HYSTERESIS BRAKES AND CLUTCHES

PROVIDING TECHNICAL SOLUTIONS TO YOUR TENSION CONTROL PROBLEMS Frictionless n Longer Expected Life n Superior Repeatability n Less Maintenance n Less Downtime

Pioneers in Hysteresis Torque Control

Founded in 1953, Magtrol, Inc. pioneered the technology of applying the principles of magnetic hysteresis to meet the critical needs for reliable, smooth and adjustable torque control. This pioneering effort led to the development of Magtrols Hysteresis Brake and Clutch products, which feature superior torque repeatability, longer expected life, a broad speed range and lower operating costs. A leading edge company, Magtrol serves a wide array of torque and tension control applications and continues to develop innovations in hysteresis technology. This catalog features our standard English brake and clutch products. A complete line of metric hysteresis devices are also available. For more information, please refer to Magtrols Hysteresis Brake Metric Product Guide which can be accessed from our web site at http://www.magtrol.com/brochures/metricbrake.pdf.

Principles & Advantages of Hysteresis Brakes .... page 3

Hysteresis Brakes ............................................... pages 4-7

Hysteresis Clutches......................................... pages 8-10

Matched Brakes and Applications ............ pages 11-13

Permanent Magnet Brakes & Clutches..... pages 1415

How to Select a Brake or Clutch ................ pages 16-17

Special Designs and Modifications .................. page 18

Options and Accessories .................................. page 19

Hysteresis Principles
PRINCIPLES OF HYSTERESIS
Overview The hysteresis effect in magnetism is applied to torque control by the use of two basic components a reticulated pole structure and a specialty steel rotor/shaft assemblyfastened together but not in physical contact. Until the field coil is energized, the drag cup can spin freely on the ball bearings. When a magnetizing force from either a field coil or magnet is applied to the pole structure, the air gap becomes a flux field. The rotor is magnetically restrained, ROTOR providing a braking (Drag Cup) action between the pole structure and rotor.
HUB

Control In an electrically operated Hysteresis Brake, adjustment and control of torque is provided by a field coil. This allows for complete control of torque by adjusting DC current to the field coil. POLE STRUCTURE Adjustability from a minimum value (bearing SHAFT drag) to a maximum value of rated torque is possible. Additional torque in the BALL BEARINGS range of 15-25% above rated torque may be FIELD COIL available on some brakes. The amount of braking torque transmitted by the brake is proportional to the amount of current flowing through the field coil. The AIR GAP direction of current flow (polarity) is of no consequence to the operation of the brake. For optimum torque stability, a DC supply with current regulation is recommended. This will help to minimize torque drift attributable to changes in coil temperature and in-line voltage, which can result in changes in coil current, and consequently, in torque.

Because torque is produced strictly through a magnetic air gap, without the use of friction or shear forces, Magtrol Hysteresis Brakes provide absolutely smooth, infinitely controllable torque loads, independent of speed, and they operate quietly without any physical contact of interactive members. As a result, with the exception of shaft bearings, no wear components exist.

ADVANTAGES OF HYSTERESIS DEVICES

Long, Maintenance-Free Life Magtrol Hysteresis Brakes produce torque strictly through a magnetic air gap, making them distinctly different from mechanical-friction and magnetic particle devices. Because hysteresis devices do not depend on friction or shear forces to produce torque, they do not suffer the problems of wear, particle aging, and seal leakage. As a result, hysteresis devices typically have life expectancies many times that of friction and magnetic particle devices. Life Cycle Cost Advantages While the initial cost of hysteresis devices may be the same or slightly more than that of their counterparts, the high cost of replacing, repairing and maintaining friction and magnetic particle devices often makes hysteresis devices the most cost-effective means of tension and torque control available. Operational Smoothness Because they do not depend on mechanical friction or particles in shear, Hysteresis Brakes are absolutely smooth at any slip ratio. This feature is often critical in wire drawing, packaging and many other converting applications. Superior Torque Repeatability Because torque is generated magnetically without any contacting parts or particles, Hysteresis Brakes provide superior torque repeatability. Friction and magnetic particle devices are usually subject to wear and aging with resultant loss of repeatability. Magtrol devices will repeat their performance precisely, to ensure the highest level of process control. Broad Speed Range Magtrol hysteresis devices offer the highest slip speed range of all electric torque control devices. Depending on size, kinetic power requirements and bearing loads, many Magtrol Brakes can be operated at speeds in excess of 10,000 rpm. In addition, full torque is available even at zero slip speed and torque remains absolutely smooth at any slip speed. Excellent Environmental Stability Magtrol hysteresis devices can withstand significant variation in temperature and other operating conditions. In addition, because they have no particles or contacting active parts, Hysteresis Brakes are extremely clean. Magtrol devices are used in food and drug packaging operations, in clean rooms, and environmental test chambers.

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HB Series Hysteresis Brakes

DESCRIPTION
Pure Hysteresis Brakes produce torque strictly through a magnetic air gap without the use of magnetic particles or friction components. This method of braking provides far superior operating characteristics (smoother torque, longer life, superior repeatability, high degree of controllability, and less maintenance and down time) which make them the preferred choice for precise tension control during the processing of nearly any material, web or strand.

