KTR-STOP® - A new system for braking!

Newly developed brake system for applications with the production of high forces and adverse environmental conditions Introduction Just like in so-called offshore applications, there are numerous applications in mining which make special demands on the characteristics of brake systems. In particular abrasive influences and corrosion are the two worst enemies of the technology used in mining and as a result of the brake systems. Though brake systems, specifically in underground mining, are supposed to have small sizes due to a lack of space, whereas low weights are beneficial in the offshore range, since this makes less lifting force necessary with the assembly, as an example, on ships or platforms. This is a situation leaving enough space for a new development. KTR, a manufacturer of drive and hydraulic components acknowledged throughout the world, has combined this know-how and the long-lasting experience with the distribution and project work of brakes to develop a totally new brake system. The result is the new brake system KTR-STOP. Text Demands on brake systems using the example of mining Brake systems basically have two different functions in mining: • Use as a service brake. • Use as an emergency stop system. Usually the service brakes are mounted on the input shaft of a gearbox ensuring a corresponding deceleration when being activated. In case of standstill of the plant the brake system ensures a safe stop of the load. For that purpose they are typically designed as spring-actuated brakes locking or remaining locked, respectively, with rated load in case of a voltage interruption. KTR-STOP is a newly developed floating caliper brake having numerous benefits in design compared to conventional brakes making them particularly sturdy, long-lasting and easy to maintain. As a result it is predestined for the use in mining (illustration 1). Mining is subdivided into three ranges: • Surface mining • Underground mining. • Drill hole mining - considering offshore applications in particular. The demands on the brake systems for the three aforementioned types of mining are extremely different. In surface mining, here in particular brown coal open cast mining, giant equipment is often used. Part of such equipment are, for example, bucket-wheel excavators or spreaders having daily outputs of up to 240.000 m³ (illustrations 2 and 3). Conveyor lines with a transport capacity of in part more than 30.000 t/h connect the machines with each other or with the downstream or inserted operations such as processing, mixing bunkers, drying plants or power stations. Special demands in surface mining are both dry and humid application conditions with a high claim on the abrasiveness resistance of the materials used, caused by the almost ubiquitous presence of sand with a more or less high content of crystal. In contrast to that the equipment and plants used in underground mining are rather small. Here special demands result from the mostly humid and warm climate and the presence of abrasive material which is pressed into almost every small gap due to the permanent ventilation. In addition, corrosive influences, in particular resulting from the digging of potash, rock salt or sulphur compound (copper), but almost always by pit water containing resolved minerals in a different composition, are present and produce heavy corrosion. Moreover, a lack of space requests for designs with high power density. In offshore applications mainly the heavily corrosive influences of sea salt and the necessity to save weight, in particular in the range of swimming oil platforms, make high demands on the technology used. Anyway, high-tech is used in overall mining. Enormous masses are moved and big forces have to be controlled. Mining sets the highest demands on safety and reliability in almost every place of the world. Thus, in addition to safety, reliability and economic efficiency of a brake system the followin

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