I. Upgrade of gear-type energized braking system, widespread application of CKB gear-type energized brake
In industrial automation, such as automatic division transmission, assembly line positioning, rotating worktables, intermittent conveying equipment, most operations require immediate braking upon energization and free rotation upon de-energization. Conventional friction-type energized brakes rely on friction surfaces for braking, and in high-frequency positioning scenarios, they are prone to slipping, have large positioning deviations, and consume friction materials rapidly, making them difficult to meet the requirements of high-precision point locking. The CKB gear-type energized brake is developed based on a mechanical gear meshing braking structure and belongs to an open-type electromagnetic braking accessory. It adheres to the logic of immediate energized meshing braking and disengaged release operation upon de-energization. Unlike the common friction braking categories on the market, it achieves rigid braking by relying on high-precision gear discs' interlocking, ensuring stable positioning accuracy, strong anti-torque slip resistance, and suitable for regular precise start-stop and fixed-position limitation operations in factory environments. It also fills the industry gap of inaccurate positioning and frequent replacement of consumable parts for friction-type energized brakes.
At present, non-standard automation equipment, woodworking division machinery, packaging rotating equipment mostly adopt the energized braking limitation process. When the equipment rotates without load, there is no need for braking. When the position is in place, it is energized and locked immediately. The CKB gear-type energized brake is compatible with industrial AC/DC power control, has a strong structural rigidity, fast braking response, is suitable for various load transmissions, has a universal installation capability, and can be equipped with new and old automation equipment, meeting the requirements of factory quality improvement, efficiency enhancement, and simplification of maintenance. It also addresses the industry shortcomings of inaccurate positioning and frequent replacement of consumable parts for friction-type energized brakes.
II. Operating principle, detailed explanation of CKB gear-type energized brake structure
The CKB gear-type energized brake adopts an integrated modular architecture. The entire unit consists of an electromagnetic excitation coil, clutch guiding components, hardened meshing gear discs, reset springs, sealed dust-proof housing, and manual unlocking components. The overall structure is compact and suitable for installation in narrow transmission spaces. The product operates in a normally open mode. When the equipment is in a normally de-energized state, the reset spring opens the gear disc structure, and the inner and outer gears are completely separated. The transmission shaft operates freely without resistance, allowing the equipment to freely rotate, move, and adjust speed.
When the equipment reaches the position and requires limit braking, connect the rated voltage and current, the coil is excited to generate electromagnetic thrust, pushing the moving gear disc axially, precisely meshing with the fixed gear disc, relying on the mechanical locking of the gear teeth to lock the transmission shaft, completing immediate braking and positioning. When the braking is released, the power is cut off, the electromagnetic thrust dissipates, and the reset spring automatically retracts the gear disc, restoring the free operation state of the equipment. The mechanical gear meshing has no friction slip risks, and it is equipped with a manual unlocking structure. During equipment debugging and fault troubleshooting, the gear disc can be manually separated, reducing the difficulty of equipment maintenance.
III. Performance advantages are prominent, differentiating from traditional friction-type energized brakes
Gear-type rigid locking, stable and controllable positioning accuracy. Relying on high-frequency quenched gear discs for meshing braking, there is no friction sliding distance. Upon energization, it can lock immediately, with smaller rotation and positioning errors during rotation and positioning. It is suitable for repetitive positioning operations of automation equipment, avoiding processing misalignment and position deviation caused by friction braking inertia slip, ensuring the uniformity of equipment processing and positioning.
It has stronger wear resistance and durability, reducing maintenance workload. The core of braking relies on the mechanical locking of gear teeth, without long-term wear of friction plates. The process of frequently replacing friction consumables is omitted. The surface layer of the gear disc is hardened, with excellent resistance to compression and anti-biting deformation. Under high-frequency repeated meshing operations, the structural wear is slow, the maintenance cycle is longer, and the frequency of disassembly maintenance and component replacement is reduced, lowering the labor and material costs of equipment maintenance.
It has wide adaptability to working conditions and strong environmental interference resistance. The integrated sealed housing of the whole machine is combined with multiple dust-proof sealing structures, effectively blocking iron filings, dust, and water vapor from entering the meshing cavity, suitable for woodworking dust workshops, hardware processing workshops, and humid factory environments. It is suitable for working in a wide temperature range environment. Temperature fluctuations will not affect the electromagnetic thrust and the spring rebound force. The braking action is continuous and without any lag. It is compatible with all-weather continuous automated production.
The electronic control is convenient to adapt, and the modification adaptation threshold is low. The CKB gear-type energized brake is compatible with 24V DC and 380V AC industrial conventional voltages. It can directly connect to the original control system of the equipment without adding additional power conversion or rectification peripherals. It follows the industry standard flange installation dimensions and is compatible with various installation methods such as motor side mounting, reducer input end, and rotating transmission shaft. Old equipment does not need to modify the transmission base, and can be directly replaced and put into use.
The braking noise is low, and it is suitable for the production norms of the factory area. The optimized tooth meshing angle and rebound buffering structure weaken the noise of the tooth disk impact, and the clutch engagement is smooth. The overall machine operation has low vibration, and it will not cause the transmission shaft to shake, which can protect the linked components such as bearings and gears, and also meets the requirements of quiet production operations in the factory area.
Four. Multi-industry adaptation scenarios, precise braking solution implementation
Woodworking automation machinery: CNC panel cutting machine, indexing rotary woodworking equipment. When the equipment rotates for feeding and定点 cutting， it is locked by energization， with precise positioning， ensuring uniform processing dimensions of the board， and suitable for high-frequency indexing operations in the workshop.
Packaging and printing equipment： Rotating packaging machine， printing indexing transmission equipment. After the workstation is switched， it is immediately braked and limited by energization， suitable for assembly line rhythmized operations， improving the alignment accuracy of packaging and printing， and reducing the rate of defective materials.
Non-standard conveying machinery： Reciprocating material conveyor， transplant platform. The fixed stop position is used for limiting， the braking is stable and does not slip， ensuring the smooth transfer of materials， suitable for automated material circulation operations in the factory area.
Small rotary equipment： Workholding rotary table， simple indexing platform. It has strong adaptability for small and medium-sized loads， small installation volume， does not occupy the transmission space of the equipment， suitable for lightweight matching of small-scale automation equipment.
Five. Standardized operation and maintenance， helping equipment long-term operation
The operation and maintenance of CKB gear-type energized brake is relatively low. Daily maintenance only requires regular appearance inspection， cleaning of dust and debris attached to the shell， and regular inspection of the waterproof protection performance of the connection terminals. Avoid operating beyond the rated torque load to prevent the tooth disk from deforming； in long-term high-frequency operation conditions， regularly add lubricating medium to the guiding clutch structure to ensure smooth separation and meshing of the tooth disk. During equipment idleness， regular power-on testing of the clutch status can be conducted to avoid rusting and adhesion of the tooth teeth.
Currently， CKB gear-type energized brake has achieved standardized mass production， with uniform tooth disk precision， coil parameters， and spring elasticity. Products in the same batch have balanced clutch speed and braking torque， suitable for batch procurement of projects with multiple components. Nowadays， automated equipment increasingly values precise positioning and low-cost operation maintenance. The gear-type energized brake is gradually replacing traditional friction energized brakes. CKB gear-type energized brake， with high precision， low loss， and easy adaptation advantages， enables the automation transmission equipment to improve quality and stable production， and optimizes the braking component system of industrial equipment.
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