Altra Motion - Experts & Thought Leaders

Six-axis robots have become the standard solution for automated assembly tasks due to their ability to carry out complex maneuvers. As they have grown in popularity, robot OEMs have strived to reduce the size and mass of their six-axis designs to promote space efficiency and productivity. When a German manufacturer of stepper motors was approached by a robot OEM to downsize its assemblies for a six-axis robot, they turned to Warner Electric to deliver highly compact X-Small (XS) and WR Series brakes. components and assemblies Able to approach a workpiece from any angle, six-axis robots are now a common sight on manufacturing lines. However, floor space is still at a premium, so there is a continuing design trend towards decreasing the size and mass of robots. Reducing size improves space efficiency, allowing for the addition of more robots or other equipment on the line.  Any advantage that can be gained from reducing the size and mass of components and assemblies Minimizing mass allows for six-axis robots to enhance speed and acceleration without compromising payload – which results in increased productivity. The end goal is a production line with a high density of robots, working within reduced space, delivering high output. Therefore, any advantage that can be gained from reducing the size and mass of components and assemblies must be seized by robot OEMs. Specifying an optimal robot brake This has been exemplified by a robot OEM, which asked its German supplier of stepper motors to assess downsizing opportunities for an updated six-axis robot design optimized for small component assembly. The German manufacturer quickly identified the brakes mounted on the back of each stepper motor as an area for optimization. The brakes provide static holding in precise positions, ensuring the accuracy of the assembly process. Particularly, the stepper motor controlling the sixth axis of movement, which holds and turns the tooling at the end of the robot arm, required a specialized braking solution. The manufacturer contacted Warner Electric, a pioneering brand of Altra Industrial Motion Corp., due to its exceptional expertise regarding advanced braking technologies. After collaboration with the customer’s engineering team, Warner Electric experts recommended an XS electrically released, spring-set brake to fit the stepper motor on the sixth axis. Significant size and mass advantage The XSB33S supplied to the German motor manufacturer offered a torque rating of 35 N cm Warner Electric’s range of XS brakes is specifically designed for applications where weight-saving and space efficiency are paramount. Each model offers reliable braking to an optimized torque level. Consequently, XS brakes are often specified for applications in aeronautics and robotics. It is a highly versatile range featuring six standard sizes, with Warner Electric able to customize designs to exactly match application requirements. The XSB33S supplied to the German motor manufacturer offered a torque rating of 35 N cm and a weight of only 90 g. Its design ensured a significant size and mass advantage compared to the previously utilized brake. A customized adaptor flange was also included to allow for customer-specific mounting. Delivering tangible improvement For the higher braking torques required on the other five axes of the robot, Warner Electric supplied highly compact Model WR220 and WR225 spring-applied, electrically-released brakes. These are specifically designed as statically engaged/disengaged holding brakes, ensuring reliable positioning of the robot arm in operation. With the new brakes now installed, the German motor manufacturer could approach the robot OEM with a highly optimized design that reduces footprint without compromising productivity. This delivered increased space efficiency for end users, improving available floor space and enhancing production capacity. Specific application requirements Warner Electric provides a global design, development, manufacturing, and supply service to its customers – offering standard and custom braking solutions tailored to specific application requirements. Experts worldwide work closely with customers’ engineering teams to provide products that deliver tangible operational improvements. This ensures that the special requirements of advanced industries such as robotics can be met with exact solutions.

