Clutches and brakes Use in food technology

Five applications from the food technology show the diversity of Mayr brakes and clutches from Mauerstetten. A linear brake secures the Cheese production by Chalon Mégard. Packing and Palletizing of beverages disk pack couplings safely transmit the torques in the drive. A shaft coupling masters high temperature differences baking lines. The input and output disconnection in an emergency packaging equipment take over slip hubs, which are also in the ice making provide the necessary security.

 

Contents

• Linear brake secures systems in the production of cheese
• Safety brakes and shaft couplings for beverage technology
• Powerful shaft coupling for bakery technology
• Safety couplings when used in the packaging industry
• Reliable coupling secure ice cream and cream cheese production
  
  

Linear brake secures systems in the production of cheese

23.10.2019/XNUMX/XNUMX | The systems for making cheese are just as sophisticated as the delicatessen itself. The French manufacturer Chalon Mégard relies on the reliable machine for its cheese production linear brake from Mayr Antriebstechnik. The corrosion-protected braking systems withstand the operating conditions Food industry stand without any problems and ensure, for example, in a vertical conveyor system that the heavy cheese wheels do not fall.

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Compensating couplings for high temperatures

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There are more types of cheese in France than there are days in the year. According to estimates by the national dairy industry association, there are around 1200. Equipment is required for their production - whether traditionally by hand in a small business or automated in production plants. The renowned manufacturer of Cheese and milk products Chalon Mégard from the Auvergne-Rhône-Alpes region. It offers solutions for all process steps from milk preparation and curdling to curdling, curd cheese, forming and bathing in brine to fermentation and maturing.

Cheese making machines

With machines, moisture and cleaning fluids are part of the daily environmental conditions. Therefore, the company relies on robust Drive Technology, with product properties that withstand the conditions of use. In a conveyor system at an end customer, for example, the proven "Roba-linearstop" Safety brakes from Mauerstetten in the Allgäu in a corrosion-protected version made of stainless steel.

In the system, 20 kg cheese wheels are made with a Speed ​​of 2 m / s transported to the maturing cellar via an 8 m high elevator. Two pneumatic linear brakes with a holding force of 50.000 N each secure the elevator. They hold the loads and bring them in an emergency - if, for example, the drive belts tears - to a standstill within fractions of a second. The redundant design ensures the necessary security.

Reliably secure vertical axes

The compact one linear brake Roba-linearstop is particularly suitable for securing the gravity-loaded axes in the vertical conveyor system, as they act on separate brake rods independently of the drive train. There are no Timing belts, Couplings or Spindle nuts in the brake safety line. Like all safety brakes from the manufacturer, the linear brake also works according to the fail-safe principle.

That means that they are closed in the de-energized state. The braking force is through compression springs generated. the Roba-linearstop works without a self-reinforcing wedge effect and thus acts in both directions of movement of the axes. Due to the power generation without this "getting stuck" and the very short reaction time, the axis does not sag when closing.

Other linear brakesthat work with a self-reinforcing wedge effect generate a high braking force. However, the wedge effect of the linear brake only works in one direction and in order to generate the wedge effect, the brake has to "reset" when it closes. If the wedge effect of the linear brake is not limited, the braking force increases to infinity. The machine design must absorb this shock. In addition, the clamping must often be released to release the linear brake. This is not necessary with the Roba-linearstop.

In addition to the pneumatic versions, the Roba-linearstop linear brake is also available as a hydraulische and electromagnetic Design. Thus, depending on the application, the right functional principle with the corresponding product properties can be selected. As a compact brake unit, it can also be integrated into existing machine and plant constructions easily, quickly and without time-consuming adjustment work.

Short switching times of the linear brake over the service life

For the safety of man and machine, there is a vertical axis short stopping distances important. The switching times of the linear brake are decisive for the braking distance. Because in the time of free fall until the brake closes and the deceleration begins, the mass accelerates additionally.

"When configuring the linear brakes, users should therefore pay attention to the shortest possible, verified switching times," explains Bernd Kees, Product Manager at Mayr. “And you should also configure it in such a way that these switching times are maintained over the entire life of the linear brake.