HB Series Data Sheet

RATINGS
Number 1 Coil Number 2 Coil Number 3 Coil Minimum Torque Res. at Res. at Res. at Watts Rated Watts Rated Watts Brake at Rated Rated 25C VDC 25C VDC 25C VDC (Nom.) Current (Nom.) Current (Nom.) Model Current Current 10% 10% 10% ozin mA At Rated I mA At Rated I mA At Rated I HB-2.5 2.5 37 2430.0 90.0 3.3 146 171 25.0 3.7 333 36.0 12.0 4.0 HB-8 8 38 1900.0 72.0 2.7 133 180 24.0 3.2 270 45.0 12.0 3.3 HB-16 16 45 2300.0 103.0 4.6 192 125 24.0 4.6 375 32.0 12.0 4.5 HB-32 32 67 1350.0 90.0 6.1 250 105 26.3 6.6 530 22.5 12.0 6.4 HB-50 50 67 1350.0 90.0 6.0 253 95 24.0 6.1 480 25.0 12.0 5.8 HB-140 140 60 1537.0 93.0 5.6 253 95 24.0 6.1 504 23.2 11.7 5.9 HB-250 250 89 957.0 84.9 7.5 270 96 25.9 7.0 533 24.0 12.8 6.8 HB-450 450 116 805.0 93.6 10.9 442 50 22.1 9.8 703 19.5 13.7 9.6 HB-750 750 107 845.0 90.0 9.6 383 60 23.0 8.8 N/A HB-840 840 160 562.5 90.0 14.4 600 40 24.0 14.4 1230 9.8 12.0 14.8 HB-1750 1750 149 604.0 90.0 13.4 500 52 26.0 13.0 N/A HB-3500 3500 298 302.0 90.0 26.8 1000 26 26.0 26.0 N/A Maximum Speed rpm 20,000 20,000 20,000 15,000 15,000 12,000 10,000 8,000 7,000 6,000 6,000 6,000 Kinetic Power Rating* Drag Torque** watts De-energized 5 Minutes Continuous ozin 20 5 0.05 60 15 0.10 75 20 0.10 90 25 0.20 90 23 0.20 300 75 0.70 450 110 1.00 670 160 2.00 1,000 200 7.00 1,340 300 4.00 2,400 350 13.00 4,800 600 19.20 External Inertia lbins 3.8 10-6 3.3 10-5 5.6 10-5 8.6 10-5 1.478 10-4 9.1 10-4 2.75 10-3 6.55 10-3 1.283 10-2 1.31 10-2 5.28 10-2 1.056 10-1 Angular Model Weight Acceleration rad/s lb 41,100 0.24 15,200 0.49 17,900 0.65 23,300 1.06 21,000 1.72 9,620 4.06 5,680 7.73 4,290 12.90 3,450 28.30 4,010 26.30 2,070 54.00 2,070 110.00

Brake Model HB-2.5 HB-8 HB-16 HB-32 HB-50 HB-140 HB-250 HB-450 HB-750 HB-840 HB-1750 HB-3500

* Kinetic power ratings are maximum values based on limiting coil and/or bearing temperature to approximately 100C, and should not be exceeded. Actual values in service may vary 50% depending on mounting, ventilation, ambient temperature, etc. ** Drag torque is based on 1000 rpm shaft speed.

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Dimensions
BRAKE DIMENSIONS
E D

HB Series

A C B

NOTE: All dimensions are in English units (inches). Metric brakes are available as a separate product lineplease refer to our Metric Product Guide available online at http://www.magtrol.com/brochures/ metricbrake.pdf

F K (3) Mounting Holes - equally spaced L Bore Circle J I G H

Brake Model HB-2.5 HB-8 HB-16 HB-32 HB-50 HB-140 HB-250 HB-450 HB-750 HB-840 HB-1750 HB-3500

A 1.250 1.800 1.970 2.155 2.360 3.624 4.437 5.420 6.220 5.485 8.900 8.900

B 0.1250 0.1875 0.1875 0.2500 0.2500 0.3750 0.5000 0.5000 0.6250 0.5000 1.0000 1.0000

C 0.375 0.500 0.500 0.625 0.625 0.875 1.125 1.125 1.375 * 2.000 *

D 0.012 0.021 0.015 0.025 0.033 0.025 0.035 0.035 0.035 * 0.056 *

E 0.030 0.096 0.096 0.094 0.096 0.140 0.156 0.156 0.163 * 0.250 *

H 0.29 0.50 0.51 0.56 0.56 1.00 1.06 1.06 1.50 1.00 2.04 2.04

I 0.94 1.00 0.95 1.69 1.69 2.00 2.53 2.87 3.74 * 4.18 *

0.73 1.564 0.82 2.120 0.81 2.109 1.25 3.000 1.56 3.000 1.53 3.968 1.98 4.718 2.06 5.156 2.87 6.930 4.13 7.750 3.00 8.312 6.00 12.460

0.29 #4-40 0.16 0.750 0.50 #4-40 0.19 0.687 0.55 #4-40 0.19 0.750 0.63 #6-32 0.25 0.906 0.63 #6-32 0.25 0.906 0.80 #8-32 0.37 1.500 0.93 #10-32 0.50 1.750 1.03 #10-32 0.37 1.750 1.50 14-20 0.44 2.750 * * 1.00 1.79 14-20 0.50 3.000 * * 2.04

----0.375 0.025 0.375 0.025 0.375 0.025 0.375 0.025 0.625 0.060 0.625 0.060 0.625 0.060 0.750 0.060 0.625 0.060 keyway keyway

Solid Model 3 3 3 3 3 3 3 3 3 3 3 3

* HB-840 and HB-3500 are double brake assemblies that require base mounting. See base mounting under Brake Options for details. Magtrol manufactures double brakes to increase torque capability. For more information and a drawing, contact Magtrol.

