WE KNOW BRAKES

Our Disc brakes

Johnson designs and manufactures a range of disc brakes in our factories.  The disc brakes come in various configurations, either hydraulic, pneumatic, electric, or manual models depending on customer preference and the application.  The brake systems come in power applied and spring applied fail safe versions.  The two mounting styles available for most models are side or foot mounted.  Johnson also produces brakes with custom engineered mounting designs as required by the customer.  There are direct spring acting, free floating designs and lever brakes as well.  Our free floating brake designs will compensate for various amounts of axial run-out in power transmission equipment.  Johnson has a standard range of control systems for all of the styles of brakes, and custom engineered brake control systems are also available.

Johnson disc brakes are in service around the world on mining conveyors, oil field, nuclear, steel industry, crane hoists and other material handling or power transmission equipment.

Scroll down to see all the types of industrial brake systems we manufacture which include, hydraulic, pneumatic, electrical and manual versions.

DS (Direct Spring Acting) Hydraulic Disc Brakes

[vc_nested_tabs top_margin=”none”][vc_nested_tab title=”Brakes Information” tab_id=”1398059214-1-85″]

01

Model: DS1050D Opposing Piston, Floating Assembly

Dual Actuators, US Navy Whip Hoist

02

Model: DS3040A, Direct Acting and Free Floating, Spring / Hydraulic Disc Brakes

Base style “A”, US Navy Portal Crane Hoists

03

Model: DS3040B

Base Style “B”, Mine Hoist Application

04

Model: DS2040C, Direct Acting and Free Floating, Spring / Hydraulic Disc Brakes

Base Style “C”, Ship Loader Hoist Brake

Direct Acting Spring Disc Brakes

– Applications include:

– Hoist and Conveyor systems

DS Brake Features include:

  • Spring set, hydraulic pressure release
  • Self-contained removable actuators
  • Many spring stack options
  • Stroke / wear adjustment
  • Spring caging feature
  • Hydraulic pressure isolated from disc
  • Actuator manual release / retraction
  • Fixed assemblies with opposing actuators
  • Floating assemblies with low friction float bearings
  • Floating assemblies with single or opposing actuators
  • Narrow profile with actuators on one side
  • Single and multiple actuator assemblies
  • Optional bases for fixed and floating assemblies
  • Optional release and wear proximity – switches
  • Flow through actuators – better oil filtering

Direct Acting Brake Caliper Selection:

The brake size must be chosen to give required braking torque and to dissipate the energy during stopping without over heating the disc. Brake torque is often related to drive motor torque by an arbitrary service factor typically 75% -100% full load torque for crane travel and similar inertial loads which tend to be self stopping or 150% -200% for crane hoists and other overhauling loads. If a precise stop time or distance is specified, then the brake torque must be calculated.
[/vc_nested_tab][vc_nested_tab title=”Brake Model Data” tab_id=”1398059214-2-1″]
MODEL
Swept Face “F”
in(mm)
MIN. DISC DIA. “D”
in(mm)
MIN. Dynamic TORQUE
Lb.ft(Nm)
APPLIED FORCE
lb(n)
DS1025-08
8 (200) 30 (762) 27000 (36700) 59200 (263300)
DS2025-08
8 (200) 40 (1016) 79000 (107500) 119000 (529000)
DS3025-08
8 (200) 60 (1524) 192800 (261400) 178000 (792000)
DS1040-09
9 (229) 35 (889) 45500 (61600) 84000 (373000)
DS2040-09
9 (229) 50 (1270) 142600 (193400) 167000 (743000)
DS3040-09
9 (229) 70 (1778) 318900 (432400) 251000 (1117000)
DS1050-10
10 (254) 40 (1016) 64300 (87200) 103000 (458000)
DS2050-10
10 (254) 55 (1397) 192100 (260500) 205000 (912000)
DS3070-10
10 (254) 80 (2032) 449100 (608900) 308000 (1370000)
DS1070-12
12 (305) 50 (1270) 113200 (153400) 143000 (636000)
DS2070-12
12 (305) 70 (1778) 346700 (470100) 287000 (1277000)
DS3070-12
12 (305) 100 (2540) 788300 (1068800) 430000 (1913000)
[/vc_nested_tab][/vc_nested_tabs]