In order to achieve the greatest possible safety in the respective application and to guarantee the configured switching times over the entire service life, the linear brakes must be equipped with a reliable switching status control. " 

The pneumatic version The linear brake has been tested and confirmed as a fully-fledged dynamic braking device by TÜV Süd. It easily fulfills the test principle for emergency braking with holding function for linear movements (GS-MF-28) of the professional association institute for occupational safety (BIA). This test principle defines 1 million switching operations, both with and without load transfer, as well as an additional 1000 dynamic braking operations.

"And the pneumatic clamping units are also certified," explains Bernd Kees. “In addition to the required test criteria for Holding brakes we also carried out 100 dynamic braking actions with our pneumatic clamping unit as part of the certification by TÜV Süd,” he emphasizes. "This test, which is not normally part of the TÜV test for holding brakes, was important to us because dynamic braking occurs again and again in practice." The pneumatic clamping units were also tested under realistic conditions and easily meet all requirements.

Every single safety brake that leaves the Mayr factory must have a 100% exam consist. All measured values ​​determined are archived in the electronic database together with the associated serial number of the brake. This guarantees 100 percent traceability.

Safety brakes and shaft couplings for beverage technology

18.09.2019/XNUMX/XNUMX | The traditional family company Beyer Maschinenbau plans, develops and builds efficient packing and palletizing systems for the beverage and food industry. The patented "Roba-DS" Disc pack clutch from Mayr Antriebstechnik transmits precise torques in these systems. In lifting applications, the "Roba-linearstop" Safety brakes reliable for the safety of people and material.

The most popular non-alcoholic cold drink among Germans is natural mineral water. In 2018, every German citizen drank an average of around 145 liters per capita. When it comes to alcoholic beverages, Germans actually prefer beer. The average annual consumption here is 110 liters per capita. For efficient and fast Packaging, transport and sorting of beverage bottles Packing, transporting or sorting efficiently and quickly requires intelligent and powerful machines.

Bayer mechanical engineering from Roßwein in Saxony has specialized in the development and construction of packaging and palletizing systems for the beverage and food industry. Customers include not only well-known mineral springs and Breweries, but also other well-known beverage manufacturers. "Regardless of whether it's a large brewery or a small family business, we plan and build conveyor and packaging technology that is specially tailored to the needs of our customers - from the individual machine to complete systems," explains Til Beyer, who is now the fourth generation to run the company.

The Packing and palletizing systems sometimes have to lift very heavy weights and load them in the exact position. That is why the machine builder relies on the robust and powerful Roba-DS disk pack couplings from Mayr in the systems. The proven Roba-linearstop pneumatic safety brakes also ensure the safety of people and material.

Palletizing technology in several axes

With the "Multipal" family of palletizers, Beyer offers a wide range of different column and portal palletizers as well as Industrial robotsn, which, depending on the application and task, can be up to three, four or six axes can be designed. “The Multipal machines depalletize pallets, for example with empty beverage crates, in layers. At the same time he raises grabalways remove a layer of eight or 16 crates from the pallet and place them on a conveyor belt,” says Till Beyer, describing one of the possible applications.

The crates are then transported via the conveyor belt, for example to the Cleaning and filling plant. The crates then come back filled, are stacked in layers or rows on the pallets by the palletizer and are then ready for transport. "Depending on the application, our palletizers can lift loads of up to 700 kilograms and process up to 4000 boxes per hour," explains Till Beyer. To ensure that the operation always runs smoothly even with these services, all movements must be carried out with great precision, ie the crates must be stacked exactly on top of each other or bottles must be positioned exactly in the compartments provided in the crates.

From the drive unit to the gripper head

A coupling that transfers the torque from the drive unit to the guide of the gripper head, for example, must work with high precision and at the same time withstand the high loads. The Roba-DS disk pack couplings are used here. They transmit the torque without backlash and are extremely torsionally rigid and compensate for radial, axial and angular shaft misalignment. They not only ensure precise torque transmission, but also protect the bearings installed in the shaft train from unwanted loads. The Roba DS are robust, reliable and temperature-resistant. In addition, they work wear-free and thus reduce the necessary maintenance effort to a minimum.

