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You are at:Home»News»Electric & Hybrid Vehicles»Warner Electric brakes help
increase EV run time
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WARNER ELECTRIC BRAKES HELP INCREASE EV RUN TIME

0
By Saul Wordsworth on 2nd August 2023 Electric & Hybrid Vehicles

The off-highway industry is currently moving through a significant transition.
The journey started 10-12 years ago as the forklift truck industry began
converting from internal combustion engines into electric drives. Today,
construction equipment, more precisely, compact construction equipment, has also
begun the transformative conversion to electric drives.

The move to electric

As with the automotive industry, national and municipal emission regulations are
rapidly becoming more restrictive for off-highway vehicles and equipment. In
some areas, the use of gas-powered equipment has already been completely banned.
Some analysts believe that by 2030, 50% of the construction equipment market
will be electric powered.

As environmental awareness grows, construction equipment manufacturers have
begun to respond with electric powered equipment that meets various mandated
emission regulations. However, they are also being driven by voluntary
environmental policies adopted by construction contractors and large equipment
rental companies.

This new generation of much quieter equipment is not only environmentally
friendly, but also provides increased operator comfort, health and safety
benefits.

Reducing power consumption

Warner Electric offers innovative braking solutions designed to reduce power
consumption on a wide variety of battery-powered construction equipment,
including slewing and track drives on excavators, wheel and track motors on
compact track loaders, skid steers, wheeled excavators and mobile elevating work
platforms (MEWPs).

Highly experienced Warner Electric application engineers routinely work with
Tier 1 drivetrain OEMs as well as major construction equipment manufacturer
engineering teams to develop compact, energy efficient braking solutions to meet
the needs of each vehicle requirement, whether it’s for a completely new design
or the electric conversion of existing equipment.

Its design process typically starts with one of its existing industry-proven
braking solutions, including the popular PK and CBTB ranges. Once selected,
customization of the unit begins, including IP rating, manual release cables,
connectors, sensors and friction material. The result is a plug and play product
that the OEM can easily integrate into his drivetrain.

Proven design

Warner Electric’s market-leading PK (Very Thin) brake is the industry’s original
compact, proven brake design. These pre-assembled on/off dry safety brakes are
used for parking and offer emergency stop capabilities. The vehicle’s AC motor
is used in combination with the PK brake for regenerative braking of the
vehicle.

The benefits of this cost competitive range include one-piece design for easy
assembly, lower power consumption, longer battery life, and overall lower
maintenance costs. These brakes are enclosed to withstand harsh outdoor
environments. IP67-Rated models are available to meet challenging washdown
application requirements.
The recently launched PK- Low Noise Design brake features a unique
patent-pending dampening system that significantly reduces operating
(engagement) noise to below 70db. The new brake was developed for applications
where high noise levels can be annoying such as under-cab slewing drives on mini
excavators.

High-torque, high-speed brakes

The CBTB family of electomagnetic axle brakes are specifically for use on
battery-powered, dual-drive vehicles with capacities generally up to 8 tons
(17,900 lbs.). These advanced high-speed, high-torque brakes provide reliable
emergency and parking brake functionality and allow for increased maximum
vehicle speed and improved productivity.

Proprietary W134 non-stick dry friction material, designed and manufactured
in-house, is available on PK and CBTB models for increased high-capacity braking
requirements at very high speeds. The linear speed of the friction material
determines the speed limit, certain brakes and design sizes have been
functionally tested at speeds of 12,000 rpm.

With multiple manufacturing facilities strategically positioned around the
world, Warner can provide short lead times while meeting the demanding delivery
requirements of global OEM production schedules.

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ABOUT AUTHOR

Saul Wordsworth

Saul Wordsworth is deputy editor of the iVT brand - which includes digital and
print editions of a quarterly magazine and Off-Highway Annual, as well as
ivtinternational.com. He is a keen cyclist and lives in north London.


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