Magnetic Disc Brakes

[vc_nested_tabs top_margin=”none”][vc_nested_tab title=”Brake Information” tab_id=”1397177467-1-22″]

03

Type CU, DC Magnetic Disc Brakes

(Nuclear Industry)

01

CX Series DC Magnet Disc Brakes

02

CX Series DC Magnet Disc Brake

Spring Set DC Magnet Released Disc Brakes

– Service Duty (Type CU) and Emergency Stop Duty (Type CX) DC Magnet Disc Brakes

Dimensions:

  • Metric, foot mounted

Construction:

  • Fabricated steel mechanism
  • All pins ground stainless steel
  • Friction linings, high temperature non asbestos

Options:

  • Service brake self adjusting device
    (compensates for brake lining wear)
  • Limit switches to monitor release / set or wear
  • Special materials, tests and finishes as required;
  • High integrity requirements such as the nuclear industry

Electrical:

  • Separate enclosed control units for DC or AC supplies
  • Economy circuits available
  • Shunt or series magnets available

Applications:

  • Mechanical handling equipment, cranes, winches,conveyors and mills etc.
  • Emergency stop brakes often installed on flange of crane winding drum

Engineering:

  • Design and selection assistance available
[/vc_nested_tab][vc_nested_tab title=”Brake Model Data” tab_id=”1397177467-2-97″]
BRAKE
MODEL
DISC
DIA. “D” (1)
APPLIED
FORCE “AF”
EFFECTIVE
FACE “F”
WEIGHT
mm(in) kN(Lb) mm(in) kg(lb)
CU01 250-400(9.8-15.7) 3.6(809) 50(2) 30(66)
CU1 315-500(12.4-19.7) 6.1(1370) 60(2.36) 50(110)
CU2 400-710(15.7-27.9) 16.4(3690) 86(3.4) 142(313)
CU3 500-800(19.7-31.5) 37.9(8520) 120(4.7) 230(507)
CU4 630-800(24.8-31.5) 54.0(12100) 120(4.7) 292(644)
CX10 380-600(15-23.6) 25(5620) 60(2.36) 89(196)
CX20 450-710(17.7-27.9) 50(11200) 75(2.95) 102(225)
CX40 500-800(19.7-31.5) 100(22500) 90(3.5) 157(346)
CX60 600-960(23.6-37.8) 150(33700) 114(4.5) 280(617)
CX90 960-1500(37.8-59) 225(50600) 134(5.27) 440(970)
CX135 – details on application

Magnetic Actuator:

Short stroke DC tractive type with encapsulated coil and screw-off release nut with optional switch. All fabricated steel construction.
  • Resin encapsulated coil with Class F insulation
  • Optional replaceable coil arrangement for CX range
  • 100% continuously rated up to +40°C ambient
  • Air gap dust and drip protected by neoprene gaiter
  • Terminal box IP55 enclosure

Characteristics:

All DC magnets tend to inherently slow response due to build up and decay of the magnetic field. The actual times are dependent on size and vary with excitation voltage, coil temperature and spring loading (torque) and also the magnet stroke which increases as brake linings wear.

Coil Forcing:

(Shunt Wound Voltage Operated)
All CU & CX Range brakes are forced open by electric current creating a magnetic field. Brake release and set times are reduced by a separate brake control unit to apply increased power magnetic force during a short preset start period . Control units are enclosed ventilated drip proof IP22 for DC supplies or totally enclosed IP55 with rectifier for 1 or 3 phase AC supplies.
[/vc_nested_tab][/vc_nested_tabs]

Thruster Disc Brakes

[vc_nested_tabs top_margin=”none”][vc_nested_tab title=”Brake Information” tab_id=”1398015888-1-67″]

01

CL Series Thruster Disc Brake (Port Industry, Steel Industry)

02

MB Series Motor Mounted Thruster Disc Brake (Lumber Industry)

04

CL Series Thruster Disc Brake (Port Industry, Steel Industry)

