A new generation of brakes for demanding machine applications

Warner Electric’s latest Gen4 range has been designed to suit demanding, high speed applications, offering high torque density, low response time and a 100% duty cycle at rated torque.

Warner Electric has built more than 90 years of design and manufacturing experience into its latest Gen4 range of spring operated, electromagnetically released brakes. The new design offers exceptional performance and longevity in a compact form factor, together with features and options that maximise flexibility and ease of integration for customers

Spring operated, electromagnetically released disc brakes are a rugged and reliable solution for the control of rotating machinery in a diverse range of applications. Warner Electric – part of the Altra Industrial Motion Corporation – has been building electrically operated brakes since 1927, and it continues to refine and improve its design to meet the changing needs of customers around the world.

The company’s latest Gen4 range has been designed to suit demanding, high speed applications, offering high torque density, low response time and a 100% duty cycle at rated torque. The brake is available in single or dual disc variants in five standard disc diameters with nominal torques ranging from 200Nm to 3,200Nm. All but the largest sizes in the range are suitable for operating speeds up to 4,700rpm. The Gen4 brakes incorporate wear compensation features for an exceptionally long operating life, and a built-in wear sensor means users can monitor brake condition during operation for assured reliability. Integration with sophisticated machine control systems is further assisted by a release detection microswitch, and the brakes are built with holes to permit the mounting of a rotatory encoder for speed monitoring.

Designed for tough environmental conditions, the Gen4 brakes are protected to IP67 standards and rated to operate in ambient temperatures from -40°C to +50°C and up to 100% humidity. They are available with marine certification on request.

Warner offers a comprehensive range of configuration options to allow users to tailor the Gen4 brakes to the requirements of their applications. Those options include single or dual voltage operation, radial or axial cable output, the addition of an internal or external hand lever, as well as a multiple disk configuration. The units can be manufactured with alternative hub dimensions to suit user requirements and standard EN 50347 mounting flanges can also be provided. Options to suit demanding operating environments include the incorporation of an ant-condensation heater and an IP67-rated breather.

Thanks to Warner’s investment in highly flexible, lean manufacturing operations, custom brakes can be manufactured with short lead times in volumes that suit customer requirements.

About Warner Electric
For over 70 years, Warner Electric has grown to become a global leader in electromagnetic clutch & brake solutions. Warner engineers utilise the latest design, materials and manufacturing technologies to develop easy-to-use and install clutches and brakes with longer life and improved accuracy and repeatability. Warner Electric offers the broadest selection of industrial clutches, brakes, controls, web tension systems, sensors and switches available from a single manufacturer.

Reliable Warner Electric components are used in a very wide range of markets including material handling, packaging machinery, food & beverage, elevator & escalator, turf & garden, agriculture and off-highway, forklift, crane and motion control. Applications include conveyors, lift trucks, wrapping machines, servo motors, capping equipment, combines and balers, baggage handling systems, military vehicles, hoist drives and lawn mowers.