PILLOW BLOCK DIMENSIONS

U V (Drill Thru and
Counter-bore for 3 Socket Head Cap Screws)

T R Q P O

W (holes thru)

X Y

Pillow Block Model 4736 4702 4703 4705 4705 4711 4714 4717 4720 4722

For Brake Model HB-2.5 HB-8 HB-16 HB-32 HB-50 HB-140 HB-250 HB-450 HB-750 HB-1750

O 1.75 2.50 2.50 2.50 2.50 4.00 4.00 4.62 5.25 7.50

P 1.500 2.125 2.125 2.125 2.125 3.500 3.500 4.000 4.500 6.500

Q 0.31 0.37 0.37 0.37 0.37 0.37 0.37 0.50 0.75 1.00

R 1.000 1.437 1.437 1.437 1.437 2.000 2.375 3.000 3.250 5.000

S 1.500 2.120 2.120 2.120 2.120 3.190 3.690 4.310 5.125 7.000

T 0.25 0.38 0.38 0.38 0.38 0.50 0.50 0.56 0.75 1.00

U 0.750 0.687 0.750 0.906 0.906 1.500 1.750 1.750 2.750 3.000

V #4-40 #4-40 #4-40 #6-32 #6-32 #8-32 #10-32 #10-32 14-20 14-20

W 0.125 0.201 0.201 0.201 0.201 0.201 0.201 0.201 0.343 0.328

X 0.125 0.187 0.187 0.187 0.187 0.250 0.250 0.250 0.375 0.500

Y 0.25 0.38 0.38 0.38 0.38 0.50 0.50 0.50 0.75 1.00

Solid Model 3 3 3 3 3

3 Solid 3-D models are available for this unit by contacting Magtrol Customer Service.

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Applications
Idler Rollers

HB Series
Slitter Blades
Ribbons

Magtrol Hysteresis Brakes offer frictionless, non-breakaway force for tensioning materials during slitting and many other material processing operations.

Brake Roller

Slitting Tension Brake

Unwind Tension Holding Hysteresis Brake

Motor

Hysteresis Brake

Hysteresis Clutch

Ball Screw
Load

Magtrol Hysteresis Brake used for holding of backdriving load. Motor

Ball Screw
Load

Motor

Hysteresis Brakes

Magtrol Hysteresis Brakes are widely used in load simulation applications for life testing on electric motors, actuators, small gas engines, gearboxes, and many other rotating devices and assemblies.

Motors

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Applications
Magtrol Hysteresis Brakes provide precise control of wire tension during wind, hook and cut operation of high speed automated winding machines.

HB Series

Control Panel Armature

Hysteresis Brake Wire Magazine

Hysteresis Brake Wire Magazine

Hysteresis Brakes

Transformer and coil winding operations employing Hysteresis Brakes in open loop control for maintaining precise tension during winding process.
Wound Coil

Wire Spool

Regardless of control scheme (dancer roll, follower arm, photo or ultrasonic sensors), Magtrol Hysteresis Brakes provide the ultimate in tension control devices.
Follower Arm

Holdback Hysteresis Brake

Photo Eye Gap Controller/ Power Supply Hysteresis Brake Potentiometer

Controller/ Power Supply

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HCS Series Hysteresis Clutches

DESCRIPTION
Like Magtrols Hysteresis Brake, the Hysteresis Clutch develops torque strictly through a magnetic air gap, ensuring an absolutely smooth transmission of torque from the drive unit to the driven element. Designed to be powered without the use of brushes or slip rings, and being a pure hysteresis device that does not rely on friction elements or magnetic particles, there is never any fear of contamination due to wear particles or leaky seals. This makes Magtrol Hysteresis Clutches and Brakes ideal for use in food processing and clean room environments.

HCS Series Data Sheet

RATINGS
Number 1 Coil Number 2 Coil Number 3 Coil Minimum Torque Res. at Res. at Res. at Clutch Watts Rated Watts Rated Watts at Rated Rated 25C VDC 25C VDC 25C VDC Model (Nom.) Current (Nom.) Current (Nom.) Current Current 10% 10% 10% ozin mA At Rated I mA At Rated I mA At Rated I HCS-8 8 38 1,900 72 2.5 197 142.0 28 5.51 361 33 12 4.3 HCS-16 16 45 2,300 103 4.5 192 125.0 24 4.61 375 32 12 4.5 HCS-32 32 71 1,500 106 7.5 332 72.5 24 8.00 667 18 12 8.0 HCS-120 120 79 1,200 95 7.5 200 120.0 24 4.80 400 30 12 4.8 HCS-210 210 123 751 93 11.4 375 75.0 28 10.50 736 19 14 10.2 HCS-420 420 162 517 84 13.6 460 52.0 24 11.00 914 30 12 10.8

Clutch Model HCS-8 HCS-16 HCS-32 HCS-120 HCS-210 HCS-420

Maximum Speed rpm 3,600 3,600 3,600 3,600 3,600 3,600

Kinetic Power Rating* Drag Torque** watts De-energized 5 Minutes Continuous ozin 60 15 0.1 75 20 0.1 90 25 0.1 300 75 0.7 450 110 1.0 670 160 2.0

External Inertia lbins 3.3 10-5 5.6 10-5 8.6 10-5 9.1 10-4 2.75 10-3 6.55 10-3

Angular Model Weight Acceleration rad/s lb 15,200 0.33 17,900 0.94 23,300 1.56 8,240 4.78 4,700 9.15 4,010 19.50

* Kinetic power ratings are maximum values based on limiting coil and/or bearing temperature to approximately 100C, and should not be exceeded. Actual values in service may vary 50% depending on mounting, ventilation, ambient temperature, etc. ** Drag torque is based on 1000 rpm shaft speed.

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Dimensions
CLUTCH DIMENSIONS
Coil Assembly
Lead Wires (2) 12 Lg. Standard

HCS Series

Output Shaft

Input Shaft

N B

D E
C

K (3) Mounting Holes - equally spaced

L Bore Circle

NOTE: All dimensions are in English units (inches).