Spring Set 3 Phase Thruster Released Disc Brakes

Dimensions:

  • All metric in-line and compact type

Construction:

  • Fabricated steel mechanism
  • Major pivots non-ferrous bushed
  • All pins ground stainless steel
  • Friction linings high temperature non asbestos
  • Optional sintered metallic linings

Thrusters:

  • Standard Eltma Elhy EB series IP56 enclosed

Special Options -Self adjusting mechanism :

  • Mechanical release lever
  • Limit switches to monitor release/ set or wear
  • Electronic modulated torque by remote pedal

Applications:

  • Mechanical handling equipment, cranes, winches, stacker reclaimers and conveyors etc.

Engineering:

  • Design and selection assistance available
[/vc_nested_tab][vc_nested_tab title=”Brake Model Data” tab_id=”1398015888-2-40″]
BRAKE
MODEL
DISC
DIA. “D” (1)
THRUSTER
MODEL
APPLIED
FORCE “AF”
SWEPT
FACE “F”
WEIGHT
mm (in) kN (Lb) mm (in) kg (lb)
CL11 250-500
(9.8-19.7)
EB220 5250
(1180)
55 (2.2) 56 (123)
  EB300 7125
(1600)
CL10 315-630
(12.4-24.8)
EB20 4980
(1120)
80 (3.15) 95 (209)
EB300 7910
(1780)
95 (209)
EB50 12483
(2806)
99 (218)
EB80 21386
(4808)
105 (232)
CL20 400-710
(15.7-27.9)
EB50 14690
(3300)
120 (4.7) 157 (346)
  EB80 23519
(5287)
163 (359)
EB150 38000
(8546)
163 (359)
CL30 630-800
(24.8-31.5)
EB150 38990
(8766)
130 (5.1) 255 (562)
EB250 62780
(14110)
268 (591)
EB320 95160
(21390)
275 (606)
CL25 450-1000
(17.7-39.3)
EB1250 38300
(8620)
120 (4.7) 230 (507)
EB2000 62300
(14015)
275 (606)

Thruster data:

  • Standard EB Series
  • Fluid; transformer oil BS148 typical Shell diala ‘B’
  • Approximate operating times: brake release 0.1 seconds
  • Brake set 0.25 -0.5 seconds depending on size and brake spring load.
  • Optional features
  • High temperature viton seals.
  • Internal preset hydraulic delay valve(s)
  • Dust protecting hood
  • Internal return c-spring
  • Converter unit to operate from DC supply 220-440V
  • Explosion proof design EExd Group I and II

Alternative Thrusters:

  • Johnson/Eldro/Elhy/Elco to din 15430.
  • Johnson DC Custom
  • Thrusters Also type KT/TKF can be supplied.
  • Flame proof available
[/vc_nested_tab][/vc_nested_tabs]

Hydraulic Disc Brakes

[vc_nested_tabs top_margin=”none”][vc_nested_tab title=”Brake Information” tab_id=”1397093609-1-39″]

28hhh

28HHH Hydraulic Disc Brakes

Small Conveyor System for a gold mine

58HHH

58HHH High Duty Cycle Hydraulic Disc Brakes

Log Handling Crane, Lumber Industry

01

74HHH High Duty Cycle, Spring Applied / Hydraulic Disc Brake

Ship Loader Boom Hoist, Coal Industry

02

3836HX Hydraulic Applied Disc Brake

Winch Hoist Cable Tensioner, Electrical Industry

03

DS1040-08 Direct Acting and Free Floating, Spring / Hydraulic Disc Brakes

Mounted on a Pinion Drive for a Mine Hoist

04

7600 Series Spring Applied / Hydraulic Release Disc Brake

SMARF Facility NASA, Emergency Rocket Hoist Brakes, Tandem Brake Discs

LEVER ACTUATED DISC BRAKE CALIPERS:

– Spring Set / Hydraulic Released Disc Brakes

– Hydraulic set / Spring Released Disc Brakes

Dynamic and Static Application
Disc Brakes for:

  • Industrial
  • Ski Lifts
  • Offshore / Onshore Oil Industry
  • Marine
  • Mining
  • Logging

