SBD365-C-2200*40IRL Safety Brake

 

1. Model Interpretation & Core Function

The SBD365-C-2200×40IRL's model code directly reflects its design orientation and performance parameters, facilitating quick equipment matching:

Model Segment	Meaning
SBD	Safety Brake Design (fail-safe, spring-engaged, hydraulic-released type)
365	Nominal braking torque: 365 kN·m (for ultra-heavy load machinery)
C	Heavy-Duty Reinforced Series (reinforced structure, high torque capacity, harsh-environment adapted)
2200	Compatible brake disc diameter: 2200 mm (large-disc design for uniform pressure distribution)
40	Compatible brake disc thickness: 40 mm (high-strength alloy steel, wear-resistant)
I	Integrated Actuation (hydraulic cylinder, caliper, and valve block integrated design)
RL	Mounting orientation: Right-Left dual-compatible (flexible installation for diverse layouts)

Its core functions target safety-critical scenarios requiring ultra-high reliability:

Emergency Stopping: Rapidly decelerating or stopping machinery within ≤ 0.3 seconds under rated load (e.g., mine hoist overspeed, crane load swing).

Static Load Holding: Securing extra-heavy loads (e.g., 80-ton containers, hoisted ore batches) during downtime, maintenance, or power outages-preventing accidental movement.

Overload & Fault Protection: Automatically engaging in power loss, hydraulic leakage, or abnormal torque (detected by sensors), acting as the final safety barrier to avoid equipment collapse or catastrophic accidents.

2. Working Principle

The SBD365-C-2200×40IRL operates on a fail-safe principle (spring-engaged for braking, hydraulic pressure for release), ensuring braking capability even if the actuation system fails. Its working cycle includes three key states:

2.1 Brake Engagement (Safety State)

When the machinery is stationary, in emergency, or powered off, internal high-tension disc springs (60Si2MnA alloy steel, stacked in parallel) expand.

The springs push the integrated dual-sided calipers toward the rotating brake disc, clamping the disc between high-performance friction pads.

Friction between the pads and disc generates 365 kN·m of stable braking torque, stopping the disc (and connected machinery shaft) or holding it firmly in place.

2.2 Brake Release (Operating State)

When the machinery needs to run, the control system supplies hydraulic pressure (15–25 MPa) to the integrated hydraulic cylinders on the calipers.

Hydraulic force overcomes the disc spring tension, pulling the calipers away from the brake disc and creating a 0.5–1.0 mm clearance.

The brake disc rotates freely with the machinery shaft, enabling normal operation (e.g., crane hoisting, conveyor movement).

2.3 Emergency Response (Fault State)

In case of power loss, hydraulic system leakage, or sensor-detected abnormalities (e.g., overspeed ≥ 110% of rated speed), the actuation force dissipates instantly.

Disc springs expand within ≤ 0.2 seconds, driving the calipers to clamp the disc-generating peak braking torque (up to 420 kN·m) to stop the machinery immediately.

3. Core Structure & Key Components

The SBD365-C-2200×40IRL features a robust, reinforced design with five critical subsystems, optimized for ultra-heavy loads and harsh environments:

3.1 Integrated Caliper & Actuation Unit (Core Assembly)

Reinforced Dual-Sided Calipers: Cast steel (QT600-3) calipers with thickened walls (15–20 mm thicker than standard models) to resist deformation under high clamping force. Each caliper integrates 6–8 hydraulic cylinders for uniform force distribution.

High-Performance Friction Pads: Ceramic-metallic composite pads with a friction coefficient (μ ≥ 0.48) and heat resistance up to 650°C. Pads are bolted with quick-release fasteners for replacement (≤ 25 minutes per set).

Automatic Wear & Clearance Adjuster: Precision mechanical adjusters that compensate for pad wear (up to 18 mm) and maintain consistent brake clearance, eliminating manual calibration.

3.2 Disc Spring Mechanism (Safety Core)

High-Strength Spring Stack: 60Si2MnA alloy steel disc springs arranged in parallel, providing total clamping force of 180–220 kN. The stack is coated with anti-corrosion and anti-fatigue layers to extend service life.

Guided Spring Sleeve: Wear-resistant alloy steel sleeve that ensures uniform spring expansion/contraction, avoiding jamming in dusty or vibrating environments.

3.3 Safety & Sensing System (Control Core)

Dual Limit Switches: Two position sensors (one for "fully engaged," one for "fully released") with redundant signals to the machinery's PLC, enabling interlock control (machinery starts only when brake is released).

Multi-Parameter Sensors: Built-in wear sensors (trigger alerts when pad thickness ≤ 3 mm), temperature sensors (monitor disc temperature ≤ 600°C), and hydraulic pressure sensors (detect abnormal pressure drops).

Emergency Manual Release: Mechanical lever for manual brake release during power loss, facilitating maintenance and emergency reset.

