Anodizer Puts Brakes on Weakest Link

Better yet, Rhode and Dave Price of Industri/Motion brought the Force Control “Road Show” to Linetec.  This demonstration trailer, equipped with oil shear brakes that can be actuated and demonstrated, allowed Brubacher and the entire shop maintenance and operations crew to better understand the differences between traditional brakes and oil shear technology.

An initial order was placed for a single MagnaShear MSB6 motor brake, which was put into service as a trial. After six months with virtually no maintenance and no failures, the Linetec team was convinced of the viability of the oil shear design, and began formulating a plan for a capital expenditure to replace all of their dry brakes.

“We’re very pleased with the performance of the Force Control brakes” said Brubacher.  “We have not had a single issue with them since they were installed. With oil shear brakes on all of our cranes and hoists we’ve reduced downtime significantly and increased our productivity.”

Normal dry clutch brakes and brakes employ a sacrificial surface – the brake disc or pad – to engage the load.  Having no good way to remove the heat caused from engagement between the disk and plate, this material must absorb the heat.  These extremely high temperatures will eventually degrade the friction material.  As the friction surface wears away and begins to glaze the spring force is also reduced causing the ensuing torque fade. This causes positioning errors which require adjustment or replacement of the friction surface.

Oil-shear technology plays a major role in ensuring that the cranes at Linetec operate continuously. Since a fluid film flows between the friction surfaces, as the brake is engaged, the fluid is compressed. The automatic transmission fluid particles in shear transmit torque to the other side.

This torque transmission causes the stationary surface to turn, bringing it up to the same relative speed as the moving surface.  Since most of the work is done by the fluid particles in shear, by the time the surfaces actually meet or “lock up” wear is virtually eliminated.

In addition to transmitting torque, the ATF also helps to dissipate heat, due to a patented fluid recirculation system.  Along with torque transmission and heat removal, the fluid also serves to continually lubricate all components – thus extending their service life.  Oil Shear Technology also provides a “cushioned” stop that reduces shock to the drive system – further extending service life.

Unlike dry clutch brakes, the totally enclosed oil shear system is impervious to external elements such as wet, dusty or dirty environments. Since the layer of oil eliminates wear, the MagnaShear motor brake provides a long service life. With elimination of wear comes elimination of adjustment – and increased “uptime” for Linetec.

The reliability and durability of oil shear technology helps plants with a critical pathway to maintain high production. Oil shear technology has helped Linetec eliminate brake failures – as well as dramatically reduce crane brake maintenance. And that allows the anodizing plant to run with virtually no crane maintenance downtime.

In addition to increased production, the plant has shaved nearly 2 hours per week from their maintenance time (7.5 minutes per week per brake for the old system and virtually none for the new oil shear brakes), plus another 8 hours per quarter.  In addition to the maintenance savings and elimination of $8000 annual parts expenditures, there is no more of the $1500/hour downtime for repairs and breakdowns.

Investing in Oil Shear brake technology from Force Control Industries has boosted the bottom line at Linetec by significantly increasing productivity while reducing maintenance time and costs.

Force Control Industries, 3660 Dixie Highway, Fairfield, OH 45014, 513-868-0900, www.forcecontrol.com.