BRAKES

SAFETY STANDARDS HOISTS

USED TO TRANSPORT PEOPLE
• BRAKES
• CLUTCH
• DEPTH INDICATOR
• EMERGENCY STOP
• DEAD MAN
• COMMUNICATION
• OVERSPEED CONTROLS
• SAFETY CATCHES
• OVERWIND CONTROLS
• INSPECTIONS & RECORDS
• HOIST ENGINEER
• ON AUTOMATIC OR
SEMI – AUTOMATIC HOISTS
– EMERGENCY BRAKE
– HOLDING BRAKE
– MOTOR DOES NORMAL BRAKING
• ON MANUAL HOISTS
– PRIMARY MEANS OF BREAKING
FOR ALL STOPS
• JAW -------------

• PARALLEL
MOTION ----

• DISC ------------
 TYPES OF RING BRAKES
Earliest Brakes - Lever Applied

Nordberg Nordberg “ Post”

Uniform Pressure or “Parallel Motion”
Jaw Brakes Brakes
 Post (or Parallel Motion) Brakes
• Common from late 1800’s to 1980’s
• Now for large hoist applications only
• Excellent heat dissipation characteristics
• Typically hydraulic release, weight applied
• Typically rated to handle 150% of out-of-
balance torque
Hepburn Post Brake - 1980’s
Vintage
 Post (Parallel Motion) Brakes
• Pre-1950’s – Low Pressure (100 psi)
systems
– Large volume of oil in brake cylinder
– Slow set reaction time (> 1 sec)
• Post-1950s – Higher Pressure (500 psi)
– Smaller volume of oil
– Better reaction time (0.5 sec)
 Post Brake – 1930’s Vintage Nordberg Hoist

High Volume Brake Cylinder

 What should I look for on Post
Brakes?
• Are the brake shoes centered?
• Similar gaps between brake path and brake
shoes (at top and bottom)

• Are the brake pads worn evenly?

• Any movement of posts/shoes during hoist

operation?
JAW RING BREAK
 Jaw Brakes – Less common
• One Hinge Point for Both Shoes
• Typically Air with Weight Back-up
– Air Release
– Air Set
– Booster for End Zones (200%)
• Fast Reaction Time
• 1960’s and 1970’s Vintage Friction Hoists
 Jaw Brakes - Concerns
• Sticking valves
• System air leaks
• Parts availability
– Less common brake type
 Other concerns
• Cracks in Brake Shoes and Brake Posts
• Many 20 to 50 year old hoists with Fatigue
Cracks
• Examine ends of shoes in weld zones
CRITICAL INSPECTION
AREAS
Brake Post with weld repair
Post Brakes – Some Weld Cracks on Older Shoes
Look for cracks near end of shoes
HYDRAULIC SYSTEM
BRAKE WEIGHTS
CONTROL SYSTEM
 NEWER SYSTEMS
• Is there a filter? Not common in old systems
• Three main valves
– Operating Valve
• Operating Spool
• Emergency Spool
– Regulating Valve
• Connected to Lilly by linkage
• Fast braking at endzones
– Emergency Valve
 Nordberg Brake Operating Valve

Operating Spool

Emergency Spool
 What is popular today ?
• Disc Brake Systems

• Why?
• Fast-acting -- < 0.3 second typical
• Fail-safe – Spring-applied
• Easier to Maintain
 DISC
BRAKES
Advanced Slope Transport in Open Pit Mines
Reference: Three-Rope Friction Hoist, Germany

RMS Power 7 500 kW / 10 000 HP, Pulley Diameter 7 000mm / 23 ft

Advanced Slope Transport in Open Pit Mines
Reference: Six-Rope Hoist, Consol 3, Germany

RMS Power 2 x 4 600 kW / 2 x 6250 HP, Payload 45 t / 50 tons

Hydraulically operated
Disc Brake Systems
Combined
• manual brake
• holding brake
• safety brake

Hoist with Hydraulic Electrical Electrical hoist

brake posts Unit control cubicle control
 Disc Brakes – Means of Control
• Types of Pressure Control Systems
– Constant Force
• Set Braking Force regardless of load

– Constant Deceleration
• Feedback from hoist drum during braking
• Modulate system pressure to achieve decel rate
 Disc Brakes – Why control the
pressure and set time?
• Disc brake systems often have high
redundancy (200 to 400% of braking effort)
• Need to control to avoid too much braking
• Maximum allowable deceleration rates
• Rope slip for friction hoists
Disc Brake Hydraulic Units – Typical
Features
• Tank Conditions
– Temperature (Heater and Cooler)
– Viscosity is critical
– Oil Level
• System Conditions
– Pressure Transducers
– Isolation Valves for Testing
• Accumulators for Pressurized Flow
– Brake units low volume
 Disc Brakes – How is length of
braking controlled?
• Metered Flow Control Valves
• Valves set to allow brake pressure to decay
during stopping time

• Function of Relief and Flow Control Valves

can be combined in Proportional Valves
Disc Brakes – How is Braking Force
Controlled
• Relief Valves determine brake “back
pressure”
• Example:
Retraction Pressure of Brake = 1000 psi
Relief Valve set at 400 psi
Brake can provide 60% Braking Effort
(1000-400)/1000 = 60%
 Disc Brakes - Philosophy
• Brake Spring Force counteracted by System
Pressure – Inverse Relationship
– When System Pressure = Maximum Braking
Effort = Zero
– When System Pressure = Zero Braking
Effort = Maximum
• Typically each disc rated at 150% to 200%
of Out-of-Balance Torque
 Disc Brake Caliper