K L 1.250 1.250 1.437 2.750 3.000 3.875 M 0.37 0.37 0.37 0.50 ----N 0.02 0.02 0.03 0.06 -----

Clutch Model HCS-8 HCS-16 HCS-32 HCS-120 HCS-210 HCS-420

A 1.88 2.00 2.09 3.62 4.47 5.72

B 0.1875 0.1875 0.2500 0.3750 0.5000 0.7500

C 0.375 0.375 0.500 0.625 0.750 1.000

D 0.8750 0.8750 1.1250 1.6250 2.1654 2.6772

E 1.56 1.67 1.67 3.20 3.96 5.07

F 0.100 0.100 0.212 0.312 0.312 0.375

I 1.156 1.321 2.006 2.625 2.975 3.811

0.897 0.69 1.062 0.75 1.603 * 0.87 1.430 1.00 1.912 1.10 2.449 1.25

0.750 #4-40 0.19 0.875 #6-32 0.22 0.740 #6-32 0.28 0.952 #10-32 0.25 1.312 #10-32 0.39 1.686 #10-32 0.38

* HCS-32 shaft is stepped up to 0.3750/0.3745 inches diameter, 0.59 inches from end of shaft, for R6 bearing. Please contact Magtrol if additional information is required.

PILLOW BLOCK DIMENSIONS

U
Bore Circle

V (Drill Thru and

AA

BB

Counter-bore for 3 Socket Head Cap Screws equally spaced)

Bearing

NOTE: Mounting screws are supplied with each pillow block kit,

P
O
REAR VIEW

X Z
SIDE VIEW FRONT VIEW

(4) Thru Holes

Pillow Block Model 4742 4744 4753 4755 4760 4759

For Clutch Model HCS-8 HCS-16 HCS-32 HCS-120 HCS-210 HCS-420

O 2.625 2.625 2.625 4.250 5.000 6.000

P 2.250 2.250 2.250 3.750 4.500 5.500

Q 0.38 0.38 0.38 0.50 0.50 0.50

R 1.437 1.437 1.437 2.000 3.000 3.500

S 2.25 2.25 2.31 3.62 4.88 5.88

T 1.94 1.94 2.06 3.20 4.25 5.12

Y 0.38 0.38 0.38 0.50 0.50 0.62

Z 1.906 2.071 2.756 3.625 3.970 5.061

AA 1.156 1.321 2.006 2.625 2.970 3.811

BB 1.88 1.88 1.88 3.25 4.00 5.00

Screw Bearing Number Number 50-5729 50-5707 50-5707 50-5731 50-5770 50-5770 50-6432 50-6432 50-6460 50-6460 50-6192 50-6432

1.250 #4-40 0.201 1.531 1.250 #6-32 0.201 1.696 1.437 #6-32 0.201 2.381 2.750 #10-32 0.204 3.125 3.000 #10-32 0.266 3.470 3.875 #10-32 0.266 4.436

If Magtrol pillow block kits are not used, the clutch must be piloted and adequately supported on the input bearing. The mounting face must be square to the centerline of the input and output shafts to within 0.001 per inch and the output shaft must be supported using the bearing listed in the table above.

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Applications
Closed-loop winding tension and speed control Hysteresis Clutch on powered rewind. Tension controlled by means of dancer roller with potentiometer, clutch and controller

HCS Series

Dancer Roll

Hysteresis Clutch

Potentiometer

Motor

Controller/ Power Supply

Hysteresis Clutches

Bottles without caps

Bottles with caps

Magtrol Hysteresis Clutches provide precise control of torque for capping,bolting and other screw applications. Their clean particlefree nature eliminates fear of contamination, making them ideal for use in food processing and clean room environments.

Hysteresis Brake

Torque limiting Hysteresis Clutch arrangement prevents over torque and provides precise, stable and smooth application of torque. Ball Screw
Load

Hysteresis Clutch

Ball Screw
Motor

Load

10
Motor

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MHB Series MatchedHysteresisBrakes

DESCRIPTION
In tension control applications that have multiple webs or multiple strands, it is very desirable to match the tension of each web or strand. This is most commonly attained by using a closed loop servo control system which controls current to a braking device through the use of dancer arms, follower arms and in-line tension transducers. The problem with such systems is that each web or strand must be individually controlled, increasing the cost and complicating the system with multiple sensors and power supplies. Magtrol has developed a system to assure that every brake of a given model designation will be matched, at a predetermined torque and current point, to other brakes of the same model designation regardless of material and manufacturing tolerances. Each brake will be matched at the selected match point to within a tolerance of 1%. The maximum deviation in torque from brake to brake at any point along their torque/ current curve (from 0 torque up to the selected matched torque point) will be less than 4% of the selected matched torque

MHB Series Data Sheet

value. With this level of matching, a system with multiple tension rollers would provide tension consistency within 1% if set at the matched point with all brakes receiving the same current. The matched point can be any value between 50% and 100% of rated torque, which allows the brakes to be optimized for specific applications.

