pneumatic Brakes

Pneumatic brakes are powered by compressed air. Because many industrial spaces have &#;shop&#; air available, these are a popular option. Pneumatic industrial caliper disc brakes are often used to slow, stop, or hold rotating or linear moving parts. They usually operate around 70-120 PSI and max out at 200 PSI, as opposed to hydraulic brakes which operate at higher pressures. W.C. Branham offers many pneumatic brake options to fit a wide range of braking force requirements.

Hydraulic Brakes

Hydraulic brakes are powered by compressed fluid &#; hydraulic oil in the case of most industrial equipment. Hydraulic brakes are designed to withstand higher pressures, which allow for maximum braking force, so they are ideal when you need to stop, hold, or tension equipment with higher torque. Hydraulic brakes are standardly used in mining, agricultural, or similar heavy duty equipment. As a standard, W.C. Branham brakes are designed with seals to be used with hydraulic oil, but we do offer options where automotive brake fluid is used.

If you have shop air but need the higher pressure capability of hydraulic brakes, you can purchase air/oil intensifiers that convert shop air into hydraulic pressure. This cost-friendly solution allows you to use hydraulic industrial caliper brakes even if you have no hydraulic pressure source.

Pneumatic or Hydraulic Spring Applied Brakes

Spring applied brakes work differently. Instead of directly-applied pressure, internal springs apply braking pressure. The springs maintain tension until the spring is pressurized. The actuating power source can be either hydraulic or pneumatic. W.C. Branham carries one of the widest selections of both in the market.

These types of brakes are best for emergency stop applications and are often referred to as &#;fail-safe&#;or &#;E-stop&#; brakes in industrial settings. There are many combinations of pneumatic and hydraulic spring applied brake options.

Mechanical Brakes

Mechanical brakes operate with a simple lever and require no external power source. This series of brakes exerts braking force effectively to objects in rotary or linear motion and are often used in manufacturing applications where air or hydraulics are not available or not needed. A good example is an industrial cart that requires manual braking with a lever. We offer several mechanical brake options that feature cast or extruded aluminum construction, hard coated housings, and replaceable, non-asbestos friction pads.

Which industrial caliper brake is right for your application?

In an earlier blog article we talked about how to choose the right size caliper disc brakes, but prior to sizing the brake it is important to determine the right kind of brake. To do that, you need to know your:

power source: pneumatic,hydraulic or manual;
braking needs: stopping or holding (or both), emergency stopping, tensioning;
application: breaking linear rail or rotor;
potential space constraints or mounting requirements.

Brake Sizing Can Determine Braking Power

In most cases, you can vary the disc diameter, number of calipers per disc, and actuating pressure to achieve your application&#;s specific stopping or holding requirements. Increasing caliper piston size increases clamping pressure, but overly-large pistons can cause the brakes to lock up.

You can mount calipers in a fixed position, in which case the caliper will operate using opposing inner and outer pistons to apply pressure equally from both sides. Calipers can also float, mounted on a pin that is attached to the spindle.

Options are particularly important when it comes to industrial caliper brake design, because optimum braking ensures safe, reliable, and efficient equipment operation. You can learn more in this product guide.

Right-sizing your brake will assure braking power and performance without sacrificing cost-effectiveness. You need the right diameter disc as well as the right brake. The larger the diameter, the greater the braking torque. We&#;ve pulled together all the data tables and formulas you&#;ll need to do the calculations, plus some helpful tips, in this caliper disc brake sizing guide. Download the guide and keep it handy for future reference. It&#;ll help you get the braking force you need without overspending.

Every Design Starts with a Need &#; and an Idea

At W.C. Branham, tech support doesn&#;t start after the sale, it starts the moment you have a question or need a detailed consultation regarding options. While detailed specs for all our products are available online, our engineers and manufacturing experts are also here to help. So why not take advantage of their experience and insight?

You can run your idea by us to get specific recommendations. We can modify nearly all our standard products to fit your specs, but we are also the go-to-resource when you need a unique design. We respond quickly, and we use the latest 3D software. Our goal is to help you create the most efficient, cost-effective solution, no matter the application.

Are you interested in learning more about Non-contact rotary caliper? Contact us today to secure an expert consultation!

What Are the Best Brake Calipers for My Vehicle?

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Choosing the best brake calipers for your vehicle can feel overwhelming. With so many options on the market, it can be difficult to know if you&#;re making the right choice.

When it comes to your vehicle&#;s performance and safety, calipers play an essential role. They help your vehicle stop on a dime, especially when it matters most.

Understanding the Function of Brake Calipers

Brake calipers are integral components of your vehicle&#;s braking system. They are responsible for clamping down on the brake pads, which then press against the rotors to create the friction needed to slow down or stop the vehicle. As your vehicle&#;s forward momentum is converted into heat energy through this friction, the brake calipers play a crucial role in ensuring that this process is efficient and controlled.

