Brakes

Precise control for maximum safety

While autonomous driving in road traffic is still in the pilot phase, it is already common practice in the area of industrial trucks. The example of the US manufacturer Bastian Solutions shows how this trend affects the design of conveyors and subsequently also the brake design. Kendrion Intorq has equipped its driverless forklift truck Bastian Solutions CB18 with customer-specific spring-applied brakes, which are characterized, among other things, by a finely tuned braking torque within a narrow tolerance band.

If the driver becomes redundant, then the space for the seat and cabin can also be saved. Bastian Solutions, an American industrial truck manufacturer from the Toyota Group, came to this conclusion when developing a new autonomous forklift. The shorter length and shortened axle distance not only make the truck lighter and more maneuverable, but also have a significant influence on its braking behavior and tipping resistance, especially when loaded. At this point in the project, Kendrion's brake specialists came into play. The experts worked with their customer to develop an individual brake solution that meets all the requirements and special features of this application.

Dr.-Ing. Stefan Weigelt, head of customer-specific development at Kendrion Intorq

“On the one hand, our specifications included a very narrow braking torque tolerance. Bastian Solutions also had special specifications for the switching times of our brakes, the tolerable emergency stop energy and the minimum possible number of emergency stops.” The particularly high requirements for the braking torque tolerances result from the shortened vehicle design. The minimum torque must ensure compliance with the maximum braking distance in accordance with legal requirements. In contrast, the maximum torque is only slightly higher, in order to ensure that the truck is not tipped over in the event of an emergency stop with the payload raised.

“Our development department in Aerzen developed the right solution together with Bastian Solutions,” says Stefan Weigelt, describing the process. “Based on the technical data of the self-propelled industrial truck (AGV), such as drive wheel diameter, gear ratio and transmission efficiency, we have determined the parameters for an optimal brake design with which we can safely maintain the required braking torques.” The customer-specific brake is based on the Intorq BFK557 model in size 12 from Kendrion. The modifications by Stefan Weigelt's team included, among other things, the adjustment of the spring force as well as the selection and qualification of an appropriate friction system, consisting of the rotor with a friction lining suitable for the special requirements and the matching counter friction surfaces.

Six engineers are currently involved in the customer-specific development of add-on brakes at the Aerzen location. Based on the Kendrion Intorq brake series and existing technologies, the team develops customized solutions for the areas of intralogistics, mechanical engineering, medical technology and wind power, among others. The modifications that arise here range from simple adjustments, for example to the power supply and a special torque setting, to significantly modified geometric brakes for special installation spaces. “Kendrion has extensive expertise in analyzing the requirements of an application,” summarizes Stefan Weigelt. “We develop the relevant specifications together with our customers and design individual solutions on this basis.”