Matched to the respective drive units of the various palletizing and packing machines, the Roba-DS disk pack coupling is used in different sizes and with different torques. Depending on the application and requirements, there is sometimes a coupling with a very short design or also with an intermediate sleeve of up to three meters necessary.

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Robotic grippers, EOAT, gripper kits for cobots and industrial robots

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The nominal torques specified in the catalog can be used with all disk pack couplings without any restrictions. A reduction of the nominal torque due to displacement, collective load or balancing requirement is not necessary. The multi-plate clutches are compact, power-dense and very small. They transmit torques up to the nominal torque absolutely backlash-free and with consistently high torsional rigidity. The specified shaft misalignments can be used 100% in total without affecting the transmittable torque.

Safety for vertical axes

In order to increase the safety of the Multipal and Multipac palletizing and packing machines, Beyer Maschinenbau has equipped the systems with Mayr's Roba-linearstop safety brakes. “The brakes ensure safety in the lifting applications,” explains Thomas Luckman, Head of Design at Beyer Maschinenbau. “If a belt breaks, for example, they make sure nothing breaks. These are protective cells in which no one is present during operation. During maintenance, however, these areas must also be entered. The safety brakes then ensure the safety of the personnel.”  

The brakes work after the Fail-safe principle. So they are closed in the de-energized state. The braking force is generated by compression springs. The Roba-linearstop acts on a separate brake rod. When the brake closes, the rod is held with no play. The brake works without a self-reinforcing wedge effect and thus works in both directions of movement.

As a compact brake unit, it can also be integrated into existing machine and plant constructions easily, quickly and without time-consuming adjustment work. There they are next to the pneumaticen version also as electromagnetice and hydraulice execution. All linear brakes from the drive specialist are suitable for emergency stop braking. The pneumatic version has also been tested and confirmed by the TÜV as a fully-fledged dynamic braking device. It easily meets the test principle for emergency braking with a holding function for linear movements (GS-MF-28) of the Employer's Liability Insurance Institute for Occupational Safety and Health (BIA). This requires 1 million switching operations, both with and without load transfer, as well as an additional 1000 dynamic braking operations.

Every single safety brake that leaves the Mayr factory must have one after complete assembly and adjustment 100% exam exist. All measured values ​​are archived in the electronic database together with the corresponding serial number of the brake. This guarantees XNUMX% traceability.

Powerful shaft coupling for bakery technology

14.01.2019/XNUMX/XNUMX | In large European bakeries they are running Baking streets sometimes around the clock for the production of baguettes. The bakery technology with all its components must therefore be able to withstand the high demands. That's why a manufacturer relies on the robust and powerful Roba-DS Couplings from Mayr drive technology. They easily and maintenance-free withstand the high temperature differences between the oven and cooling or freezing lines.

According to tradition, a baker from Vienna who was around 1830 moved to Paris baked French baguette for the first time to have. What was done back then in laborious manual work is now done in many bakeries with modern technology and - depending on the size of the company - partly also on fully automated baking lines. All process steps are integrated in such lines, from dough production and processing to proofing lines and the oven to cooling and freezing systems and finally to packaging. In order to connect the many units, a manufacturer relies on the proven Roba-DS disk pack couplings from Mayr in its bakery technology.

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Roller chain for the high demands of food technology

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"Among other things, the variety of variants and flexibility were important for the customer," describes Ralph Eple, Product Manager at Mayr in Mauerstetten, the requirements. For example, Roba-DS shaft couplings with radially divisible half-shell hubs enable easy and quick assembly of large modules. These modules are positioned and aligned on site and only then connected by the coupling. Smaller modules, which are manufactured in advance, could be easily assembled using a coupling with clamping hubs.

Variable standard kit with hub and sleeves

"Our Roba-DS series has a wide standard kit with a variety of different hubs and spacers. The customer can serve himself from one pot and does not have to resort to another coupling series, "adds Ralf Epple.