RATINGS
Number 1 Coil Number 2 Coil Number 3 Coil Minimum Torque Res. at Res. at Res. at Watts Rated Watts Rated Watts Brake at Rated Rated 25C VDC 25C VDC 25C VDC (Nom.) Current (Nom.) Current (Nom.) Model Current Current 10% 10% 10% ozin mA At Rated I mA At Rated I mA At Rated I MHB-2.5 2.5 30 2724 82.0 2.47 98 262 26.0 2.53 353 34.0 13.0 4.00 MHB-10.5 11 52 1803 95.0 5.00 201 113 23.0 4.57 317 43.0 14.0 4.35 MHB-38 38 79 1052 83.0 6.60 250 105 26.3 6.60 461 26.7 12.3 5.70 MHB-50 50 67 1350 90.0 6.00 253 95 24.0 6.10 480 25.0 12.0 5.80 MHB-140 140 60 1537 93.0 5.60 253 95 24.0 6.10 504 23.2 11.7 5.90 MHB-250 250 89 957 84.9 7.50 270 96 25.9 7.00 533 24.0 12.8 6.80 MHB-450 450 116 805 93.6 10.90 442 50 22.1 9.80 703 19.5 13.7 9.60 MHB-750 750 107 845 90.0 9.60 383 60 23.0 8.80 N/A MHB-1750 1750 149 604 90.0 13.40 500 52 26.0 13.00 N/A Maximum Speed rpm 20,000 20,000 15,000 15,000 12,000 10,000 8,000 7,000 6,000 Kinetic Power Rating* Drag Torque** watts De-energized 5 Minutes Continuous ozin 20 7 0.05 60 15 0.10 90 25 0.20 90 23 0.20 300 75 0.70 450 110 1.00 670 160 2.00 1,000 200 7.00 2,400 350 13.00 External Inertia lbins 3.8 10-6 3.3 10-5 8.6 10-5 1.478 10-4 9.1 10-4 2.75 10-3 6.55 10-3 1.283 10-2 5.28 10-2 Angular Model Weight Acceleration rad/s lb 41,100 0.24 19,900 0.49 27,600 1.06 21,000 1.72 9,620 4.06 5,680 7.73 4,290 12.90 3,450 28.30 2,070 54.00

Brake Model MHB-2.5 MHB-10.5 MHB-38 MHB-50 MHB-140 MHB-250 MHB-450 MHB-750 MHB-1750

* Kinetic power ratings are maximum values based on limiting coil and/or bearing temperature to approximately 100C, and should not be exceeded. Actual values in service may vary 50% depending on mounting, ventilation, ambient temperature, etc. ** Drag torque is based on 1000 rpm shaft speed.

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Dimensions
BRAKE DIMENSIONS
E D

MHB Series

A C B

NOTE: All dimensions are in English units (inches). Metric brakes are available as a separate product lineplease refer to our Metric Product Guide available online at http://www.magtrol.com/brochures/ metricbrake.pdf

F K (3) Mounting Holes - equally spaced L Bore Circle J I G H

Brake Model MHB-2.5 MHB-38 MHB-50 MHB-140 MHB-250 MHB-450 MHB-750

F 0.73 0.82 1.25 1.56 1.53 1.98 2.06 2.87 3.00

G 1.564 2.159 3.000 3.000 3.968 4.718 5.156 6.930 8.312

H 0.30 0.50 0.56 0.56 1.00 1.06 1.06 1.50 2.04

I 0.94 1.00 1.69 1.69 2.00 2.53 2.87 3.74 4.18

J 0.29 0.55 0.63 0.63 0.80

M ---

N ---

1.250 0.1250 0.375 0.010 0.030 2.155 0.2500 0.625 0.032 0.096 2.360 0.2500 0.625 0.033 0.096 3.624 0.3750 0.875 0.025 0.140 4.437 0.5000 1.125 0.035 0.156 5.420 0.5000 1.125 0.035 0.156 6.220 0.6250 1.375 0.035 0.163

#4-40 0.16 0.750

Solid Model 3

MHB-10.5 1.800 0.1875 0.500 0.015 0.096

#4-40 0.19 0.687 0.375 0.025 #6-32 0.25 0.906 0.375 0.025 #6-32 0.25 0.906 0.375 0.025 #8-32 0.37 1.500 0.625 0.060 3

0.93 #10-32 0.50 1.750 0.625 0.060 1.03 #10-32 0.37 1.750 0.625 0.060 1.50 1.79 14-20 0.44 2.750 0.750 0.060 14-20 0.50 3.000 keyway 3

MHB-1750 8.900 1.0000 2.000 0.056 0.250

PILLOW BLOCK DIMENSIONS

U V (Drill Thru and
Counter-bore for 3 Socket Head Cap Screws)

T R Q P O

W (holes thru)

X Y

Pillow Block Model 4736 4702 4705 4705 4711 4714 4717 4720 4722

For Brake Model MHB-2.5 MHB-10.5 MHB-38 MHB-50 MHB-140 MHB-250 MHB-450 MHB-750 MHB-1750

O 1.75 2.50 2.50 2.50 4.00 4.00 4.62 5.25 7.50

P 1.500 2.125 2.125 2.125 3.500 3.500 4.000 4.500 6.500

Q 0.31 0.37 0.37 0.37 0.37 0.37 0.50 0.75 1.00

R 1.000 1.437 1.437 1.437 2.000 2.375 3.000 3.250 5.000

S 1.500 2.120 2.120 2.120 3.190 3.690 4.310 5.125 7.000

T 0.25 0.38 0.38 0.38 0.50 0.50 0.56 0.75 1.00

U 0.750 0.687 0.906 0.906 1.500

V #4-40 #4-40 #6-32 #6-32 #8-32

W 0.125 0.201 0.201 0.201 0.201 0.201 0.201 0.343 0.328

X 0.125 0.187 0.187 0.187 0.250 0.250 0.250 0.375 0.500

Y 0.25 0.38 0.38 0.38 0.50 0.50 0.50 0.75 1.00

Solid Model 3 3 3 3

1.750 #10-32 1.750 #10-32 2.750 3.000 14-20 14-20

3 Solid models are available for this unit by contacting Magtrol Customer Service.

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Applications
TYPICAL BRAKES VS. MATCHED
Typical
Brake

MHB Series

Fi b er

Matched Brakes
Brake

op t

ic

s nd ra St

Power Supply

Transducer

Power Supply

Transducer

Brake Brake

Power Supply

Transducer Brake Brake

Matched Large Bore Hysteresis Brakes

Power Supply

Brake Transducer

Hysteresis Brakes, installed in a fiber optic stranding machine to control the tension of the wrapping material.

