High Quality DLZ Series Power-driven Wheel Brakes

 

 

1. Series Overview & Core Function

The DLZ Series (D = Direct Wheel-Mounted, L = Load-Adaptive, Z = Power-Driven) is distinguished by its multi-power compatibility and wheel-centric design, setting it apart from single-actuation brakes. Its core functions align with the safety and operational needs of wheeled machinery:

Dynamic Wheel Braking: Decelerating or stopping wheeled equipment (e.g., mobile cranes, industrial trucks) with controlled torque to avoid skidding, load sway, or component damage-critical for navigating tight spaces or uneven terrain.

Static Wheel Holding: Securing machinery in place during downtime, maintenance, or on inclines (e.g., parking construction trucks on slopes, locking port transporter wheels during cargo loading).

Emergency Braking: Automatically engaging in power system faults (e.g., pressure loss, electrical failure) or overspeed to prevent equipment runaway, serving as a safety barrier for high-risk operations.

The series offers three actuation variants to match machinery power sources: DLZ-E (Electric), DLZ-H (Hydraulic), and DLZ-P (Pneumatic), ensuring seamless integration across different industrial environments.

2. Working Principle

The DLZ Series operates on a power-driven clamping principle, where electric, hydraulic, or pneumatic power drives brake pads to clamp onto the wheel rim or a hub-mounted brake disc. While actuation power differs by variant, the core working cycle is consistent:

2.1 1. Brake Release (Normal Operation)

When the machinery is in motion, the control system activates the brake's power unit (electric motor, hydraulic cylinder, or pneumatic cylinder).

The power unit generates force to retract the brake pads, creating a gap (0.4–0.8mm) between the pads and the wheel rim/disc. The wheel rotates freely, enabling normal travel or operation.

2.2 2. Brake Engagement (Controlled Stopping/Holding)

Controlled Stopping: To slow or stop the machinery, the control system reduces power input to the actuation unit. Internal return springs (or reduced pressure/voltage) push the brake pads against the rotating wheel interface.

Torque Generation: Friction between the pads and wheel rim/disc generates braking torque, with force proportional to the power input-allowing smooth, adjustable deceleration (e.g., industrial trucks moving fragile cargo).

Static Holding: For long-term parking or load security, power to the actuation unit is cut off. Return springs (or mechanical locks) keep the pads clamped to the wheel, maintaining torque without consuming energy.

2.3 3. Emergency Braking (Fault Scenarios)

In case of power system failure (e.g., hydraulic leak, pneumatic pressure loss, electrical short) or overspeed (detected by wheel speed sensors), the brake engages instantly.

Backup springs or redundant power reserves (e.g., hydraulic accumulators for DLZ-H) drive the pads against the wheel with maximum force, generating peak torque to stop the wheel within ≤ 1.2 seconds (under rated load)-preventing accidents.

3. Core Structure & Key Components

The DLZ Series features a modular, wheel-adaptive design with shared structural components and variant-specific actuation units:

3.1 Shared Components (Across All Variants)

Wheel Braking Assembly:

Brake Pads: Arc-shaped composite pads (material varies by variant: resin-semi-metallic for DLZ-E/P, ceramic-semi-metallic for DLZ-H) with a friction coefficient (μ ≥ 0.42–0.48) and heat resistance up to 400°C. Pads are bolted to a carrier ring for easy replacement.

Braking Interface: Dual-compatible design for wheel rims (300–1,200mm diameter) or hub-mounted discs (thickness: 15–40mm), adapting to different machinery wheel configurations.

Carrier Ring: High-strength steel ring that distributes clamping force evenly across the wheel interface, avoiding uneven wear and ensuring stable torque output.

Return & Safety Mechanism:

High-Tension Return Springs: Manganese-steel springs that provide fail-safe engagement force when power is cut off, ensuring basic braking capability in all fault scenarios.

Wear Adjusters: Automatic or manual screws that compensate for pad wear, maintaining a consistent brake gap (0.4–0.8mm) and eliminating frequent re-calibration.

Protection Components:

Environmental Housing: Steel or aluminum casing with IP64/IP65 protection (IP65 for outdoor variants) to resist dust, moisture, and mild impact-suitable for both indoor (warehouses) and outdoor (construction) use.

Anti-Corrosion Coating: Epoxy resin coating (80–100μm thickness) on metal parts to resist rust and chemical exposure (e.g., port salt spray, mining dust).

3.2 Variant-Specific Actuation Units

DLZ-E (Electric Actuation):

An electric motor (0.75–3.0 kW) paired with a gearbox and lead screw. The motor drives the screw to retract/extend the pad carrier, converting electrical energy into linear clamping force. Ideal for indoor machinery (e.g., warehouse transporters) with accessible AC power (380V/220V).

DLZ-H (Hydraulic Actuation):

1–4 double-acting hydraulic cylinders (working pressure: 12–25 MPa) mounted circumferentially around the wheel. Pressurized hydraulic fluid drives cylinder pistons to control pad movement. Suited for heavy-duty outdoor machinery (e.g., mobile cranes, construction trucks) with existing hydraulic systems.

DLZ-P (Pneumatic Actuation):

1–4 pneumatic cylinders (working pressure: 0.6–1.0 MPa) that use compressed air to actuate the pad carrier. Designed for machinery in factories or ports with readily available compressed air (e.g., port transporters, assembly line trucks).

4. Key Features & Advantages

The DLZ Series stands out for its versatility and adaptive performance, with core benefits across all variants:

4.1 1. Multi-Power Compatibility

Offering electric, hydraulic, and pneumatic actuation variants eliminates the need for custom power system modifications, reducing integration costs and ensuring compatibility with diverse machinery (e.g., DLZ-H for hydraulic excavators, DLZ-E for electric warehouse trucks).

4.2 2. Direct Wheel-Mounted Efficiency

By clamping directly onto the wheel rim or hub disc, the brake eliminates torque loss through transmission shafts-delivering 15–20% higher braking efficiency compared to shaft-mounted brakes. This ensures faster response and more precise control for heavy loads.

4.3 3. Load-Adaptive Torque

Braking torque is adjustable via power input (e.g., voltage for DLZ-E, pressure for DLZ-H/P), allowing operators to match force to load demands-preventing over-braking (e.g., for fragile cargo) or under-braking (e.g., for heavy loads).

4.4 4. Low Maintenance & Durability

Modular design allows independent replacement of actuation units or brake pads, reducing maintenance time by 30% compared to integrated brakes.

High-quality friction pads and sealed actuation components ensure a service life of ≥ 8,000–12,000 working hours (varies by variant), lowering long-term operational costs.

4.5 5. Safety Compliance

Meets global industrial safety standards, including ISO 3450 (hydraulic/pneumatic wheel brakes), IEC 60034 (electric actuation safety), GB/T 13329 (Chinese wheel brake standards), and CE (EU Machinery Directive). DLZ-H/P variants for mining also comply with ATEX explosive environment regulations (optional).

5. Typical Applications

The DLZ Series adapts to diverse machinery via its multi-power variants, with key use cases by model:

Variant	Applications
DLZ-E	Indoor industrial trucks, warehouse transporters, electric mobile cranes (20–50 tons), and automated guided vehicles (AGVs) for logistics.
DLZ-H	Heavy-duty construction vehicles (dump trucks, mobile cranes), mining auxiliary trucks (50–200 tons), and port RTG crane travel wheels.
DLZ-P	Port container transporters, factory assembly line trucks, and light-to-medium duty construction carts (30–80 tons) with compressed air systems.

 

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