Safety factor is the margin between the brake’s rated torque and the maximum torque your application may demand. The correct factor depends on application risk, load variability, environmental conditions, and regulatory requirements. For lifting (cranes, hoists, elevators), safety factors are typically higher because failure can cause catastrophic load drop. For conveyors, especially downhill or regenerative conveyors, additional margin is often required to prevent runaway or rollback.
A common mistake is selecting a brake based only on “normal operating torque.” Instead, consider worst-case conditions: overload, emergency stops, wind loads, shock events, friction coefficient changes, and temperature effects. Also consider wear: as linings wear, response and torque can change if adjustment is neglected.
Use applicable standards and OEM guidance first. If standards are not explicit, conservative practice is to size for worst-case torque with an additional margin, then verify thermal capacity and duty cycle. A higher torque rating alone is not enough—ensure the brake can absorb the required energy without overheating.
