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Posts Tagged ‘Brake’
Tuesday, November 13th, 2012
There are many methods to mount a Clutch/Brake hub to the shaft of a Stamping Press or other heavy machinery. Torque Inc will help you pick the best type of connection for your application. The following is a summary of the benefits and limitations of the various methods:
Key with clearance
Using a clearance fit between the hub and the shaft while and hand fitting the key (or two keys) is the most common method. Clearance of a couple of thousandths of an inch with line/line for the keyway is typical. This connection will likely gradually get loose at some point in time, is likely the most common type used on a press.
Key with interference
Adding a slight interference with a hand fit key is a more permanent solution, albeit requiring a modest heating of the hub (to about 250- 300 degrees F through via oil bath, oven or induction heater). Typical fit of line/line to .001”/.002” for shaft size of 6”.
Key with heavier interference
Increasing shrink to .0005” per inch of diameter (ie. .003” interference for 6” bore ) is achievable with a 300-400 degree heat and dry ice of the shaft. This fit is recommended for high shock load/high reversing loads like shears and high stripping force dies, cold forging etc. Care must be taken not to end up with too tight a fit over a key, in that this can cause the hub to split through the keyway. Heavy interference fits are difficult to remove without damaging the shaft/bore interface.
Heavy Interference without key
Using a .001” per inch of shaft diameter interference (ie. .006”-.009” shrink for a 6” shaft) , or more, can often times gain enough torque to drive without a key or supplemental locking device. However, we do not recommend retrofitting using this method due to the following problems, indluding but not limited to:
1. Precise material specifications are required,
2. Precise machining is required,
3. Installation is tricky
4. Removal does damage to the shaft and hub bore.
The best system is a Engineered Locking Element without a key
Using an engineered locking device such as a Ringfeder, Climax or Bloc creates the advantages of heavy inference shrink fit connection (ie. No backlash ever, removability, ease of assembly and strongest possible shaft and hub design due to no stress risers from keys) without the disadvantages. Some applications are hard to retrofit due to space and material issues. These devices require proper dimensions and installation procedures and torque instruction be followed in order to function properly. However the devices have a 100% success rate when properly engineered and installed (in fact they frequently can carry more torque than the shaft itself can!) .
There are two primary types of keyless locking devices.
 Wichita Clutch CCB with Shrink Disc mounted hub
The “shrink disc” goes outside of a hub extension and squeezes the hub to the shaft. Advantages are a infinite choice of shaft sizes (ie. Can match any existing shaft assuming it is round and finished properly) and has a relatively high torque rating. Material can be cast iron or steel
 Industrial Clutch Hub mounted to shaft with internal locking element.
The internal “locking assembly “ is sometimes easier to fit in (goes inside existing hub) but can only fit a finite number of standard shaft sizes and requires an adequate OD to provide enough strength the keep hub from cracking. Material required to be steel or steel sleeved cast iron.
- Proper selection of either version of an engineered locking element requires the qualified engineering assistance that Torque Inc. can provide to insure a successful installation.
- Often the cost of the device is offset by the reduction in labor/machining cost associated with putting a connection together!
Tags: Brake, Clutch, Industrial Clutch, Installation, Retrofit, Torque Tips, Wichita Clutch
Posted in Clutch, Rebuilding, Retrofit, Wichita | No Comments »
Thursday, January 27th, 2011
Story detailing the new Wichita Clutch AquaMakks 24″ and 36″ Water Cooled Brakes in the news:
http://www.manufacturingtalk.com/news/jaz/jaz113.html
Tags: Brake, Wichita Brake, Wichita Clutch
Posted in Kopper Kool Brake (KKB), Tension Control, Wichita | No Comments »
Tuesday, October 26th, 2010
Wichita Clutch supplies standard Kopper Kool Brake (KKB) renewal kits in two configurations to make repairing and rebuilding your brakes easier and more cost effective. KKB Renewal kits include the following items:
- Copper Wear Plates
- ID/OD O-rings
- Nut’s and Bolts
- Springs if used in current rev. of Parts List.
- Friction Material, Rivets and Washers (partial)- or – Complete Drive Plate assemblies (complete)
 KKB Renwal Kit Parts Breakdown Contact your local Torque Inc., Application Engineer if you have any questions. They are happy to be of assistance.
Tags: Brake, KKB, Rebuilding, Wichita, Wichita Brake, Wichita Clutch
Posted in Kopper Kool Brake (KKB), Rebuilding, Tips, Wichita | No Comments »
Monday, October 11th, 2010
 Brake Drive Plate with teeth worn by excessive angular alignment. Above is a photo of a customer who was rapidly wearing teeth of a Wichita 118 KKB. This is a typical symptom of excessive angular alignment.
 Uncoiler Brake with rapid tooth wear, ready to check alignment.  Angular Alignment was over .300", Wichita specification is .009" TIR. Angular Alignment is checked by placing the magnetic base of a dial indicator of the shaft and indicating the face of the back water jacket at an 18″ diameter (for Wichita 118″ KKB). This application indicated over .300″ TIR, well beyond the maximum limit of .009″ TIR published by Wichita Clutch. This explains the rapid tooth wear of the Drive Plates and Hub. It was noted the high/low point wear at 3 o clock and 9 o clock with the 12 and 6 o clock positions being the same reading.
