Background:
A local systems integrator contacted Hindon for assistance supporting a Western U.S. aluminum mill by upgrading their slitter machine to include a more robust and reliable holding brake system. A slitter is an adjustable cutting machine used to efficiently slice large rolls of aluminum to a specified width. Slitters typically consist of three main components: an unwind section to secure and feed the parent roll, a slitting section to cut the material, and a rewind section to collect the rolls after they have been cut.
Aluminum slitters are commonly used to slice sheets of aluminum to specified widths
Upon contacting Hindon, the end user was relying on the rewind motor brake to hold the slitter drivetrain while the machine was not in use, but was experiencing frequent failures of the motor brake, which was expensive to replace and had a lengthy lead time. This type of failure is common in high cycle applications where a motor brake experiences significant pad wear due to timing issues and using the brake to stop the load instead of only holding it. In search of a new, more robust braking solution that could be easily installed without changing the location of the existing motor, the customer contacted Hindon for support.
Application Challenges:
- Evaluating the failure of the previous braking system and determining new requirements for a reliable, robust braking system
- Retrofit solution designed around existing dimensional constraints and does not require changing the location of the existing motor
Rough 3D model of the application illustrating the positioning of the motor, gearbox, and disc braking system. This model was used to help check for potential interferences between the customer’s existing equipment and Hindon’s proposed braking system.
Solution:
Leveraging readily available shop air, a pneumatic disc brake system offered the client a simple and economical solution. The spring-applied, pneumatically released design provided reliable fail-safe operation, reverting to a secure state if air pressure is lost, preventing potential hazards or damage. Compared to hydraulic counterparts, pneumatic systems are cleaner, less susceptible to leaks, and offer a simpler design, leading to reduced maintenance requirement. Their relatively lightweight and compact nature makes pneumatic disc brakes an ideal, cost-effective choice for tight spaces in applications with lower braking torque demands, making them particularly well-suited for holding brake applications.
To avoid repositioning the existing motor and since the customer already used a gear type coupling in the application, Hindon also designed and supplied a new double engagement gear coupling integrated with a 400mm diameter x 15mm thick brake disc. Engineered for durability, this coupling excels at handling high torque and speed, making it ideal for challenging, space-constrained heavy-duty applications that demand flexible connections. Its design simplifies on-site installation and reduces upkeep by preserving the shaft and gearbox alignment. This solution successfully met the braking torque demands and spatial restrictions, all while providing ease of installation and long-term serviceability.