Brake fade happens when heat reduces the effective friction coefficient, leading to longer stopping distances or reduced holding capability. To prevent overheating on overhead and gantry cranes, size the brake for thermal capacity, not just torque. Consider energy per stop, stops per hour, ambient temperature, and worst-case emergency stopping scenarios. Disc brakes often dissipate heat well, while heavy-duty drum brakes require correct sizing and ventilation.
Operational strategy also matters. Use VFD-controlled deceleration or regenerative braking for routine stops when possible, and reserve the mechanical brake for holding and emergencies. Ensure the brake fully releases—dragging is a major hidden heat source. Maintain correct clearances, replace worn linings early, and keep friction surfaces free from contamination. For high-inertia or downhill applications, staged (two-step) braking can reduce peak heat and shock. Overheating is usually a system-level problem; solving it combines proper selection, correct adjustment, and smart control timing.