 Steel Uncoiler using Pillow Block Bearings that need to be restrained. Uncoiler is built using Pillow Brock Bearings to support the mandrel. This design, like others we see using Pillow Block Bearings, has the tension force in the same plane as the Pillow Block Bearing mounting surface. Under high tension operation there is a real potential for the bearings to slip. Most users correct this design issue by welding hard stops to the uncoiler base with jacking screws to restrain the bearings from sliding and allowing easy adjustment for brake alignment.
Tags: Alignment, Brake, Installation, KKB, Wichita, Wichita Brake
Posted in Kopper Kool Brake (KKB), Tips, Wichita | No Comments »
Saturday, July 17th, 2010
Testing of rebuilt pendulum shear gear box by Horsburgh & Scott Rebuild Center. Video shows Wichita Clutch ATD 236 LIC mounted to Flywheel on intermediate gear Quill Shaft. Wichita ATD 260 LIB mounted on output shaft on back of gear box.
httpv://www.youtube.com/watch?v=F7B3NNB7hgw
Tags: Brake, Clutch, Installation, Rebuilding, Wichita Brake, Wichita Clutch
Posted in Clutch, Rebuilding, Spring Set Brake, Wichita | No Comments »
Sunday, July 11th, 2010
Wichita clutch Press Release detailing release of the new Water Cooled AquaMaKKs Brakes:
 Wichita AquaMakks Water Cooled Brake Wichita Clutch Press Relase – AquaMaKKs.
Tags: Brake, KKB, Wichita Clutch
Posted in Kopper Kool Brake (KKB), News Article, Wichita | No Comments »
Sunday, July 11th, 2010
Machine Design Article detailing Wichita Clutch AquaMaKKs water cooled brakes:
Wichita AquaMakks Water Cooled Brake Water-Cooled Clutches and Brakes | Machine Design.
Tags: Brake, KKB, Uncoiler, Wichita Clutch
Posted in Kopper Kool Brake (KKB), News Article, Tension Control, Wichita | No Comments »
Sunday, July 11th, 2010
Machine Design Article detailing Wichita Clutch new Composite Water Jackets used for AquaMaKKs and Kopper Kool Brakes.
 Compsite Water Jacket for New Wichita AquaMakks Wichita AquaMakks Water Cooled Brake Beefy Clutches, Brakes Go Svelte Thanks to Composite Water Jacket | Machine Design.
Tags: Brake, KKB, Wichita Clutch
Posted in Kopper Kool Brake (KKB), Tension Control | Comments Off
Tuesday, May 11th, 2010
Precise unwind tension control sometimes requires brakes with a wide torque range to meet the wide range of materials (tensions) and widths run on a line. This is further complicated by the larger rolls (coils) to be unwound (uncoiled). To put this in perspective, a roll with 72″ OD and 6″ core will require a 12:1 decrease in air pressure from start to core. If you start at 60 PSI, you would finish the roll at 5 PSI, this leaves little adjustment for a wide tension range for lighter/heavier materials and wider/narrower widths.
Wichita KKB brake designs are very proportional from8 PSI to 80 PSI or a 10:1 ratio, the high performance ModEvo design is good to 3/4 PSI for a 20:1 ratio. To accommodate the demands of modern equipment, Wichita has many creative designs available to increase the range of control of unwind brakes by using multiple actuators.
Below is a photo of a special “Tandem” Wichita ATD 208/214 KKB (Kopper Kool Brake) used on Pro Eco slitting lines with the Core-Flex unit for exit tension/elongation control. These lines require precise uncoiling tension control for a wide range of widths and gauges of material, using a “Tandem” Wichita KKB allows precise control over a 53:1 range. Using the Kopper Kool design with proper water cooling system allows for high speed operation up to 140 HP. In addition to the ATD 208/214 Tandem KKB, Wichita offers other size combination’s with even higher capacity with precise control.
 Tandem Wichita KKB For Paper, Film and Foil processing, Wichita Clutch offers the ModEvo modular Tension Brake. This family of products allows Torque Inc. application engineers to select an optimal solution for your application with a variety of rotor’s, friction material and actuators. We have had good success using these products on low speed coil processing lines, where heat is limited and the cost of operating a KKB (Kopper Kool Brake) is prohibitive. In addition, we can engineer unique multiple caliper solutions using Kobelt Calipers for heavy duty applications.
 Wichita ModEvo Tension Control Brake
Tags: Brake, KKB, ModEvo, Uncoiler, Unwind, Wichita Clutch
Posted in Kopper Kool Brake (KKB), Tension Control, Wichita | No Comments »
Monday, April 19th, 2010
In order to rebuild a Wichita KKB the Waterjackets need to be clean from corrosion and have adequate o-ring grooves and copper support ribbing.
 Wichita KKB Waterjacket beyond repair  Wichita KKB waterjacket after HCL cleaning and painting
Tags: Brake, KKB, Rebuilding, Wichita
Posted in Kopper Kool Brake (KKB), Rebuilding, Tips, Wichita | No Comments »
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