Multiple Pay-Off System

Extruder
Wires or Thread

Matched Hysteresis Brake

Spool

Magtrol Matched Hysteresis Brakes used in a multiple pay-off system where one sensor controls tension in the system. Due to specially calibrated matched brakes, it is possible to hold each pay-of f tension within 1% at matched point value.

Follower Arm

Pot

(Enlarged View)

Controller/ Power Supply

Matched Hysteresis Brakes

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HPM Series Permanent MagnetBrakes&Clutches

DESCRIPTION
Magtrol Hysteresis Permanent Magnet Brakes and Clutches are ideal in applications where electrical power cannot be provided to a brake or clutch coil. While best suited to applications where fixed torque is to be applied, adjustable units can be made specifically tailored to the application. While typically provided as brake units, by the addition of an input shaft, the same unit can be used as a clutch. In a clutch application, the pole/case member becomes the drive element, and the rotor/ shaft assembly becomes the driven element of the clutch with torque being transmitted through the magnetic air-gap. Magtrol Hysteresis Permanent Magnet devices provide all the superior operating characteristics of smooth operation, precise repeatability and long life inherent in our standard Hysteresis Brakes and Clutches.

HPM Series Data Sheet

PERMANENT MAGNET BRAKE RATINGS

Brake Model HPM-2.5 HPM-8 HPM-16 HPM-32 HPM-120 HPM-210 Rated Torque* ozin 2.5 8 16 32 120 210 Maximum Speed** rpm 10,820 10,140 6,340 3,800 3,380 2,900 Kinetic Power Ratings watts 5 Minutes Continuous 20 60 75 90 300 450 7 15 20 25 75 110 External Inertia lbins 3.8 10-6 3.3 10-5 5.6 10-5 8.6 10-5 9.1 10-4 2.75 10-3 Angular Acceleration rad/s 41,100 15,200 17,900 23,300 8,240 4,770 Model Weight lb 0.17 0.49 0.65 1.06 4.06 7.73

PERMANENT MAGNET CLUTCH RATINGS

Clutch Model HPMC-2.5 HPMC-8 HPMC-16 HPMC-32 HPMC-120 HPMC-210 Rated Torque* ozin 2.5 8 16 32 120 210 Maximum Speed** rpm 10,820 10,140 6,340 3,800 3,380 2,900 Kinetic Power Ratings watts 5 Minutes Continuous 20 60 75 90 300 450 7 15 20 25 75 110 External Inertia lbins 3.8 10-6 3.3 10-5 5.6 10-5 8.6 10-5 9.1 10-4 2.75 10-3 Angular Acceleration rad/s 41,100 15,200 17,900 23,300 8,240 4,770 Model Weight lb 0.17 0.49 0.65 1.06 4.06 7.73

* Permanent Magnet Brakes can be charged at factory to produce lower torque if desired. ** Maximum speed listed will produce 5-minute kinetic power rating at rated torque.

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Dimensions
PERMANENT MAGNET BRAKE DIMENSIONS
E D

HPM Series

A C B

F K (3) Mounting Holes - equally spaced L Bore Circle J I G H

Brake Model HPM-2.5 HPM-8 HPM-16 HPM-32 HPM-120 HPM-210

A 1.250 1.750 1.970 2.250 3.625 4.437

B 0.1250 0.1875 0.1875 0.2500 0.3750 0.5000

C 0.375 0.500 0.500 0.625 0.875 1.125

D 0.015 0.015 0.015 0.025 0.025 0.035

E 0.030 0.060 0.096 0.094 0.130 0.156

F 0.840 0.915 0.812 0.865 0.985 2.410

G 1.564 2.109 2.109 2.431 3.490 4.693

H 0.290 0.500 0.515 0.562 0.910 1.062

I 0.940 0.953 0.946 1.125 1.654 2.510

J 0.290 0.584 0.545 0.625 0.800 0.930

K #4-40 0.16 #4-40 0.16 #4-40 0.25 #6-32 0.20 #8-32 0.25 #10-32 0.38

L 0.750 0.687 0.750 0.906 1.500 1.750

M --0.375 0.375 0.375 0.625 0.625

N --0.025 0.025 0.030 0.060 0.060

Solid Model 3

PERMANENT MAGNET CLUTCH DIMENSIONS

E D

A C B

F K (3) Mounting Holes - equally spaced L Bore Circle J I G H

Clutch Model HPMC-2.5 HPMC-8 HPMC-16 HPMC-32 HPMC-120 HPMC-210

A 1.250 1.750 1.970 2.250 3.500 4.437

B 0.1250 0.1875 0.1875 0.2500 0.3750 0.5000

C 1.059 1.000 1.000 1.500 2.000 2.250

D 0.032 0.032 0.032 0.032 0.032 0.062

E 0.250 0.312 0.312 0.375 0.375 0.500

F 0.840 0.915 0.812 0.865 1.150 2.410

G 1.803 2.375 2.350 2.719 3.732 5.060

H 0.290 0.500 0.515 0.562 1.000 1.062

I 1.224 1.295 1.290 1.532 1.932 3.067

J 0.290 0.584 0.545 0.625 0.800 0.935

K #4-40 #4-40 #4-40 #6-32 #8-32 #10-32

L 0.750 0.687 0.750 0.906 1.500 1.750

M --0.375 0.375 0.375 0.625 0.625

Solid Model --3 0.025 3 0.025 0.030 0.060 0.060 N

3 Solid models are available for this unit by contacting Magtrol Customer Service.

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How to Select a Brake or Clutch

To properly size a brake or clutch, the operating parameters of MAXIMUM TORQUE (T), SLIP SPEED (RPM), and KINETIC POWER (W) have to be determined. Once calculated, these parameters can be used to select the proper size brake or clutch from the technical data provided on the product data sheets found in this catalog. These parameters are easily calculated from system operating requirements such as: total web or strand tension (F); the radius of the full reel, roller, pulley, etc. (d/2); and linear velocity/feed rate (v). The following example is given to show the relationship of these system requirements to the calculation of the brake operating parameters. Since this example is not meant to cover all possible applications, an application data sheet is provided on the following page. If additional assistance is needed, simply complete a copy of the data sheet and fax it to Magtrol. Our Application Engineering staff will be pleased to assist you.

