YP21–560 Series Electro-hydraulic Disc Brakes

The YP21–560 series electro-hydraulic disc brake is a high-performance, heavy-duty braking device developed for large-scale industrial machinery. It integrates hydraulic drive and mechanical braking, featuring automatic wear compensation, stable braking torque, and modular design. As a core product in the YP series (Summaries 1, 2, 5), it is specifically engineered for deceleration, emergency stopping, and parking braking of large loading/unloading equipment, lifting transport machinery, metallurgical devices, and mining machinery-delivering reliable performance in harsh industrial environments.

Core Technical Specifications

Parameter	Standard Value	Notes
Brake Type	Electro-hydraulic disc brake (spring-applied, hydraulic-released)	Fail-safe design: brakes automatically on power/hydraulic failure
Rated Disc Diameter	560 mm	Matches large machinery's high-torque braking needs
Braking Torque Range	3200–9200 N·m	Adjustable externally (refer to USB3-III series torque logic, Summary 3); adapts to heavy-load scenarios
Actuation Principle	Hydraulic release via electro-hydraulic thruster	Thruster model matches E-series (e.g., ED50/6) for stable pressure output
Key Functional Features	- Automatic lining wear compensation- Automatic shoe clearance balancing- PLC interlock protection (via limit switches)	Reduces manual maintenance; ensures consistent braking performance (Summary 5)
Protection Class	IP54/IP65 (optional)	Dustproof, water-resistant; suitable for dusty, humid mining/metallurgical environments
Working Conditions	- Ambient Temperature: -20℃～+50℃- Relative Humidity: ≤90%- Duty Cycle: S3-60% (intermittent heavy load)	No flammable/explosive gases (for non-explosive industrial areas)
Lining Material	Non-asbestos high-temperature composite	Friction coefficient ≥0.38; low fading (≤15% at 250℃); long service life (≥3000 working hours)
Installation Style	Modular mounting	Compatible with standard industrial machinery interfaces; easy to assemble/disassemble
Weight (w/o Thruster)	~180–220 kg	Robust structure for heavy-duty operation

Key Structural & Functional Advantages

Fail-Safe Spring-Applied BrakingThe brake adopts a spring-applied, hydraulic-released design (consistent with USB3-III series logic, Summary 3). When power or hydraulic pressure is lost, high-strength disc springs drive the brake calipers to clamp the 560 mm disc instantly, generating up to 9200 N·m of braking torque. This prevents equipment slipping or runaway-critical for heavy-load machinery like port cranes and mining conveyors.

Dual Automatic Adjustment Mechanisms

Automatic Wear Compensation: As the friction lining wears, an internal mechanical compensator dynamically adjusts the caliper stroke, maintaining a stable brake-disc clearance (0.8–1.2 mm) without manual intervention. This avoids torque loss and ensures consistent braking (Summary 5).

Automatic Clearance Balancing: The symmetric caliper design and linkage mechanism ensure equal clearance on both sides of the disc, eliminating uneven wear caused by one-sided contact and extending the disc's service life.

Modular & Low-Maintenance Design

Modular components (caliper, thruster, limit switch) allow independent replacement, reducing maintenance time by 40% compared to integrated brakes (Summary 4).

Self-lubricating hinges and sealed hydraulic joints minimize wear and oil leakage, lowering maintenance frequency. The non-asbestos linings use a clip-on structure for quick replacement (≤15 minutes per set).

PLC Interlock Safety ProtectionEquipped with multiple limit switches (release confirmation, lining wear alarm) that send real-time signals to the host PLC (Summary 5). If the brake fails to release or linings are excessively worn, the system triggers an emergency shutdown-preventing mechanical damage or safety accidents.

Working Principle

The YP21–560 operates on the "hydraulic release + spring braking" core logic, coordinated with an electro-hydraulic thruster:

Brake Release (Equipment Operation)When the host machinery starts, the electro-hydraulic thruster is energized. Its motor drives a hydraulic pump to build pressure, pushing the piston rod to extend. The rod acts on the brake caliper's lever mechanism, overcoming the pre-tightening force of the disc springs. This pulls the calipers apart, separating the friction linings from the 560 mm disc-allowing the equipment to run smoothly.

Brake Application (Stopping/Emergency)

Normal Stopping: The control system reduces thruster pressure, and the disc springs gradually push the calipers inward. The linings make contact with the disc, generating adjustable torque (3200–9200 N·m) to decelerate the equipment stably.

Emergency Braking: In case of power failure or hydraulic system malfunction, thruster pressure drops instantly. The disc springs fully engage, clamping the disc tightly to stop the equipment within ≤0.6 seconds-meeting safety standards for heavy machinery.

Wear Compensation ProcessAfter repeated braking, lining wear increases the disc-lining gap. The automatic compensator's ratchet-pawl mechanism triggers during each braking cycle, extending the caliper's stroke to reset the gap to the standard range. This ensures consistent braking torque without manual adjustment.

Typical Applications

Aligned with YP series application scenarios (Summaries 2, 5, 6), the YP21–560 is widely used in:

Port & Loading/Unloading Machinery

Large container cranes, gantry cranes, and ship unloaders: Provides high-torque braking for lifting and travel mechanisms, ensuring precise positioning of heavy containers (up to 50 tons) and resistance to wind loads.

Bulk material handlers (coal, ore): Adapts to dusty port environments (IP65 optional) and handles frequent start-stop cycles.

Mining & Metallurgical Equipment

Mine winders and belt conveyors: Delivers reliable emergency braking to prevent conveyor reversal on inclined shafts; the high-temperature linings (resistant to 250℃) withstand heat from long-term use.

Metallurgical rolling mills and blast furnace charging machines: Handles heavy loads and vibration, ensuring stable braking during steel production processes.

Lifting & Construction Machinery

Large bridge cranes and 塔式起重机 (tower cranes): Ensures safe parking of heavy loads (e.g., prefabricated building components) and smooth deceleration during lifting.

Construction site concrete mixers and pile drivers: Adapts to outdoor humid environments, with modular design facilitating on-site maintenance.

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