Overview

This document provides detailed technical information on permanent magnet hysteresis brakes and couplings manufactured by a German company in Kiel. These devices are primarily used for tension control in wire, glass fiber, and cable applications, as well as general drive technology.

Principle of Operation

The hysteresis units function based on magnetic interaction between two segmented permanent ring magnets and a central hysteresis disc. Torque is generated by magnetic saturation in the disc, controlled by the angular alignment of the magnets. This design ensures infinitely adjustable torque without physical contact, resulting in wear-free and stable operation.

Key Advantages

• No breakaway torque, enabling smooth start-up
• Silent operation due to frictionless design
• Wear-free mechanism ensuring long service life

Design Features

• Built-in bearings support bending moments on shafts
• Customizable shaft length and diameter per customer requirements
• High-energy, precisely ground magnets for frictionless movement
• Torque adjustment via set screw and calibrated housing scale

Product Range and Specifications

The catalog covers multiple hysteresis brake and coupling types with varying torque ranges, maximum speeds, moments of inertia, power dissipation limits, and weights. Examples include:

• Type 513: 0.001–0.014 Nm torque, 4000 rpm max speed, ~0.073 kg weight
• Type 520: 0.001–0.14 Nm torque, 3000 rpm max speed, ~0.31–0.33 kg weight
• Type 610 variants: 0.14–4.5 Nm torque, 1000 rpm max speed, ~4.8–5.0 kg weight

Many models offer stainless steel shafts/housings and hollow shaft options.

Mechanical and Material Details

• Stainless steel (V2A) used for housings and shafts
• Brake casings coated with wear-resistant polyurethane
• Torque adjustments secured by set or lock screws
• Bending moment capacities range from 0.3 Nm to 17 Nm depending on type

Operational Parameters and Recommendations

• Maximum permissible speeds vary between 500 and 4000 rpm by model
• Power dissipation limits ensure safe thermal operation
• Application speeds should be calculated using referenced loss power diagrams
• Custom shaft and bore dimensions available on request

Parts Lists and Component Descriptions

Detailed parts lists for various coupling types include item numbers, quantities, part numbers, and descriptions of components such as housings, magnets, spacers, screws, bearings, hysteresis discs, shafts, and locking washers. These facilitate assembly, maintenance, and ordering.

Technical Specifications of Hysteresis Couplings

• Torque ranges vary widely, e.g., Typ 608 (0.68–7.8 Nm), Typ 929 (0.33–15.8 Nm)
• Moments of inertia range from 4.0 to 282 ×10⁻⁵ kg·m²
• Power dissipation limits from 18 W to 270 W
• Maximum speeds typically 1000 rpm
• Weights range from 2.7 kg to 13.7 kg
• Bending moment limits specified for heavy-duty units (e.g., 225 Nm for Typ 608)

Mechanical Drawings and Dimensions

Precise mechanical dimensions with tolerances are provided for housings, shafts, and mounting holes to support accurate manufacturing and assembly.

Torque Adjustment and Locking Mechanisms

Torque is adjusted via lock screws or tensioning wheels on various models. The Easylock Type EL III clamping system allows variable tension on hardened shafts (minimum 55 HRC) with safe, adjustable clamping force.

Accessories and Additional Components

• Drive plates with detailed dimensions and part numbers
• Flexible elastomeric shaft couplings (Wellen-Klauenkupplungen) available for all shaft diameters
• Special bore sizes and custom versions available on request

Payoff Units with Hysteresis Brakes

Examples include units with additional bearings, spool adapters, and shaft locks designed for various spool diameters and weights, allowing modular configurations.

Constant Tension Brake Assemblies

• Typ 600-040: For winding diameters 150–405 mm, tension 2.3–30 N, weight 5.2 kg, right/left swinging versions
• Typ 651-006: For winding diameters 30–280 mm, tension 0.15–5 N, weight 1.2 kg, right/left swinging versions

General Recommendations and Notes

• Coordinate application speeds with power dissipation curves
• Use hardened shafts (≥55 HRC) for certain clamping systems
• Torque adjustment and locking screws ensure precise, secure operation

Torque Figures and Clamping Hub Specifications

Torque values for clamping hubs made of aluminum vary by bore diameter (Ø 2 to Ø 38 mm) and hub size (Size 19 X 6 and 28 X 10). Torque increases with bore size and depends on hub execution (e.g., slotted with keyway, threaded).

Selection Criteria for Brakes and Couplings

• Required Torque: Calculated from tension/braking force and distance from rotational axis
• Bending Moment: Based on load force and distance from spool center of gravity to shaft
• Allowable Heat Dissipation: Determined by RPM and torque using operating curves

Torque Characteristics of Permanent Magnetic Hysteresis Brakes

These brakes provide constant torque independent of RPM, with torque building during the first 25° of rotation and stable even at standstill, eliminating stick-slip effects common in friction brakes.

Operating Curves and Thermal Considerations

• Blue Area: Safe for continuous 100% duty
• Yellow Area: Suitable for intermittent duty cycles
• Red Area: Risk of thermal overload; larger brake recommended

Mechanical energy converts to heat during operation; thermal load depends on speed and torque setting.

Popular Mounting Arrangements

• As Coupling: For overload protection or torque limiting; slips when torque exceeds set value
• As Clutch: Driven housing with output shaft, connected via timing belt or gear
• As Pay-Off Brake: Stationary brake with reel mounted on shaft; tension varies with reel diameter

Applications of Hysteresis Brakes

Ideal for tension control in fine wires, sensitive materials, and drive applications such as torque limiting and load simulation. Advantages include wear-free operation, torque repeatability, no electrical power needed, smooth running without stick-slip, and low maintenance compared to friction brakes. Widely used in spooler lines for wire, foil, magnetic tapes, and as safety torque limiters.

Product Range and Global Representation

The catalog includes magnetic particle brakes and clutches, magnetic capping clutches, magnetic disc couplings, current-controlled hysteresis brakes, and permanent magnetic hysteresis brakes and couplings. Contact details for global agents across multiple countries are provided for sales and support.