Brake disk

Pressure Line

Brake Pad

Pressure oil

Spring set

Brake post

SIEMAG Brake Caliper BE 100

 CLUTCH
INTERLOCK
 Clutch / Brake Interlock
• Brake on Unclutched Drum MUST be
prevented from releasing
• Hydraulic and Electrical Interlocks
• Mechanical Lever Interlocks (T-slots)
Clutch/Brake Handle on Operator Console
Clutch is “out”; brakes
cannot be released
Typical “Nordberg” Face Tooth
Clutch
 DEPTH INDICATOR
SHOWS ALL POINTS IN SHAFT
WHERE TO SLOW DOWN &
STOP AT THE LANDINGS
 DEPTH
INDICATOR
 EMERGENCY STOP
A DEVICE THAT WILL
STOP THE CONVEYANCE
FROM INSIDE THE CAGE,
ANYWHERE IN THE
SHAFT
EMERGENCY
STOP BUTTON
• TWO TYPES OF COMMUNICATION
BETWEEN HOIST ROOM & LANDINGS
• ONE OF WHICH SHALL BE VOICE
• THESE SYSTEMS SHALL BE TESTED
DAILY
• ELEVATOR & CAGE TELEPHONE
• STANDARD SIGNALING CODE WHEN
BELLS ARE USED
COMMUNICATION SYSTEMS

HOIST BELL TELEPHONE

INDICATOR LIGHTS
RADIO
 SIMPLE
STANDARD
SIGNAL
CODE
COMPLICATED
STANDARD
SIGNAL CODE
THE OVERSPEED CONTROLLER IS
CONNECTED DIRECTLY TO THE
SHAFT OF THE DRUM. WHEN THE
SPEED OF THE CAGE EXCEEDS
IT’S MAXIMUM ALLOWABLE
SPEED BY 10% TO 15%, THE
CONTROLLER KNOCKS THE
POWER TO THE HOIST AND SETS
THE BREAKS ON THE DRUM.
OVERSPEED CONTROLS
NORMAL POSITION
LOCATION TO SET BRAKES
 THE OVERWIND OR LIMIT
SWITCH IS A DEVICE THAT
WILL NOT ALLOW THE
CAGE TO BE PULLED INTO
THE HEADSHEAVE OR INTO
THE SUMP
OVERTRAVEL
SWITCH
OR
LIMIT
SWITCH
LIMIT SWITCH
 RECORDS
• DAILY
INSPECTION
• MAINTENANCE
• ELECTRICAL
• ELEVATOR
INSPECTION
 IS REQUIRED TO BE:
• CERTIFIED BY STATE
– VARIES FROM STATE TO STATE
• CERTIFIED BY MSHA
– MSHA ACCEPTS STATES
CERTIFICATION
• MEDICAL CERTIFICATE
– SOMETIMES
BREATHING APPARATUS or
FRESH AIR SUPPLY
for EMERGENCY
AUTOMATIC CONTROLLER
• OVERSPEED CONTROLS
• OVERWIND CONTROLS
• LIMITATION OF
ACCELERATION
• EMERGENCY STOP
AUTOMATIC CONTROLLER
LILLY CONTROLLER
TYPES OF CONTROLLERS
• SIMPLEX max 500 ft
• Lilly Model D 500 ft – 1000 ft
• Lilly Model C 1000 ft – 2000 ft
• Lilly Model C duplex
– 3000 ft – 5000 ft
AUTOMATIC CONTROLLER
OVERSPEED CONTROLS
OVERSPEED CONTROLS
NORMAL POSITION
LOCATION TO SET BRAKES
MANUALLY TESTING
OVERSPEED
SPEED CONTROL CAM
LEVER
• DIFFERENT
CAMS FOR
DIFFERENT
STOPPING
AND SLOW
DOWN
POINTS
 LILLY
CONTROLLER
CONNECTED
DIRECTLY TO
HOIST’S
SHAFT
RETARDATION OF
SPEED FOR
DIFFERENT
LEVELS,
CONTROLLED BY
THE LILLY
CONTROLLER
DC DRIVE MOTOR
• SMOOTH
• STEPLESS
• INLINE WITH SHAFT
• VIBRATIONS
• ACCURATE
• SENSITIVE
TACK GENERATOR
SLACK ROPE DEVICE
SLACK ROPE DEVICE
PERSONNEL CAGE
• WELL CONSTRUCTED
• ENCLOSED SIDES
• HANDHOLDS
• STEEL BONNET
• SAFETY CHAIN
• CAPACITY (SIGN MAX)
• SAFETY CATCHES
• MAINTENANCE
WEDGE TYPE DOGS
CHISEL TOOTH DOGS
CHISEL TOOTH DOGS
TESTING SAFETY CATCHES
 SAFETY CATCHES TEST
LOWER CAGE ON TO CHAIR
 WHEN ROPE SLACKS
SAFETY CATCHES ENGAGE
LIMIT SWITCH
• CHECK FOUNDATION
• APPROACH TO TOP OF
HEADFRAME
• HEAD SHEAVE
• HANDRAILS & TOE BOARDS
• MAX MEN ON CAGE
• SHAFT GATE
• DERAIL
• OBSERVE HOISTING
CYCLE
SIGN (MEN MAX)
SUBSTANTIAL GATE
WITH LOCK
DERAIL
• GUIDES
• SHAFT INTEGRITY
• COUNTERWEIGHT
• ROPE & TERMINATION
SHAFT GUIDES
STEEL GUIDE
HOW DOES THIS GUIDE
LOOK ?
RUSTY GUIDE
THE END