Incorrect or unstable voltage can cause serious brake performance issues. If voltage is too low, electromagnetic brakes may not fully release, leading to dragging, overheating, rapid lining wear, and higher motor current. If voltage is too high, coils can overheat, insulation can degrade, and coil life shortens dramatically. Voltage ripple or poor rectification can cause buzzing, vibration, and inconsistent engagement.
In fail-safe systems, unstable voltage can also affect timing—delayed release may create harsh starts, while delayed engagement may increase stopping distance or reduce holding safety during shutdown. For cranes and hoists, this is a significant risk.
To prevent problems, verify power supply design (correct rectifier, surge suppression, and coil ratings), check cable sizing to reduce voltage drop, and ensure control circuits are correctly wired. If using VFDs, confirm that brake control is coordinated and that the brake coil is not powered from an unstable source. Monitoring coil temperature and brake air gap can help detect issues early. Treat electrical stability as part of brake safety, not just an electrical detail.