Usage of electromagnetic brakes is becoming more common in demanding applications. From heavy-duty electrified vehicles to outdoor equipment, the traditional limitations of electromagnetic brakes are being overcome to deliver weight, performance, and maintenance advantages. At the center of this revolution is Warner Electric, which is offering OEMs access to a combination of solutions that form the next generation of electromagnetic braking systems. Mourade Vaneeckhoutte, Global Sales Director at Altra Industrial Motion Corp., explains. Controlling cost Outdoor and certain indoor applications place greater demands on an electromagnetic brake. Securing the long-term integrity of the brake in difficult conditions is important for consistent stopping performance. Ultimately, specialization is required to deliver this performance level, which in many cases, translates to an increased brake cost.  Securing the long-term virtue of the brake in difficult needs is important for a consistent version This is especially true when it comes to specifying electromagnetic brakes with a high ingress protection (IP) rating. A higher IP rating usually translates to an increased overall cost, which is before any additional options have been specified – likely in a brake that is designed for a demanding application. However, the utilization of modern composite materials is challenging this, allowing for innovative brakes to combine both high performance and value. New FRCB from Warner Electric The new FRCB from Warner Electric is a prime example. Designed with a specialized composite, the FRCB can provide highly reliable stopping performance in challenging conditions due to an IP66 rating. The result is a highly specialized brake that offers both value and performance in outdoor or demanding indoor applications. Matched with a modular design that accommodates many options – OEMs can now specify the FRCB to reduce weight and costs. However, this is achieved while still providing end users with the performance required for an optimized total cost of ownership (TOC). Consistency is key The friction material is usually tailored to provide peak-stopping version within a small operating window Like any brakes, electromagnetic brakes feature friction material. The friction material is usually tailored to provide peak stopping performance within a small operating window. While this is fine for certain applications, for heavy-duty applications where temperature and atmospheric conditions can vary greatly, this operating window compromises the consistency of braking performance. The specialization of brake friction material can therefore limit the performance of electromagnetic brakes in demanding applications. To secure consistent brake friction material performance over a wide operating window, Altra has brought the formulation of friction material in-house. This allows total control of the formulation process, which enables the operating window of the material to be widened. Range of electromagnetic brakes Furthermore, the quality consistency of the material is improved compared to sourcing from a third-party supplier. This is the exact route taken by Warner Electric. Its new W134 brake friction material has been specialized to deliver consistent performance across varying operating conditions in heavy-duty powertrain applications. Expert chemists have formulated W134 to provide static and dynamic braking functions with high torque stability, and a high friction coefficient matched by non-sticking properties ideal for outdoor applications. An exact fit for Warner’s existing range of electromagnetic brakes – W134 has been optimized to consistently carry out high-energy braking and heavy stops in all conditions. Sensitive monitoring Traditional options for brake monitoring have presented problems in several industrial applications Accurate wear monitoring is all-important for brakes in demanding applications. Ensuring that maintenance work can be carried out in a planned and efficient manner is all-important in preserving uptime. Fundamentally, actioning this structured approach to brake maintenance is dependent on the accuracy of the information supplied by the brake monitoring solution. Until now, traditional options for brake monitoring have presented problems in several industrial applications. Mechanical microswitches suffer contact pollution issues, which greatly affect the accuracy of measurement. Applications in challenging environments The other option, proximity switches, are affected by temperature which increases hysteresis and damages sensitivity. For demanding applications in challenging environments, neither is truly suited to providing accurate brake monitoring. Warner Electric Sensor ensures accurate brake monitoring as it is a contactless solution The WES (Warner Electric Sensor) ensures accurate brake monitoring as it is a contactless solution. Without relying on mechanical contact, contact pollution issues are eliminated, ensuring repeatable accuracy. Furthermore, between the operating temperatures of −40° to 105°C, hysteresis is less than 0.05 mm. Consequently, the limitations of microswitches and proximity switches are removed, allowing operators to gain highly accurate monitoring data to plan maintenance accordingly. The next-generation electromagnetic braking system While individual innovations can provide tangible benefits, combining them all within a single braking system compounds the advantage. As a pioneering brand of the Altra Industrial Motion Corp., Warner Electric’s FRCB brake range, W134 brake friction material, and the WES can all be specified together. This interoperability delivers cost-effectiveness, consistent performance, and highly accurate monitoring data within a complete assembly. The next-generation electromagnetic braking system can be supplied from a single source, providing OEMs with not only an innovative solution but a highly reliable one too.

The result of five years of independent development, Warner Electric, a brand of Altra Industrial Motion Corp., has released its new W134 brake friction material. Designed to provide consistent and reliable braking performance in a wide range of conditions integrating the W134 friction material in a Warner brake is the optimum selection for all heavy-duty powertrain applications. brake friction material Producing brake friction material that performs across a range of environmental and operational conditions is a challenging process. Usually, the friction material is specialized to operate within the pre-determined temperature and atmospheric conditions, delivering braking performance for specific applications.  reliable and consistent performance A specialized solution tailored to a variety of operating conditions is required For brake manufacturers, this presents an issue. If a brake is required to operate with reliable and consistent performance levels across a wide range of temperatures and environments – a highly focused brake friction material will not deliver. A specialized solution tailored to a variety of operating conditions is required. static and dynamic braking functions To deliver a solution, Warner Electric, a pioneer in electromagnetic brakes, has utilized its expert chemists to formulate W134 entirely in-house. From the first principle, it has been designed to deliver static and dynamic braking functions with high torque stability. Furthermore, it offers consistent performance across varying rotational speeds and a wide range of environmental conditions. outdoor applications The material is non-sticking with a high friction coefficient, making it well-suited to outdoor applications. This does not translate to increased brake wear though, with W134 optimized for high-energy braking and heavy stops due to its consistent material properties. Therefore, W134 is a perfect complement to Warner’s extensive range of high-performance brakes. brake maintenance A large manufacturing capability, strong supply networks, and engineering teams enable shortened lead times The benefits of a consistent brake friction material formula available in-house from a brake OEM are many. Total control of the formulation process ensures material quality, with Warner Electric tracking every stage of production to ensure this. A large manufacturing capability, strong supply networks, and engineering teams enable shortened lead times and responsive after-sales support. These ensure uptime is promoted and brake maintenance is shortened and simplified. easy access By specifying a Warner brake, brake operators can source a reliable product fitted with an optimal friction material that removes the fluctuations in performance often found in specialist materials. Supported by the combination of global capability and localized service centers inherent to Altra – operators of brakes in heavy-duty applications have easy access to a solution that delivers tangible application advantages.