SAMPLE PROBLEM
Select a brake to tension a 7-inch diameter payoff reel in a system requiring total (web or strand) tension of 2 lb and a process speed of 600 ft/min. GIVEN: d F v Diameter Tension/Force Linear Velocity = = = 7 in 2.0 lb 600 ft/min FIND: T W Torque (lbin) Kinetic Power (watts)

RPM Slip Speed (rpm)

Torque (T) T T T or T = = = = Force (lb) Radius (in) F (d/2) 2 lb 3.5 in = 7 lbin 32 oz 3.5 in = 112 ozin
Total Web/Strand Tension (F)

Velocity/Feed Rate (v)

Slip Speed (RPM) RPM RPM RPM RPM RPM = = = = = Linear Velocity (in/min) / Circumference (in) v (d) (600 ft/min 12) / ( 7 in) 7200 in/min / 21.98 in 327 rpm

Full Roll Diameter (d)

Hysteresis Brake

Kinetic Power (W) see notes at box in right W W W W = = = = hp 746 (torque (lbin) speed (rpm) / 63025) 746 (T RPM / 63025) 746 (7 lbin 327 rpm / 63025) 746 = 27 watts

NOTES 1 hp = 746 watts Basic Horsepower Formula: hp = torque (lbin) speed of rotation (rpm) 63025

SOLUTION:

From the Hysteresis Brake ratings on page 2, it can be seen that an HB-140 Hysteresis Brake which has a rated torque of 140 ozin, a maximum speed capability of 12,000 rpm, and a kinetic power capability of 75 watts continuous, would be the proper selection for this application.

NOTE:

In a clutch application, slip speed is the difference in rotational speed between the input and output members of the clutch assembly. If, in the above example, tensioning were being accomplished with a clutch inserted between a take-up reel and a motor driving at 500 rpm, the actual slip speed used to compute the kinetic power requirements would be 500 rpm (clutch input speed) - 327 rpm (clutch output speed = 173 rpm). The difference in speed would obviously impact the result for kinetic power.

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Application Data Sheet

Company Information
Company Address

Application Specifications
Max. Torque Required Minimum Torque Normal rpm Intermittent rpm

Contact Phone Fax E-mail

Duty Cycle Anticipated Qty Target Price

Electrical Specifications Device Type

Desired Volts, DC Available DC Current Electrical Time Constant

r r r r r r

Hysteresis Brake Matched Hysteresis Brake Large Bore Brake Hysteresis Clutch Permanent Magnet Brake Permanent Magnet Clutch

Ambient Conditions
Ambient Air Temperature Other Special Conditions

Application Description

Application Sketch

Complete the Application Data Sheet and fax, with an application sketch if necessary, to Magtrol, Inc. at (716) 668-8705.

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Special Designs and Modifications

Since 1953, Magtrol has created literally thousands of special and modified brake designs to help solve specific application problems for our customers.

COMMON MODIFICATIONS
Non-Standard Coil Voltages Special Shaft Configurations: keyways, flats, holes and hollow Dust Covers Speed Pickups Special Mounting Configurations Non-Standard Lead: material, lengths, location Higher Torque Devices High Speed Units

FORCED AIR COOLED BRAKES

Compressed Air Cooled

HIGHER TORQUE CAPABILITY

It is Magtrols policy never to overstate the capabilities of our products. As a result, our brakes are conservatively rated. Higher torque values (15-25% above rated torque) are typically available from each brake, depending on the brake being ordered. In addition, special designs capable of producing even higher torques are available.
Maximum Torque

+15 to +25%

Blower Cooled

Rated Torque

CURRENT

Unlike many other forms of braking devices, Magtrol Hysteresis Brakes can be safely operated at relatively high speeds, provided the combination of applied torque and speed of operation do not cause the brake to be operated above its kinetic power rating. The kinetic power rating of the brake can be increased significantly, when necessary, by forced air cooling. Magtrol has designed brakes with provisions for forced air cooling utilizing compressed air supplied by the machine builder and has also created special designs and blower packages for use in high-torque/high-speed applications where compressed air is not available.

METRIC HYSTERESIS BRAKES

Most of Magtrols Hysteresis Brakes and Matched Hysteresis Brakes are available in a metric design. For more details, please refer to Magtrols Hysteresis Brake Metric Product Guide which can be accessed from our web site at http://www.magtrol.com/ brochures/metricbrake.pdf. Additional brake and clutch products that are currently available in standard English dimensions can also be modified to meet metric requirements. Contact Magtrol or your local sales agent for more information. Large Bore Brakes For many years Magtrol has designed customized Hysteresis Brakes with large bores, and without a shaft or bearings. These brakes are used for superior tension control for helical wrapping, braiding and other feed through applications. Magtrol Large Bore Brakes are used in machines for manufacturing cable, wire, fiber optic cable, rope and tape, among others. Magtrol Large Bore Brakes provide smooth, repeatable torque, largely independent of speed. Maximum speeds up to 8000 rpm are available. 18

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Options and Accessories

BRAKE OPTIONS
Base Mounting Base mounting is standard on all HB-840 and HB-3500 brakes, and is an available option on all other brakes. Base Mount Ordering Information: An HB-450 with a base mount is an HB-451 and an HB-1750 with a base mount is an HB-1751.