3.4 Brake Disc Compatibility & Protection

Compatible Brake Disc: 2200 mm diameter, 40 mm thickness, made of 42CrMo alloy steel with quenched and tempered treatment (hardness HRC 28–32) for wear resistance and impact resistance.

Disc Cooling Structure: Optional circumferential cooling fins on the disc to dissipate heat quickly during high-frequency braking, avoiding thermal deformation.

3.5 Mounting & Environmental Protection Components

Reinforced Mounting Brackets: High-strength steel brackets with ±12 mm horizontal/vertical adjustment, adapting to machinery vibration and misalignment.

IP66 Protection Cover: Sealed steel cover with double-layer waterproof and dustproof design, shielding internal components from heavy dust, water immersion (short-term), and mechanical impact.

Anti-Corrosion Coating: Double-layer epoxy resin coating (120–150 μm) on calipers and brackets, resisting mine water, salt spray, and industrial chemicals.

4. Key Features & Advantages

The SBD365-C-2200×40IRL stands out for its ultra-high torque capacity, reinforced durability, and fail-safe reliability, with core benefits:

4.1 Ultra-High Braking Torque & Load Capacity

365 kN·m nominal torque and compatibility with 2200 mm large discs enable stable braking for ultra-heavy machinery (800–2500 tons), meeting the needs of large mine hoists and STS cranes.

4.2 Reinforced Structure & Harsh-Environment Adaptability

Thickened calipers, reinforced brackets, and IP66 protection enable operation in temperatures from -30°C to 120°C, high humidity (≤ 95%), heavy dust, and strong vibration.

Anti-corrosion coating and high-temperature seals ensure reliability in mines, coastal ports, and steel mills.

4.3 Integrated Design & Low Leakage

Integrated caliper, cylinder, and valve block reduce external pipelines by 85%, minimizing oil leakage and simplifying installation/maintenance in confined spaces.

4.4 Fast Response & Stable Performance

Emergency engagement time ≤ 0.2 seconds, enabling rapid stopping of high-speed machinery (e.g., hoist drums, conveyor belts).

Dual-sided clamping ensures uniform force distribution, avoiding disc warping and maintaining torque stability (±2% of nominal value).

4.5 Flexible Installation & Long Service Life

RL dual-mounting compatibility adapts to horizontal/vertical shafts and diverse machinery layouts, suitable for retrofitting legacy equipment.

Friction pads have a service life of ≥ 20,000 working hours; disc springs and seals last ≥ 8 years under normal operation.

5. Typical Applications

The SBD365-C-2200×40IRL is purpose-built for ultra-heavy-duty, safety-critical machinery across high-risk industries:

Mining Industry: Emergency brakes for large mine hoists (underground/above-ground) and extra-long inclined belt conveyors-withstanding dusty, humid environments and holding heavy ore loads during power outages.

Port Machinery: Safety brakes for ship-to-shore (STS) cranes and rail-mounted gantry (RMG) cranes-providing stable braking for 80–120 ton container loads and resisting coastal salt spray.

Metallurgical Industry: Brakes for steel mill hot rolling mill main drives and large ladle transfer cars-withstanding high temperatures (up to 120°C) and ensuring precise positioning of molten steel ladles.

Heavy-Duty Conveyors: Safety brakes for large bulk material conveyors (coal, iron ore) in power plants and quarries-stopping quickly during blockages to avoid belt tearing or material spillage.

6. Technical Specifications

Parameter	Specification (SBD365-C-2200×40IRL)
Product Type	Fail-safe spring-engaged safety brake (hydraulic-released, heavy-duty reinforced)
Nominal Braking Torque	365 kN·m
Compatible Brake Disc
- Diameter	2200 mm
- Thickness	40 mm
- Material	42CrMo alloy steel
Hydraulic System
- Working Pressure	15–25 MPa
- Cylinder Quantity	6–8
Friction Pads
- Material	Ceramic-metallic composite
- Friction Coefficient (μ)	≥ 0.48
- Service Life	≥ 20,000 working hours
Operating Conditions
- Temperature Range	-30°C to 120°C
- Protection Class	IP66
- Relative Humidity	≤ 95% (non-condensing)
- Max Disc Speed	≤ 300 RPM
Response Time
- Engagement (Emergency)	≤ 0.2 seconds
- Release	≤ 0.3 seconds
Mounting Type	Right-Left dual-compatible (RL), flange/bracket-mounted
Weight (Per Brake)	≈ 900–1050 kg
Compliance Standards	ISO 10494, GB/T 18839, CE

The SBD365-C-2200×40IRL combines ultra-high torque capacity, reinforced durability, and fail-safe reliability, making it a critical safety component for ultra-heavy-duty rotating machinery-where operational safety and stability directly impact productivity, personnel protection, and equipment integrity.

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