Some of the baking lines for the production of baguettes are in operation 24 hours a day, seven days a week. For this reason, the coupling that transmits the torque must also be able to withstand the high loads. The disk pack couplings are robust, reliable and temperature-resistant. For example, you can easily drives on the oven be used where temperatures of up to 150° C sometimes occur. And also -40° C in the freezing streets cannot harm the clutch.

In the food industry in general, there are often areas in which additional protection against corrosion is required. Depending on the application, couplings are included here Coatings or special designs in stainless steel. The Roba-DS shaft couplings are wear-free and thus reduce the necessary maintenance to a minimum. They ensure reliable and smooth operation.  

Power density with zero backlash and torsional rigidity

"Due to two other properties, the coupling is particularly well suited for use in the baking lines," continues Ralf Epple. "They transmit the Roba-DS the torque backlash-free and extremely torsionally rigid and are particularly powerful. Unique constructive details in the disk packs and the use of specially shaped collar bushings ensure a backlash-free power flow with a very high power flow density between input and output. These properties are particularly beneficial in dough kneading systems, where high forces are often at work and the load scenarios are not homogeneous due to slowly changing moments. A clutch with play cannot be used here.”

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The multi-plate clutch and its industrial applications

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With the Roba-DS, the nominal torques specified in the catalog can be used without any restrictions. A reduction of the nominal torque due to displacement, collective load or balancing requirement is not necessary. The coupling elements are not only power-dense, but also compact and very small. With providers who have to take displacements and alternating torques into account when dimensioning, a larger coupling often has to be selected for the same nominal torque and the same speed. The Roba-DS disk pack couplings transmit torques up to the nominal torque with absolutely no backlash and with constantly high torsional rigidity. The specified shaft misalignments can in total 100% exhausted will have no effect on the transmittable torque.

Safety couplings when used in the packaging industry

17.10.2017 | safety couplings ensure the reliable protection of people and material in packaging machines and filling systems. They separate input and output at lightning speed, thus preventing expensive damage. For plant operators, this means simple restarting, increased machine availability and minimized scrap costs. Mayr Antriebstechnik has developed a wide range of torque-limiting safety couplings so that the coupling is optimally suited to the respective application.

With a per capita consumption of 148,2 l in 2016, natural mineral water is the most popular non-alcoholic cold beverage in Germany. Sales are increasing continuously and in 2016 were already over 11,3 billion liters. In order to be able to fill and pack the large quantities of mineral water bottles efficiently and quickly, a intelligent, powerful machine park permanently in use. After filling, PET mineral water bottles are often grouped into packs of six or twelve and wrapped in foil, just like cartons or cans for other drinks. To ensure that all processes run smoothly in such film wrapping machines, many manufacturers and users rely on Mayr mechanical safety clutches.

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Whisper-quiet elevator brake secures elevators and escalators

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In a first step, the products are wrapped in foil in these packaging machines. So-called Foil rollover or arms guide the film around the product. If the arms encounter resistance when striking, for example against a bottle that has tipped over due to incorrect filling, the safety couplings interrupt the torque transmission at lightning speed. In this way, they reliably protect the drives in the arms from damage caused by overload. The system can therefore be put back into operation quickly and without parts having to be replaced or repaired.

Decouple masses in fractions of a second

Despite the electronic monitoring functions of the Machine control like the motor current measurement, mechanical safety clutches like the “EAS-compact^" indispensable components in the packaging industry. Because the electronic motor current measurement recognizes faults and errors, but can only switch off the drive. It is therefore too slow to avoid collisions with the constantly increasing production speeds.

The mechanical safety clutches, on the other hand, can open the drive train and masses decouple in fractions of a second. They reliably prevent expensive damage. In addition, opening the drive train makes it easy and uncomplicated to remove, for example, a jammed and possibly broken product. Processes don't have to run backwards and products don't have to be thrown away. Safety couplings make it easier to start up again, increase machine availability and help to minimize scrap costs.

