Two-stage braking (also called two-step or dual-rate braking) applies braking torque in two phases: a controlled initial stage followed by a stronger final stage. The goal is to reduce shock loads, prevent load swing, limit belt slip, and avoid mechanical stress while still ensuring safe stopping.
This approach is especially valuable on long downhill conveyors and heavy hoisting systems. If full braking torque is applied instantly, the system can experience jerks, gearbox stress, structural vibration, or belt damage. Two-stage braking allows a smoother deceleration curve—often described as “soft braking”—before the brake transitions to full holding torque.
Two-stage behavior can be achieved mechanically (dual springs/linkages) or through actuation control (hydraulic throttling, electro-hydraulic thruster control, or variable frequency drive coordination). When selecting a brake for a high-inertia system, ask not only “how much torque,” but also “how is torque applied over time?” Properly tuned staged braking improves safety, reduces maintenance, and extends lining and drivetrain life.