Brake Gear Motor For Industrial Machinery

This industrial brake gear motor integrates a 3-phase AC induction motor, a helical gear reducer, and an electromagnetic power-off brake within a single compact housing. Engineered for applications requiring precise positioning, rapid stopping, and load-holding safety, the brake automatically engages when electrical power is interrupted.

Operating across a power range from 0.1 kW to 7.5 kW, this unit delivers high output torque at reduced speeds while maintaining dynamic braking control. The integrated design eliminates external coupling alignment issues, reduces overall machine footprint, and prevents load slippage on vertical lifts, inclined conveyors, and automated process machinery.

Electromagnetic Power-Off Brake: Spring-applied safety brake locks the output shaft instantly upon power loss, preventing accidental load movement in vertical lifting and inclined transport.

Hardened Helical Gear Train: Carburized and precision-ground 20CrMnTi alloy steel gears deliver higher torque capacity, operating efficiency exceeding 92%, and low running noise under 65 dBA.

IP55 Sealed Housing: Die-cast aluminum and high-strength cast iron enclosures with double-lip oil seals prevent lubricant leakage and protect against ingress of dust or water jets.

Class F Insulation: Rated for continuous duty (S1) with a thermal limit of 155°C, ensuring stable motor performance under high ambient temperatures and frequent start-stop cycles.

Manual Brake Release: Optional manual release lever allows manual shaft rotation during machine setup, alignment, or emergency handling during power outages.

Mounting Styles:

Horizontal (Foot Mounted): Rigid mounting base for direct frame or chassis integration.

Vertical (Flange Mounted): Direct attachment to machine housings, agitators, or reduction gearboxes.

Terminal Box Positions: Standard top-mounted, configurable to left or right sides for clearance in tight enclosures.

Voltage & Frequency Options: Dual-voltage coils (230/460V @ 60Hz or 230/400V @ 50Hz) matching international grid standards.

Shaft Modifications: Custom keyways, dual shaft extensions, hollow output shafts, and customized shaft diameters.

Fast-Acting Rectifiers: Optional fast-action DC rectifiers available for ultra-fast response (<20 ms) in high-speed cycle applications.

Hoisting & Overhead Lifting: Overhead cranes, electric wire rope hoists, and construction lifts requiring reliable safety holding force when stopping mid-stroke.

Material Handling & Conveyors: Inclined belt conveyors, roller sorting tables, and palletizers requiring rapid stopping without coasting.

Automated Doors & Gates: Industrial high-speed roll-up doors and barrier gates where brake force prevents door drift under gravity or wind loads.

Packaging Machinery: Indexing turntables, cartooning equipment, and capping machinery requiring high dynamic positioning accuracy.

Stage & Theater Equipment: Rigging hoists and moving platforms where fail-safe static braking is mandatory for operator safety.

To select the correct brake gear motor configuration for your machinery, evaluate the following engineering parameters:

Calculate Required Output Torque (M2):

Determine required speed (n2) and load torque.

M2 = (9550 * P * η) / n2

(Where P is motor power in kW, n2 is output RPM, and η is gear efficiency).

Determine Duty Cycle and Start Frequency:

High start-stop frequencies (>300 cycles/hour) require upgrading thermal capacity and selecting heavy-duty friction discs to extend wear life.

Verify Overhung Load (OHL):

Check radial and axial shaft loads if installing sprockets, pulleys, or gears on the output shaft to ensure long bearing life.

Select Brake Torque Capacity:

Standard Positioning / Stopping: Brake torque = 1.0–1.5× motor rated torque.

Vertical Hoisting / Safety Holding: Brake torque = 1.5–2.0× motor rated torque.

Specify Voltage and Environmental Protection:

Identify local voltage standards and ambient conditions (damp surroundings, outdoor exposure, or fine dust requiring IP65 sealing).

Gear Machining & Heat Treatment: Gear blanks undergo precision CNC hobbing and carbonitriding to achieve a surface hardness of 58–62 HRC. Fine gear tooth grinding eliminates pitch errors and minimizes running gear noise.

Winding Insulation Test: Stator windings are processed through vacuum pressure impregnation (VPI) with resin varnish. 100% of stators undergo surge voltage testing and dielectric breakdown checks prior to final assembly.

Brake Friction Disc Quality: Non-asbestos, high-friction composite discs are surface-ground for flat contact, maintaining holding torque stability over 1,000,000 brake cycles under nominal load.

End-of-Line Inspection Routine:

No-Load Running Test: Verifies phase balance, current draw, and operating vibration level.

Brake Holding & Engagement Test: Measures mechanical response time and verifies holding torque under dynamic load.

Noise Level Testing: Acoustic measurements performed in sound-insulated testing chambers.

Helium Leak Detection: Gearbox housing seals are pressure-tested to eliminate oil leakage risks during transport and operation.

Need a Custom Drive Solution or Technical Data Sheet?
Submit your operating requirements to receive engineering review, 2D/3D CAD drawings (STEP, DWG), and a detailed commercial quote within 24 hours.
Please include the following details in your inquiry:

• Required Motor Power (kW/HP) & Input Voltage (V/Hz)
• Target Gear Ratio or Output Speed (RPM)
• Required Output Torque (N·m) or Application Description
• Mounting Style (Foot / Flange / Shaft Mounted)
• Estimated Annual Volume / Order Quantity

Hot Tags: brake gear motor for industrial machinery, China brake gear motor for industrial machinery manufacturers, factory, ac gear motor, ac gear motor for hand tools, ac gear motor for lawn mowers, ac gear motor for low temperature environment tools, ac gear motor for scanners, ac gear motor for toasters