The right coupling for every application

For the food and packaging industry, the drive specialist offers a versatile product portfolio of safety couplings for the various process steps. The EAS-compact safety clutches are one of them load-breaking clutches. They transmit the torque in a form-fitting manner, which is generated by the preload of disc springs. In the event of an overload or collision, load-disconnecting safety couplings separate the input and output, which means they interrupt the transmission of torque or power.

The EAS-Compact clutches in latching design are immediately ready for operation again after the fault has been eliminated. snap-through clutches automatically snap into place every 15 degrees, for example, or in a position defined depending on the application; Synchronous clutches after 360 degrees. The latter are often the first choice, especially for rotary tables. For example, EAS compact synchronous clutches are used in a filling plant for cream cheese. They each sit in the drive in the middle of the rotary table, which rotates the table top with the cream cheese jars for filling. In the event of an overload, for example if too many empty pots are refilled and the table jams, the safety clutch disengages. It automatically snaps back into exactly the same place after a full turn.

Disconnecting couplings for high-speed drives

safety couplings in unlocking execution on the other hand, separate completely and almost free of residual torque. They remain in this separated position until they are re-engaged by hand or devices. Disengaging safety couplings are therefore particularly suitable for high-speed drives or drives with large moments of inertia.

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Safety brakes for stage technology and action films

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The stored rotational energy can run out freely in the event of a collision. The robust ones are suitable for applications with long run-down times and drives that are difficult to access EAS reverse safety couplings. They rest simply by slowly turning backwards at a speed < 10 min^-1 automatically, without the use of pneumatics or hydraulics.

The EAS safety clutches can be set and work very precisely with high repeatability. They transmit the torque backlash-free in trouble-free operation and thus ensure a long service life and low wear. For areas of application such as the food industry, where moisture and cleaning liquids are part of the daily environmental conditions, the company offers special versions and designs, for example made of stainless steel, with a seal or housing.

Applications for load holding clutch

In filling or packaging machines, in which products are moved at an angle or vertically and which must not fall even in the event of an overload, load-holding safety clutches such as the Roba slip hubs. They transmit the torque through frictional engagement via friction linings, which are preloaded with disc springs. The stronger the disc springs are pressed together by the adjusting nut, the higher the torque that can be transmitted. In the event of an overload, the flange with the drive element slips against the resistance of the friction linings.

The clutch does not interrupt the transmission of torque, but holds the load with the set torque, the products do not crash uncontrollably. With the torque limiter, the torque can be infinitely and precisely adjusted to the respective operating conditions using a scale on the adjusting nut. Also they are robust and by their closed construction protected against the ingress of cleaning agents and other liquids. Depending on the requirements, the Roba slip hubs can also be designed to be protected against corrosion.

At the Mauerstetten coupling specialists, users receive everything from one source - based on decades of know-how, supported by a service tailored to their needs.

Reliable coupling secure ice cream and cream cheese production

 

30.06.2016/XNUMX/XNUMX | The safety coupling ensures the reliable protection of people and material in production. Mayr power transmission has a wide range to ensure that the coupling is optimally suited to the respective application torque limitingdeveloped safety couplings. For areas of application such as the food industry, where moisture and cleaning fluids are part of everyday environmental conditions, the company offers corrosion-protected drive elements made of rust-free materials.

Whether fruit flavor or milk ice cream with chocolate icing - in summer many people like to refresh themselves with an ice cream on a stick. The patent for the popular classic was registered in the United States more than 90 years ago. At that time, the ice cream was still laboriously put into molds and provided with a stick. Today, production is carried out with modern technology - depending on the product and machine size up to 30.000 popsicles an hour produces

How is an ice cream in style?

For the The Brand for example one Chocolate covered vanilla ice cream the ice mass is first pressed into a tube with an oval opening. Then the amount for exactly one ice cream is squeezed out of the tube. At that moment, another machine shoots a stick into the ice mass. A knife then separates the individual ice from the strand of ice, the ice falls onto a conveyor belt and is transported on to the next production steps.

