Crane Brakes: How an Important Feature of Crane Safety Functions

Overhead cranes can be programmed to move automatically which makes it easier than ever to move loads, but what does it take to hold that motion? Crane brakes, similar to the ones in your car, can be designed to stop and slow down even the largest loads in the case of an emergency power loss situation. These brakes are essential to overhead crane safety and function.

The Function of Crane Brakes

Crane brakes hold a crane in place after the drives have slowed down and stopped the travel of the crane. The hoist, trolley, and bridge all require brakes as they can move independently. The trolley and bridge often need to be held in place while the hoist brakes can keep a load held above the ground. No matter the type of crane, every hoist has brakes.

 The two most common types of crane brakes include:

• Drum brakes
• Disc brakes

This digital rendering highlights the parts of crane brakes on an overhead crane.

Crane Brake Breakdown

Brakes are composed of three main pieces.

• Thruster: a thruster holds a brake open until power is supplied to close it. This ensures that the brakes are disengaged during normal operation and engaged when necessary.
• Brake pads or shoes: These components apply pressure and friction to a crane’s brake rotors, effectively hold a crane’s motion.
• Brakes wheel or disc: The wheel of disc is where the brake pad applies pressure to hold a crane’s motion. This part is crucial as it must withstand significant forces and heat generated during braking.

Both of these renderings show a drum brake in different views.

Regenerative Braking

On a modern AC Morgan Crane, the motor drives the majority of the braking, except for emergency power loss scenarios. This is done through regenerative braking, a process where the motor acts as a generator during deceleration. When the crane needs to slow down, the motor reverses its function, converting the kinetic energy of the moving crane into electrical energy. This regenerated electricity is then fed back into the power grid or used to power other crane functions, enhancing overall energy efficiency. Regenerative braking not only provides smooth and controlled deceleration but also reduces wear on mechanical brake components, leading to lower maintenance costs and longer service life for the crane’s braking system.

Modern AC Cranes

Modern AC crane brakes are electrically controlled and are for holding a load when the motor is not moving, or the crane is powered off. The primary use for the brakes on our Morgan cranes is load holding, after a function is un-used for three seconds the motor deactivates and the brake actuates, taking overload holding duties from the motor.

Crane Brakes Installation

Crane brakes arrive pre-calibrated then, adjustments are made during installation, and periodically during service life to compensate for wear. These adjustments ensure the crane brakes maintain optimal performance and crane safety standards, preventing unexpected downtime and potential hazards. Regular calibration and maintenance checks are crucial as they help extend the brake’s lifespan and ensure reliable operation under varying load conditions.

Maintenance, Safety, and Upgrades

Crane brake wear can be identified through periodic inspections. Signs of wear include heat checking or cracking on drums and discs, worn pads, and shoes. Brakes should be inspected and maintained regularly, depending on the severity of the overhead crane use. For more specific guidelines for crane maintenance please review all relevant OSHA guidelines and consult with our expert Morgan Site Services team.

Crane Safety Improvements

With crane upgrades and advancements in technology, safety can be improved. On a recent DC to AC conversion, Morgan upgraded existing DC drum brakes to AC disc brakes, using an adapter plate. This conversion not only enhances braking efficiency but also reduces maintenance requirements and improves overall reliability. The AC disc brakes provide better heat dissipation and more consistent braking power, contributing to safer and more efficient crane operations.

Adding Hoist Brakes

We also added a hoist emergency brake on this crane, for improved crane safety. Emergency brakes are added to a crane which are activated in a situation where there is a failure in the drive system of a hoist. The emergency brakes ensure that the load does not fall to the floor and is held until maintenance can be performed. Disc brakes are smaller and lighter than drum brakes which makes changing and removing them easier. Due to many modern brakes sharing mounting and centerline dimensions, Morgan can replace brakes on a crane from a different manufacturer.

Contact Us About Your Crane Brakes

Crane brakes are essential to ensure your crane operates safely and efficiently. Morgan Engineering can design, repair, and upgrade brakes from any manufacturer. Our expertise ensures that your equipment meets the highest crane safety standards and performs reliably under all conditions.

Ready to enhance your crane’s safety and performance? Contact us today to get a personalized quote for your crane brake solutions.