Brake reducer cannot stop, troubleshooting steps for brake structure failure

The phenomenon of "unable to stop" (insufficient or ineffective braking force) in brake reducers usually involves multiple aspects such as mechanical structure wear, electrical control system abnormalities, and mismatch between control parameters and loads. For efficient troubleshooting, it is recommended to perform systematic testing according to the following steps:

1、 Mechanical structure inspection

The wear and physical state changes of mechanical components are the most direct causes of brake failure:

1. Check the condition of the brake pads: Observe whether the brake pads are excessively worn (with a thickness less than one-third of the original thickness), and whether there are oil stains, cracks, or uneven wear on the surface. If the above situation occurs, clean the brake surface (wipe with alcohol, do not apply lubricating oil) or replace the brake pads directly.

2. Measure and adjust the brake clearance: A clearance that is too large or too small can cause brake lag or braking. The standard gap is usually between 0.2-0.5mm. Adjustment can be made by loosening the fixing screw, turning the clearance adjustment nut, and measuring with a feeler gauge until it fits snugly and there is no abnormal noise.

3. Check the spring and fasteners: visually or with tools test whether the internal spring is loose, fatigued, or broken; At the same time, check whether the brake bracket, fixing bolts and other components are loose, and if necessary, use a torque wrench to tighten them again according to the rated torque.

4. Check coaxiality: If the coaxiality deviation between the motor and the load is too large, it can also cause inaccurate positioning during high-frequency start stop. It is recommended to use a dial gauge to correct coaxiality and ensure that radial runout is ≤ 0.1mm.

2、 Electrical control system troubleshooting

Delay in electrical signals or abnormal power supply can cause the brake to fail to respond in a timely manner:

1. Detecting coil voltage and resistance: Use a multimeter to measure whether the power supply voltage of the brake coil meets the rated value (such as DC99V, AC220V, or 24V DC), and check whether the control circuit wiring is virtual. If the measured coil resistance is much lower than the normal value (indicating a short circuit) or infinite (indicating an open circuit), the coil needs to be replaced.

2. Check encoder feedback (for servo motors): If it is a servo brake motor, inaccurate positioning may be caused by loose encoder wiring or lens contamination. Check the wiring and tighten it, clean the lens, or calibrate the encoder zero point through software.

3、 Control parameter and load adaptation troubleshooting

If it is a system controlled by a frequency converter, improper parameter settings can also cause the car to slide:

1. Optimize the starting pre torque and delay: When the output frequency of the frequency converter does not establish sufficient torque, the brake will be released, which will cause the car to slip. It is recommended to set a reasonable starting pre torque (usually 20% -30% of the rated torque) in the frequency converter and configure a brake release delay of 0.1-0.5 seconds (recommended 0.3 seconds).

2. Speed arrival signal detection: Configure the speed arrival signal detection function to ensure that the brake is only released when the motor speed reaches 10% -15% of the set value.