It is important for the quality of the ice cream that the sensitive wooden sticks do not splinter on their way through the machine. That's why a manufacturer of ice cream uses safety couplings from Chr. Mayr GmbH + Co. KG from Mauerstetten with the "Roba" slip hubs damage to the stems Reliable prevent.

Slip hub for reliable overload protection

When the machine picks up the wooden sticks from the bottom of the container in order to then transport them one by one to the top of the ice cream, the sticks can become crosswise. To the fine conveyor chain against overload and breakage zu protect, is therefore a Roba slip hub on the over Timing belts attached to the driven shaft of the take-up wheel. A second sliding hub sits directly on the shaft of the separating unit to prevent the wooden sticks from splintering due to tilting.

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Slipping clutch and overload clutch limit torques

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Type Roba is a load-holding safety coupling that Torque transmitted by friction. This means they transmit the torque via friction linings that are preloaded with plate springs. The stronger the disc springs are pressed together by the adjusting nut, the higher the torque that can be transmitted. In the event of an overload, for example a popsicle stick, the flange with the drive element slips against the resistance of the friction linings. The clutch does not interrupt the torque transmission, but holds the load with the set torque.

This is important so that the vertically or diagonally moving wooden sticks do not fall uncontrollably. With the slip hubs, the torque can be infinitely and precisely adjusted to the respective operating conditions using a scale on the adjusting nut. They are robust and thanks to their closed design protected against pollution by detergents and other liquids. Depending on the requirements, the Roba slip hubs can be designed to be protected against corrosion.

Safety clutch in release design

Ice cream cones are older than popsicles. The first ice cream cones were also being baked in the United States at the end of the 19th century. Here, too, production is now fully automated and in large quantities. To do this, the wafer sheets are first baked in the oven and given their final shape while they are still warm. For example, a winding head rolls the waffles into cones before a rotating doffing head removes the waffles and places them on a conveyor belt. In the Delivery of the waffles blockages can occur on the pickup head.

A baking machine manufacturer therefore relies in the drive of the pickup head a safety coupling of the "EAS compact" type" Safety clutch in release version on. This protects the machine from damage and the operator from injury. This safety coupling belongs to the load-disconnecting coupling category. It transmits the torque in a form-fitting manner. The torque is generated by preloading disk springs.

In the event of an overload or collision, the load-disconnecting safety clutch separates the input and output, i.e. it interrupts the torque or power transmission. Disconnecting versions separate completely and with almost no residual torque. They remain in this separated position until they are re-engaged by hand or devices. The disengaging safety clutch is therefore particularly suitable for high-speed drives or drives with large moments of inertia. The stored rotational energy can run out freely in the event of a collision.

Disengaging and engaging clutch

A locking clutch also separates input and output in the event of an overload. In contrast to unlockable versions, however, it is immediately ready for operation again after the fault has been rectified. Snap-through clutches automatically re-engage every 15 degrees, synchronous clutches after 360 degrees. The latter are often the first choice, especially for rotary tables.

In a bottling plant for cream cheese, for example, EAS compact synchronous clutches for use. They each sit in the drive in the middle of the rotary table, which rotates the table top with the cream cheese jars for filling. In the event of an overload, for example if too many empty pots are refilled and the table jams, the safety clutch disengages. It automatically snaps into place again after a full turn, exactly in the same place.

The EAS are very precisely adjustable and work with high repeatability. They transmit the torque backlash-free in trouble-free operation and thus ensure a long service life and low wear. For areas of application such as the food industry, where moisture and cleaning liquids are part of the daily environmental conditions, the company offers special versions and designs, for example made of stainless steel, with a seal or housing.

The safety coupling offers effective protection for sensitive machine elements or products. However, in order to reliably protect against overload damage, it must be optimally suited to the respective application. As the world's leading manufacturer, Mayr offers a wide, mature standard product range. But the drive specialist also develops tailor-made solutions for protection against overload to meet the increasing demand for new, application-optimized solutions with high power density and extremely high torques and speeds. The company can draw on more than 60 years of experience, comprehensive know-how in development and construction, and the latest testing facilities.

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