Order air motors with integrated brake by Mannesmann Demag online

Order Mannesmann Demag Air Motors with Holding Brakes Online

Air motors with friction-locking holding brakes from Mannesmann Demag combine pneumatic drive and positive-locking braking function in a compact design. This assembly is designed for applications where secure positioning is required after the air supply is shut off, without an additional control line or external brake. Typical fields of application include positioning tools, clamping devices, conveyor technology, and lifting/lowering equipment in the manufacturing industry.

Core Functions and Design

The motor consists of the actual rotary drive, usually designed as a two- or multi-vane or turbine motor, and an integrated friction-locking holding brake that mechanically engages the motor shaft. The brake is typically closed by spring force and opened by air pressure; when the supply is depressurized, it reliably blocks the shaft. Housing materials are typically aluminum alloys for low mass and good heat dissipation, or cast steel for increased load capacity. Bearings are needle bearings or ball bearings with NBR or FKM sealing washers for sealing against ambient media.

Mechanical interfaces include standardized flange and foot mountings according to DIN, standardized shaft dimensions, and usually right/left rotation options. Pneumatic connections are often G1/8 to G1/4, with integrated shut-off and control valves in selected versions. The brake unit uses hardened brake linings or grooved discs; contact surfaces are corrosion-protected or made of low-wear materials such as sintered metal or composite materials.

Connections, Seals, and Mounting Instructions

Pneumatic connections are designed for pressure ratios of 3–8 bar; for more precise control, combination with pressure regulating valves and pressure filters is recommended. To prevent condensation and particle ingress, oil/water separators and fine filters should be used in the air supply. Seals depend on ambient temperature and media selection: NBR seals cover standard applications, FKM (Viton) is used for elevated temperatures and chemical exposure. Mounting surfaces must be flat and free of foreign bodies; axial and radial play must be adjusted according to manufacturer specifications to avoid premature bearing and brake wear.

Performance, Control, and Braking Behavior

Mannesmann Demag air motors are available in power levels up to 1.2 kW and offer high flexibility through coordinated gear ratios and torque levels. The integrated holding brake secures standstill with loads at a defined holding torque. For dynamic applications, variants with short response times and high repeatability are available. The braking effect is temperature-dependent; in continuous operation, a thermal evaluation of the brake linings is required to avoid fade effects.

Materials, Surfaces, and Protection Classes

Housings made of anodized aluminum offer corrosion protection with low weight, while painted or powder-coated steel variants increase robustness against mechanical stress. Shafts and internal components are often made of case-hardened steels with surface hardnesses in the range of 40–60 HRC to minimize wear. Protection classes range from IP54 to IP65 depending on the version; for splash water and dusty environments, seals and covers are required. In aggressive environments, special coatings and corrosion-resistant materials are recommended.

Fields of Application and Practical Integration

In sheet metal forming, brake motors secure workpiece positions after clamping devices are closed; the holding brake prevents self-rolling in case of pressure drop. In conveyor systems, they provide end-position fixation for transfer units, thereby relieving mechanical end stops. In assembly automatons, they allow precise indexing by combining pneumatic drive and immediate fixation at standstill.

Practical examples:

• Example 1: Feeding a ratchet into an assembly station. A 0.75 kW brake motor, nominal torque 6 Nm, with flange mounting and Ø12 mm shaft, is controlled via a regulated compressed air supply at 6 bar. After reaching the target position, the air is shut off; the spring force of the holding brake immediately blocks the shaft and holds the tool against reverse torques up to 10 Nm. Recommendation: NBR seals, G1/8 supply, 5 µm oil/water separator.
• Example 2: Positioning system for material feeding in a press line. A 1.2 kW air motor with reinforced brake design and hardened brake linings secures heavy workpiece carriers. Mounted on a flanged motor support, using FKM seals at elevated ambient temperatures and compressed air pre-treatment with a dryer. Result: Standstill safety even with pressure peaks and high load torques.
• Example 3: Indexing axis in conveyor technology. A light 0.25 kW brake motor combined with a planetary gearbox and integrated brake clutch ensures precise holding points in cyclic operation. Recommended setting: Air supply 4.5–5 bar, cyclic maintenance of brake linings every 6 months in 2-shift operation.

Maintenance, Service Life, and Spare Parts

Regular maintenance reduces failure risks: checking seals, retightening fasteners, visual inspection of brake linings, and lubrication of bearings at specific intervals. The service life of brake linings varies with load, cycle frequency, and environment; documented inspection intervals increase predictability. Spare parts such as seals, brake linings, spring packages, and shaft seals are available as standard. Original Mannesmann Demag parts ensure mechanical fit and material compatibility.

Compatibility, Replacement, and Retrofit

Brake motors can often be integrated as direct replacement machines into existing systems if the flange pattern and shaft dimensions match. For retrofitting, adapter flanges, coupling discs, and pressure control modules are common measures. When converting to other control concepts, pneumatic interfaces and the control logic of the holding brake must be considered. Additional sensors such as rotary encoders or Hall sensors can be added for more precise position detection.

Safety and Normative Requirements

Holding brakes must be treated as safety-relevant components and are subject to machine safety and compressed air technology standards depending on the application. Tests for holding forces, braking deceleration, and temperature behavior are part of the acceptance process. In safety-critical applications, a redundancy solution should be considered, such as double braking systems or mechanical locking devices as additional safeguards.

Further technical information on materials, designs, and application examples can be found in the technical section and for specific practical cases: Technology and Application Examples.

Selection Criteria for Purchase

When selecting, consider the required holding torque, operating pressure, environmental influences, and mounting space. Cycle rate, continuous load profile, and maintenance capacities are also crucial. For precise selection and optimal integration, it is recommended to specify load torques, required holding time, available space, and air quality parameters when inquiring.

FAQs

1. How large must the holding torque of the integrated brake be?

The holding torque must cover at least the maximum reverse torque of the load plus a safety factor of 1.5. For short-term shock loads, a higher factor or redundant securing should be chosen.

2. Which seals are recommended for high ambient temperatures?

For temperatures above approx. 80 °C, FKM seals are preferred; PTFE-coated seals are used for chemical exposure. Material selection depends on the media and temperature profile.

3. How often do brake linings need to be maintained or replaced?

Interval-dependent: For continuous two-shift operation and medium load, a visual inspection every 6 months and replacement according to wear indication or at the latest after defined operating hours according to manufacturer specifications is recommended. Exact intervals depend on the load profile and environmental conditions.