Energy-Saving

In the field of industrial brakes, Energy-Saving refers to a control technology, primarily for fail-safe electromagnetic brakes, that significantly reduces their electrical power consumption during operation. This is achieved by intelligently managing the voltage supplied to the brake’s coil.

The core principle is based on a simple fact of electromagnetism: it requires substantially more magnetic force (and thus, more electrical power) to initially pull the armature across an air gap to release the brake than it does to simply hold the brake in the released position once the air gap is closed.

An energy-saving controller exploits this by implementing a two-stage power application:

1. Over-Excitation (Boost Phase): For a brief, precisely timed moment (typically milliseconds) upon the command to release, the controller delivers a high voltage (e.g., 100% of the rated DC voltage) to the brake coil. This creates a powerful magnetic field that rapidly and decisively overcomes the spring force to release the brake.
2. Holding Phase: Immediately after the brake is released, the controller automatically reduces the output to a much lower “holding voltage” (often as low as 30-50% of the rated voltage). This reduced power level is more than sufficient to maintain the magnetic field required to hold the brake open against the springs.

The benefits of this approach are threefold and critical for modern machinery:

• Drastic Energy Reduction: It can reduce the brake’s energy consumption by up to 70% or more while the associated motor is running.
• Reduced Heat Generation: Less power consumption means the brake coil generates significantly less heat. This extends the life of the coil’s insulation, improves the brake’s performance consistency (preventing thermal fade), and reduces the thermal load on the adjacent motor.
• Longer Service Life: A cooler-running brake is a more reliable and longer-lasting brake.

Therefore, an energy-saving feature is not just about reducing electricity bills; it is a critical engineering advancement that enhances the brake’s performance, reliability, and lifespan.