Factors to Consider When Choosing the Best Brake Calipers for Your Vehicle

When looking for the best brake calipers for your vehicle, here are some essential factors to consider:

Compatibility: Ensure that the new calipers are compatible with your vehicle&#;s make and model.
Budget: Consider your budget and research options that offer the best value for your specific needs.
Brand and Quality: Opt for a reputable brand, like PowerStop, that is known for high-quality brake components. Quality calipers are more likely to perform well and last longer, providing better safety and longevity.
Coating: Some calipers come with a protective coating, such as powder coating, to resist corrosion and enhance durability. This can be particularly important if you live in a region with harsh weather conditions.
Piston Number and Size: Different calipers have varying numbers and sizes of pistons. Larger pistons provide more stopping power, so consider your driving habits and needs. Some performance vehicles may benefit from multi-piston calipers.

PowerStop Powder Coated Calipers

PowerStop Powder Coated Calipers are ideal for any situation daily drivers may experience on the road. They are precision-engineered to fit your vehicle seamlessly, eliminating the need for any modifications. As an added bonus, the powder coating helps resist rust & corrosion.

Notable features of these calipers include:

100% Pressure Tested: All calipers are pressure tested to prevent leaks and thoroughly inspected for quality and safety.
Brand New Components: Bleeder screws and pad attachment hardware complement remanufactured calipers and brackets.
High-Temperature EPDM Rubber: High-temperature EPDM rubber extends life.
Premium Silicone Lubrication: Premium silicone lubrication provides smoother operation.

PowerStop Autospecialty OE Replacement Brake Calipers

PowerStop is committed to providing top-quality performance brakes for nearly every vehicle on the road; that&#;s why we proudly offer PowerStop Autospecialty OE Replacement Brake Calipers that are precision-made to fit your vehicle. Sold individually, these calipers bolt on directly in place of stock calipers. All of the calipers are 100% pressure tested for leaks and inspected for overall quality and safety.

Included are all-new premium boots, seals, and high-temperature silicone lubricant for a complete, easy replacement for your vehicle&#;s stock calipers.

Signs of Brake Caliper Malfunction

Brake calipers are designed to endure more miles and driving than other braking components such as brake pads. Nevertheless, there are instances where this longevity expectation is not met. When a brake caliper malfunctions, it can lead to accelerated wear on the brake pads.

Brake Fluid Leakage Near the Tire Area

Modern braking systems rely on hydraulic pressure for operation. When a caliper leaks, you may detect the presence of oily patches on the ground close to your tires. However, it&#;s important to note that the issue might not be directly related to the caliper. Consulting with a trained technician can help to accurately diagnose and rectify the problem.

Uneven Brake Pad Wear

If you observe uneven wear on your brake pads, with one side noticeably thinner than the other, there&#;s a possibility that the brake caliper is to blame. To address this issue, it&#;s advisable to take your vehicle to an auto repair shop where a skilled technician can assess the problem.

High-Pitched Squealing or Metallic Grinding Noises

If you hear strange sounds coming from one of your brakes while you&#;re driving, it might be a sign that the brake caliper is stuck or not working properly. This is different from brake pad problems, which usually make noise when you press the brakes. If you ignore a stuck caliper, it could eventually cause your brakes to completely stop working, so it&#;s important to get it checked as soon as possible.

Vehicle Drifts or Pulls to One Side During Driving or Braking

Brake calipers house pistons that respond to hydraulic pressure from the master cylinder, enabling the brake pads to engage and release the brake rotor. If these pistons become immobilized due to debris or corrosion, the brake pads may struggle to either disengage from the rotor or make proper contact. In the former case, your vehicle will pull towards the side with the problematic caliper. In the latter case, the vehicle will veer away from the affected side, whether during braking or regular driving.

Audible Clunking Sound

While this symptom is less common than the others, it&#;s possible that a malfunctioning bracket holding the brake caliper in place could be the culprit. In these cases, the defective bracket generates a noticeable clunking sound during vehicle operation. If you encounter this situation, do not drive the vehicle, as it could result in a complete brake lockup, posing a severe safety risk to both the driver and other road users.

Have a Question? PowerStop Can Help

PowerStop is dedicated to delivering top-quality performance brakes for nearly every vehicle on the road. If you have a question about any of our products, contact us today online at [ protected] or toll-free at (888) 863-. Our customer service team is available to answer your questions Monday through Friday from 8 a.m. to 5 p.m. (CST). Se habla español.

For more information, please visit Fully automatic online surface defect detection equipment with advanced sensors.

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