Features:

  • MECHANISM – free-floating when set and self-centering when released
  • ACTUATION – spring set / hydraulic released, hydraulic set / spring released – spring compensated
  • MOUNTING – foot-mount or side-mount, actuators either handing
  • CONSTRUCTION – steel and ductile iron, or aluminum shoes, stainless steel pins standard
  • CONFIGURATION – single or double actuator,offset to either side of brake disc
  • LININGS – non-asbestos compositions to suit application requirements
  • DISCS – solid or ventilated, carbon or stainless steel, cast iron or non-ferrous
  • OPTIONS – special alloys, coatings, controls and custom mountings
  • APPLICATIONS -hoists / winches, conveyors, drives, processing machines
  • ENGINEERING -application and selection assistance available
[/vc_nested_tab][vc_nested_tab title=”Brake Model Data” tab_id=”1397093609-2-42″]
Brake Model Data – 800 to 4000X Series Caliper Disc Brakes

CALIPER
SERIES
DISC
THICK.
MIN.
DIA. “D”
MAX.
DIA. “D”
SWEPT
FACE “F”
APPLIED FORCE
“AF”
TORQUE DYNAMIC
MIN. DISC DIA.
TORQUE STATIC
MIN. DISC DIA.
TORQUE DYNAMIC
60″/1524mm DIA.
TORQUE STATIC
60″/1524mm DIA.
WEIGHT
in
(mm)
in
(mm)
in
(mm)
in
(mm)
lb
(N)
lb.ft
(Nm)
lb.ft
(Nm)
lb.ft
(Nm)
lb.ft
(Nm)
lb
(kg)
800
1000
0.75
(19)
15
(380)
75
(1905)
2.56
(65)
8530
(38000)
2210
(3000)
1270
(1720)
10208
(13860)
5868
(7960)
73
(33)
1800
2000
1.25
(32)
25
(635)
85
(2159)
3.38
(87)
19200
(85400)
8650
(11700)
4612
(6200)
22650
(30700)
12080
(16400)
130
(59)
1800X
2000X
1.25
(32)
25
(635)
85
(2159)
3.38
(87)
29400
(131100)
13250
(18000)
10600
(14370)
34680
(47020)
27750
(37620)
130
(59)
2800
3000
1.75
(44)
30
(760)
90
(2290)
5.00
(127)
26650
(119000)
13900
(18800)
8000
(10800)
30500
(41500)
17600
(23860)
230
(105)
2800X
3000X
1.0
(25)
30
(760)
90
(2290)
5.00
(127)
28800
(128000)
15000
(20300)
12000
(16200)
33000
(44700)
26400
(35760)
230
(105)
3800
4000
2.0
(50)
35
(890)
95
(2413)
6.13
(156)
53300
(237000)
32000
(43500)
18500
(25100)
61800
(81000)
34500
(46800)
427
(194)
3800X
4000X
1.0
(25)
35
(890)
95
(2413)
6.13
(156)
57600
(256000)
34600
(46900)
27700
(37500)
64600
(87500)
51700
(70000)
427
(194)
Brake Model Data – 4800 to 7600 Series Caliper Disc Brakes

CALIPER
SERIES
DISC
THICK.
MIN.
DIA. “D”
MAX.
DIA. “D”
SWEPT
FACE “F”
APPLIED FORCE
“AF”
TORQUE DYNAMIC
MIN. DISC DIA.
TORQUE STATIC
MIN. DISC DIA.
TORQUE DYNAMIC
100″/2540mm DIA.
TORQUE STATIC
100″/2540mm DIA.
WEIGHT
in
(mm)
in
(mm)
in
(mm)
in
(mm)
lb
(N)
lb.ft
(Nm)
lb.ft
(Nm)
lb.ft
(Nm)
lb.ft
(Nm)
lb
(kg)
4800
5000
1.0
(25)
30
(762)
100
(2540)
6.00
(152)
39100
(174000)
19600
(265000)
15600
(21200)
75700
(103900)
61300
(83100)
332
(151)
5800
6000
1.0
(25)
40
(1016)
100
(2540)
7.13
(181)
78300
(348300)
53600
(72700)
42900
(58200)
151500
(205400)
121200
(164300)
764
(347)
T5800 1.0
(25)
40
(1016)
100
(2540)
7.13
(181)
157000
(698400)
107500
(145800)
86000
(116300)
303800
(410800)
243000
(329500)
1395
(634)
7200
7400
1.25
(32)
60
(1524)
100
(2540)
8.5
(216)
117600
(523100)
126200
(171100)
101000
(136800)
224200
(303900)
179300
(243100)
1680
(764)
7600 1.25
(32)
60
(1524)
100
(2540)
8.50
(216)
235200
(1046200)
252300
(342100)
202000
(273700)
448300
(607800)
358700
(486300)
2580
(1173)
[/vc_nested_tab][/vc_nested_tabs]

