A new generation of brakes for demanding machine applications

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Warner Electric has built more than 90 years of design and manufacturing experience into its Gen4 range of spring-operated, electromagnetically released brakes. The new design offers exceptional performance and longevity in a compact form factor, together with features and options that maximise flexibility and ease of integration for customers.

Spring operated, electromagnetically released disc brakes are a rugged and reliable option for the control of rotating machinery in a diverse range of applications. Warner Electric – part of the Altra Industrial Motion Corporation – has been building electrically operated brakes since 1927, and it continues to refine and improve its design to meet the changing needs of customers around the world.

The company’s Gen4 range has been designed to suit demanding, high-speed applications, offering high torque density, low response time and a 100 per cent duty cycle at rated torque. The brake is available in single or dual disc variants in five standard disc diameters with nominal torques ranging from 200Nm to 3,200Nm. All but the largest sizes in the range are suitable for operating speeds up to 4700rpm. The Gen4 brakes incorporate wear compensation features for an exceptionally long operating life, and a built-in wear sensor means users can monitor brake condition during operation for assured reliability. Integration with sophisticated machine control systems is further assisted by a release detection microswitch, and the brakes are built with holes to permit the mounting of a rotatory encoder for speed monitoring.

Designed for tough environmental conditions, the Gen4 brakes are protected to IP67 standards and rated to operate in ambient temperatures from -40degC to +50degC and up to 100 per cent humidity. They are available with marine certification on request.

Warner offers a comprehensive range of configuration options to allow users to tailor the Gen4 brakes to the requirements of their applications. Those options include single or dual voltage operation, radial or axial cable output, the addition of an internal or external hand lever, as well as a multiple disk configuration. The units can be manufactured with alternative hub dimensions to suit user requirements and standard EN 50347 mounting flanges can also be provided. Options to suit demanding operating environments include the incorporation of an ant-condensation heater and an IP67-rated breather.

Thanks to Warner’s investment in highly flexible, lean manufacturing operations, custom brakes can be manufactured with short lead times in volumes that suit customer requirements. More information about the Gen4 brakes can be found at

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