YPZ2-630×30II/E121-L-MSK1 Electro-Hydraulic Disc Brake - Working Principle & Applications

The YPZ2-630×30II/E121-L-MSK1 is a heavy-duty fail-safe brake designed for large-scale machinery, relying on spring-engaged braking + electro-hydraulic release with dual-caliper synchronization to deliver ultra-high torque and reliable protection. Below is its detailed working principle and typical applications:

1. Working Principle

It adheres to a fail-safe design-prioritizing automatic braking in faults while enabling smooth release for normal operation, with three core states:

1.1 Brake Engagement (Default Safety State)

When the machinery is stationary, powered off, or in emergency mode, high-tension 60Si2MnA disc springs (two sets, one per caliper) expand outward.

The total spring force (600–800 kN) pushes the dual calipers' dual-sided ceramic-metallic pads to clamp symmetrically against the 630 mm diameter, 30 mm thick 42CrMo alloy steel disc.

Friction between the pads and disc generates 1200–1800 kN·m nominal braking torque, stopping the rotating shaft or holding extra-heavy loads firmly without displacement.

1.2 Brake Release (Operating State)

When the machinery needs to run, the matched E121 electro-hydraulic thruster (7.5 kW motor) is activated, converting electrical energy into 20–28 MPa hydraulic pressure.

The thruster's 1210 N linear thrust overcomes the disc spring force, and a synchronous linkage mechanism retracts both calipers' pistons and pads simultaneously. A precise 0.5–1.2 mm clearance is created 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 E121 thruster's pressure dissipates instantly.

The disc springs rebound within ≤0.2 seconds, driving both calipers to re-clamp the disc synchronously-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 20 mm) per caliper, maintaining consistent clearance and stable torque output.

Dual-Caliper Synchronization: Symmetric clamping ensures balanced force distribution, avoiding disc warping and extending disc service life.

High Thermal Stability: Large disc surface area and 700°C heat-resistant pads prevent thermal fading during high-frequency braking.

2. Typical Applications

Designed for 1000–3000 ton heavy-duty machinery in extreme industrial environments, its applications focus on safety-critical scenarios requiring high torque, stability, and harsh-environment adaptability:

2.1 Mining Industry

Large Mine Hoists: Underground/above-ground ore hoists (100–150 ton load capacity) - provides emergency braking and static load holding during power outages, withstanding dusty, humid mine environments (IP67 protection).

Extra-Long Inclined Conveyors: Coal, iron ore, or limestone conveyors (bandwidth ≥1600 mm, slope ≤35°) - stops quickly during blockages to avoid belt tearing or material spillage.

2.2 Port Machinery

Ship-to-Shore (STS) Cranes: Handles 120–180 ton container loads - ensures stable braking during positioning and windproof holding when parked, resisting coastal salt spray via anti-corrosion coating.

Large Stacker-Reclaimers: Bulk material handling equipment in ports/quarries - adapts to high-frequency start-stop cycles and heavy dust, maintaining reliable performance.

2.3 Metallurgical Industry

Steel Mill Main Drives: Hot rolling mill main shafts and large ladle transfer cars - withstands ambient temperatures up to 130°C, ensuring precise positioning of molten steel ladles.

Non-Ferrous Metal Smelting Equipment: Large ore crushers and rotary kilns - resists industrial dust and high temperatures while delivering consistent braking torque.

2.4 Heavy-Duty Conveyors & Winches

Power Plant/Quarry Conveyors: Bulk material conveyors (coal, ore) with ≥800 ton load - stops smoothly to prevent equipment damage from inertial impact.

Heavy Winches: 100–150 ton electric winches in construction sites/offshore platforms - provides reliable load holding during lifting and emergency stopping to prevent load slippage.

Application Core Characteristics

Load Capacity: Adapts to 1000–3000 ton 级 machinery, matching high-torque demands of large-scale industrial equipment.

Environmental Adaptability: Operates in -35°C to 130°C, resists heavy dust, humidity (≤95%), salt spray, and strong vibration (≤5g).

Duty Cycle: Withstands S3-80% high-frequency braking cycles, suitable for 24/7 continuous industrial workflows.

 

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