Air Operated Disc Brakes

[vc_nested_tabs top_margin=”none” el_class=”Brake Model Data”][vc_nested_tab title=”Brakes Information” tab_id=”1398058228-1-90″]

01

58HBA Pneumatic (Air) Disc Brake

1750 HP Drives on Mining Shaft

02

816FA Pneumatic Disc Brake

Mounted on a Log Loading Machine for Forest Industry

03

816A Pneumatic Disc Brake

Air Applied / Spring Released

78HBA Series Spring Applied / Pneumatic Release

Dual Mode, Service and Parking Brake, mounted on a mobile Oil Rig

Lever Actuated Disc Brake Calipers:

– Spring Set / Air Pressure Released Disc Brakes

– Air set / Spring Released Disc Brakes

Dynamic and Static Application Disc Brakes for:

  • INDUSTRIAL
  • OFFSHORE / ONSHORE OIL INDUSTRY
  • MARINE
  • MINING
  • LOGGING

Features:

  • MECHANISM – free-floating when set and self-centering when released
  • ACTUATION – spring set / air released, air set / spring released – spring compensated
  • MOUNTING – foot-mount or side-mount, actuators either handing
  • CONSTRUCTION – steel and ductile iron, or aluminum shoes, stainless steel pins standard
  • CONFIGURATION – single or double actuator, offset to either side of brake disc
  • LININGS – non-asbestos compositions to suit application requirements
  • DISCS – solid or ventilated, carbon or stainless steel, cast iron or non-ferrous
  • OPTIONS – special alloys, coatings, controls and custom mountings
  • APPLICATIONS -hoists / winches, conveyors, drives, processing machines
  • ENGINEERING -application and selection assistance available
[/vc_nested_tab][vc_nested_tab title=”Brake Model Data” tab_id=”1398058228-2-91″]
Pneumatic / Air Brake Model Data – 800 to T5800 Series Caliper Disc Brakes

CALIPER
SERIES
DISC
THICK.
MIN.
DIA. “D”
MAX.
DIA. “D”
SWEPT
FACE “F”
MAX. APPLIED
FORCE “AF”
TORQUE DYNAMIC
MIN. DISC DIA.
TORQUE DYNAMIC
MAX. DISC DIA.
MAX. WEIGHT
in
(mm)
in
(mm)
in
(mm)
in
(mm)
lb
(N)
lb.ft
(Nm)
lb.ft
(Nm)
lb
(kg)
800
1000
0.75
(19)
15
(380)
75
(1905)
2.56
(65)
6400
(28500)
1670
(2260)
9670
(13100)
47
(21)
1800
2000
1.25
(32)
25
(635)
85
(2160)
3.38
(87)
19600
(87200)
5770
(7820)
21800
(29500)
106
(48)
1800X
2000X
1.25
(32)
25
(635)
85
(2160)
3.38
(87)
29400
(131100)
5770
(7820)
21800
(29500)
106
(48)
2800
3000
1.75
(44)
30
(760)
90
(2286)
5.00
(127)
19200
(85400)
10000
(13600)
34000
(46100)
225
(102)
2800X
3000X
1.0
(25)
30
(760)
90
(2286)
5.00
(127)
28800
(128000)
15000
(20300)
51000
(69200)
225
(102)
3800
4000
2.0
(50)
35
(890)
95
(2413)
6.13
(156)
38400
(171000)
23200
(31200)
71200
(96500)
494
(225)
3800X
4000X
1.0
(25)
35
(890)
95
(2413)
6.13
(156)
57600
(256000)
34800
(46800)
107000
(145000)
494
(225)
4800
5000
1.0
(25)
30
(762)
90
(2286)
6.00
(152)
39100
(174000)
19600
(26500)
68500
(92900)
327
(149)
5800
6000
1.0
(25)
40
(1016)
100
(2540)
7.13
(181)
78300
(348000)
53600
(72700)
151000
(205000)
754
(343)
T5800 1.0
(25)
40
(1016)
100
(2540)
7.13
(181)
157000
(698400)
108000
(145000)
303000
(411000)
1375
(625)
[/vc_nested_tab][/vc_nested_tabs]

