FEATURE MECHANICAL COMPONENTS
PUTTING THE BRAKES ON LAMINATING MACHINERY
mayr power
transmission prole rail brakes have been specied for a laminating machine,
enabling faster, safer, roller changes
A
round 70 years ago, SAUERESSIG began manufacturing printing and embossing rollers for the packaging and printing
industry, and today it is a leading supplier of calendering, embossing and rotary processing systems. Its solutions include complete production lines and customised systems for embossing, finishing, coating, smoothing, perforating and calibrating sheet materials such as paper, film or metal sheets. One example is a 6m
long, 4m wide, customised system designed to coat a steel strip on both sides with a thin protective PET film. The laminating unit consists of two nearly identical, symmetrically arranged side frames, each with a rubberised laminating roller and a contact cooling roller. The steel strip moves vertically between the two laminating rollers at a conveying speed of up to 250m/min, with the rollers pressing the film onto the hot steel strip from both sides. With temperatures of up to 260˚C, the steel
strips heat up the rubber coating on the laminating rollers. Water-cooled contact rollers dissipate this heat and limit the rubber coating’s temperature to a maximum of 90˚C. As a result, the rubber linings of the laminating rollers are subject to wear and must be replaced regularly. So, the laminating unit is designed in such a way that the automated roller replacement only takes half an hour to minimise downtime.
SAFETY BRAKES The laminating unit consists of two symmetrically arranged side frames, both of which are mounted onto profiled rail guides and can be separated axially to replace the worn laminating rollers. While the coating process is in progress, profiled rail brakes from the ROBA guidestop series by mayr power transmission hold the two
32 DESIGN SOLUTIONS APRIL 2026
tolerances on the profiled rails without losing braking force. The ROBA guidestop safety brakes are equipped with two independent brake circuits, allowing for either double holding forces or a redundant design. The profiled rail brakes are therefore directly
ROBA guidestop safety brakes
system parts in position, backlash-free and with high rigidity. To replace the rollers, these safety brakes are released hydraulically. The two machine halves can be moved apart via rack and pinion gears, and the laminating rollers can then be replaced. The ROBA guidestop profiled rail brake serves
as a reliable safety brake and backlash-free clamping unit. It can brake movements safely and quickly, and clamps the axes rigidly and backlash-free. The brakes also work according to the fail-safe principle, so are closed in de-energised condition. In addition, the brakes use pre-tensioned cup springs to press the brake shoes against the ‘waist’ of the profiled rail, thus clamping it in place. The hydraulic brake design used in the SAUERESSIG laminating unit is released using a nominal pressure of 70 bar, which is comparatively low in relation to the very high holding forces. The brake mechanism is dimensioned for relatively large strokes. As a result, the brake can compensate for production
mounted onto the masses which are to be braked or held. This minimises the risk of hazards, particularly with gravity-loaded axles, as the drive element between the motor and the moving mass, such as spindles, spindle nuts, shaft couplings and gears, do not affect safety. This is different for concepts with motor brakes, as all drive elements must transmit the braking torque to the carriage. Furthermore, every element between the brake and the carriage has a negative effect on rigidity. ROBA guidestop safety brakes are therefore considerably more rigid than motor brakes, rod brakes or band brakes, which are often subject to backlash, the company explains.
ROBA GUIDESTOP FEATURES ROBA guidestop safety brakes are available in pneumatic or electromagnetic versions in addition to the hydraulically opening design. The hydraulically releasing guidestop series
covers nominal holding forces from 5000 to 34000 N with four sizes. The pneumatically releasing version offers the greatest variety of options: Six sizes with nominal holding forces from 700 to 15000 N are available in the standard product range. Both versions are available for all common linear guides. Electromagnetically opening rail brakes do not require any pneumatic or hydraulic equipment. mayr power transmission develops this variant on request, customising it for the respective application.
mayr power transmission
www.mayr.com
www.designsolutionsmag.co.uk
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