Industrial brake “failure” is usually a chain of issues rather than a single defect. Common root causes include: friction lining wear beyond limits, oil/grease contamination reducing friction, incorrect air gap or shoe clearance, weak or broken springs, misaligned discs/drums, and overheating from excessive duty cycle or dragging.
Actuation problems are also frequent: low hydraulic pressure, air supply instability, clogged valves, electrical under-voltage, incorrect rectifier/power supply settings, or a failing thruster motor. Environmental factors—corrosion, abrasive dust, water ingress—accelerate wear and cause sticking or uneven movement.
The best prevention is a disciplined inspection routine plus correct selection. Ensure the brake is sized for both torque and thermal load, use compatible friction materials, and keep release mechanisms within spec. Finally, treat brake spare parts as safety components: non-matching linings or springs can change torque and response, creating unpredictable performance and increasing risk during emergency events.