TL Series Grinding Mill High Torque Caliper Disc Brakes

[vc_nested_tabs top_margin=”none”][vc_nested_tab title=”Brakes Information” tab_id=”1398062894-1-33″]

01

Three TL800 Series Caliper Brakes

Leaving the Main Manufacturing Facility on Transport. Used with SAG, AG, and BALL mills

02

Two model 4-TL250 Series Toggle Lever Caliper Disc Brakes

Used with SAG, AG, and BALL mills

03

Caliper levers incorporate a unique toggle mechanism to compensate for spring force resulting in constant braking torque

04

4-TL250 HIGH TORQUE Toggle Lever disc brakes

Perspective Image of the Massive 4-TL250 Brake Calipers, Application for Mining SAG Mill

TL SERIES TOGGLE LEVER CALIPER BRAKES

  • TL SERIES TOGGLE LEVER CALIPER BRAKES are the largest known spring applied, hydraulic released caliper brakes in the world. Features include a stackable design allowing 1 to 4 calipers to be mounted in a common frame and spring force compensation by toggle mechanism resulting in constant braking torque. The TL series brake is particularly well-suited to accommodate very high braking torque requirements in the harshest environments.
  • TL series brakes are ideally suited for use with equipment such as SAG mills and rock crushers.
  • TL series brakes are well suited for use with conveyors requiring high torque braking.

Design Features:

  • Caliper shoes are attached with stainless steel shoe pins. These pins Incorporate countersunk lubricating holes, tapped pin-pulling holes, and a pin retention groove.
  • Caliper levers incorporate a unique toggle mechanism to compensate for spring force. This ensures constant braking torque.
  • The system is powered by a hydraulic power unit incorporating a manifold fitted with two 010 valves (shown in blue) to accommodate brake set, creeping and inching modes.
[/vc_nested_tab][vc_nested_tab title=”Brake Model Data” tab_id=”1398062894-2-54″]
MODEL APPLIED FORCE
lb (kN)
Disc DIA.
in (mm)
DYNAMIC TORQUE
Lb.ft (kNm)
TL075 75000(334) 80 (2032) 112,500 (152)
TL150 150000(668) 144 (3658) 421,800 (571)
TL250 250000(1112) 588 (14935) 3,000,000 (4,085)
TL375 375000(1668) 600 (15240) 3,689,000 (5,000)
TL550 550000(2446) 600 (15240) 5,410,000 (7,335)
TL800 800000(3558) 600 (15240) 7,853,000 (10647)

Brake Selection::

Note: All of the above TL brake calipers can be made in stacks of up to four individual brake units. Depending on the stackup the TL brake calipers can provide a torque of up to four times what is shown in this table.

The brake size must be chosen to give required braking torque and to dissipate the energy during stopping without over heating the disc. Brake torque is often related to drive motor torque by an arbitrary service factor typically 75% -100% full load torque for crane travel and similar inertial loads which tend to be self stopping or 150% -200% for crane hoists and other overhauling loads. If a precise stop time or distance is specified, then the brake torque must be calculated.

[/vc_nested_tab][/vc_nested_tabs]
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  • Specialists in industrial braking for more than 100 years.

    Contact us for help finding the best and most cost effect solution.