YP Series Electro-hydraulic Disc Brakes YP1-800-450*20

 

The YP1-800-450×20 is a heavy-duty fail-safe brake core to large-scale machinery safety, relying on spring-engaged braking + electro-hydraulic release for ultra-high torque output and reliable protection. Below is its detailed working principle and typical applications:

1. Working Principle

It operates on a fail-safe design-prioritizing automatic braking in faults while enabling smooth release for normal operation, with three key states:

1.1 Brake Engagement (Default Safety State)

When the machinery is stationary, powered off, or in emergency mode, internal high-tension 60Si2MnA disc springs expand outward.

The spring force (400–500 kN) pushes the single caliper's dual-sided friction pads to clamp tightly against the 450 mm diameter brake disc (20 mm thick).

Friction between the ceramic-metallic pads and 42CrMo alloy steel disc generates 800 kN·m nominal braking torque, stopping the rotating shaft or holding heavy loads firmly.

1.2 Brake Release (Operating State)

When the machinery needs to run, the integrated electro-hydraulic actuator (5.5 kW motor) is activated, converting electrical energy into 18–25 MPa hydraulic pressure.

Hydraulic thrust overcomes the disc spring force, retracting the caliper piston and pads to create a 0.5–1.0 mm clearance between pads and disc.

The disc rotates freely with the machinery shaft, enabling normal operation (e.g., crane hoisting, conveyor movement) without drag friction.

1.3 Emergency Response (Fault State)

In power loss, hydraulic leakage, or emergency shutdown, the actuator's pressure dissipates instantly.

The disc springs rebound within ≤0.25 seconds, driving the pads to re-clamp the disc-engaging full braking torque to stop the machinery immediately and avoid catastrophic accidents.

Key Design Support for Working Principle

Automatic Wear Adjuster: Compensates for pad wear (up to 15 mm) to maintain consistent clearance, ensuring stable torque output.

Uniform Force Distribution: Single-caliper dual-sided clamping avoids disc warping, extending disc service life.

High Thermal Stability: Large disc surface area and heat-resistant pads (up to 650°C) prevent thermal fading during high-frequency braking.

2. Typical Applications

Designed for 800–2500 ton heavy-duty machinery in harsh industrial environments, its applications focus on safety-critical scenarios requiring high torque and reliability:

2.1 Mining Industry

Large Mine Hoists: Underground/above-ground ore hoists (50–100 ton load capacity) - provides emergency braking and static load holding during power outages, withstanding dusty, humid mine environments.

Extra-Long Inclined Conveyors: Coal, iron ore, or limestone conveyors (bandwidth ≥1200 mm, slope ≤30°) - stops quickly during blockages to avoid belt tearing or material spillage.

2.2 Port Machinery

Ship-to-Shore (STS) & Gantry Cranes: Handles 80–120 ton container loads - ensures stable braking during positioning and windproof holding when parked, resisting coastal salt spray (IP66 protection).

Stacker-Reclaimers: Large bulk material handling equipment in ports/quarries - adapts to high-frequency start-stop cycles and heavy dust.

2.3 Metallurgical Industry

Steel Mill Main Drives: Hot rolling mill main shafts and large ladle transfer cars - withstands ambient temperatures up to 120°C, ensuring precise positioning of molten steel ladles.

Non-Ferrous Metal Smelting Equipment: Large ore crushers and powder mixers - resists industrial dust and high temperatures while maintaining reliable braking.

2.4 Heavy-Duty Conveyors & Winches

Power Plant/Quarry Conveyors: Bulk material conveyors (coal, ore) with ≥500 ton load - stops smoothly to prevent equipment damage from inertial impact.

Heavy Winches: 50–100 ton electric winches in construction sites/offshore auxiliary equipment - provides load holding during lifting and emergency stopping to prevent load slippage.

 

 

 

 

 

Hot Tags: yp series electro-hydraulic disc brakes yp1-800-450*20, China, manufacturers, supplier, factory, customized