POWER SUPPLIES
For optimum torque stability, Magtrol offers four different power supplies for its Hysteresis Brakes and Clutches: Model 6100 Closed Loop SpeedControl/PowerSupply The 6100 is a durable, variable, closed loop speed control power supply governed by an adjustable proportional/integral (PI) control algorithm for unsurpassed stability in its class. Designed to work with a Magtrol Hysteresis Brake that is specially fitted with a speed pick-up, the 6100 functions as a power supply and also features an easy-to-read digital speed display. Model 5200 Power Supply The Model 5200 is an unregulated 0 to 35 VDC Power Supply which offers control and regulation of the braking torque via a 10 turn potentiometer. The 5200 is our most basic control for manual testing in an open loop torque control mode. Model 5210 Current Regulated Power Supply The Model 5210 provides the same control capabilities as the 5200, and also provides current regulation of the brake. With regulated current, the 5210 will eliminate torque drift caused by temperature changes within the brake coil. Model 5250 Current Regulated Power Supply Model 5250-2 is an open frame, current regulated power supply.

EE DD CC AA BB GG FF KK (4) Thru Holes HH

JJ

All other dimensions per standard brakes

AA HB-451 HB-840 BB CC DD EE FF GG HH JJ KK 0.201 0.406 2.50 0.25 2.00 0.50 3.15 5.25 4.75 0.25

* *

4.13 0.25 3.63 0.50 3.15 5.25 4.75 0.25 1.81 0.204

HB-1751 4.00 0.50 3.00 0.50 4.75 9.00 8.00 0.50

HB-3500 5.00 0.50 4.00 0.50 4.75 8.50 7.50 0.50 3.73 0.406

* Contact Magtrol for drawing.

Torque Current Curves Nominal performance characteristic curves similar to that shown on page 16 will be provided by Magtrol, upon request. Precise calibration curves for individual brakes can be provided, but must be specified at time of order and do require an additional charge. Contact Magtrol for price and delivery of brakes complete with calibration curves. Pillow Blocks Pillow Block Assemblies are available for all brake and clutch units except the HB-840 and HB-3500. Refer to each products dimension page for pillow block drawings and dimensions.
Pillow Block # 4702 4703 4705 4711 4714 4717 4720 4722 4736 4742 4744 4753 4755 4759 4760 Fits Brake/Clutch Model(s) HB-8, HPM-8, HPMC-8, MHB-10.5 HB-16, HPM-16, HPMC-16 HB-32, HB-50, HPM-32, HPMC-32, MHB-38, MHB-50 HB-140, HPM-120, HPMC-120, MHB-140 HB-250, HPM-210, HPMC-210, MHB-250 HB-450, MHB-450 HB-750, MHB-750 HB-1750, MHB-1760 HB-2.5, HPM-2.5, HPMC-2.5, MHB-2.5 HCS-8 HCS-16 HCS-32 HCS-120 HCS-420 HCS-210

COUPLINGS
Although intended for coupled service, moderate overhung loads can be tolerated, depending on such operating characteristics as speed, weight, and center of gravity of load. Care should be taken to make certain that the shaft is properly aligned. Couplings should be of proper size and flexibility to adequately protect bearings from undue stress and shock loading.

ORDERING INFORMATION
Specify the brake model number from the product ratings table, followed by a -1, -2, or -3 signifying the required coil voltage. For example, an HB-140 brake with a nominal 24 VDC coil would be ordered as an HB-140-2.

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OTHER MAGTROL PRODUCTS

Motor Testing Equipment
Magtrol offers three types of Dynamometers, each with a different braking system to absorb load: hysteresis, Eddycurrent and powder. The dynamometers are complemented by DSP-based controllers, power analyzers and LabVIEW based motor test software. Magtrols dynamometers, electronics and software are used for testing all types of electric and pneumatic motors, gas engines and gearheads, as well as servo drives and inverters. With over 50 dynamometers to choose from, and the availability of Customized Motor Test Systems (CMTS), virtually every motor testing requirement can be met. Features include: Torque from 0.02 Nm to 1200 Nm; Speed from 0 rpm to 70,000 rpm; Power from 7 W to 140 kW; DSP-based high speed controller with RS-232 and GPIB communication; Single and three-phase power analyzers; LabVIEW based motor test software. Customized turnkey systems with table/cabinet, power supply, PC, printer, fixtures, etc. available.

Load-Force-Weight Transducers
Highly reliable systems to measure and monitor load, force and weight, commonly used to provide safety, control and overload protection. Typical applications requiring LoadForce-Weight Systems include cranes, harbor installations, oil drilling (on and off shore), hoists, winches and other heavy lifting equipment. The systems are extremely accurate, can be used for static or dynamic measurement, and are able to withstand the most extreme environmental conditions. Features include: Nominal value up to 2500 kN; Accuracy class < 0.5%; Protection up to IP67; Transducer made of high resistance stainless steel; Overload admissible 150%; Overload at rupture up to 500%; Test and certificate for component to CE standards and material certificate on request; Analog or digital signal conditioner with inputs up to 2 channels, 010 V, 420 mA outputs or bus interface, and digital display.

Displacement Transducers
Provides contactless measurement of absolute piston position in hydraulic and pneumatic cylinders, and other applications. Features include: Accuracy of 0.3%; Range from 50 mm to 1 m; High shock and vibration resistance; Ability to withstand pressure up to 450 bar; Operating temperature of -40 C to +80 C with active temperature compensation. High temperature version up to 200 C available.

For over 50 years, Magtrol Inc and Magtrol SA have been providing customers with high quality products to test, measure and control torque-speed-power, loadforce-weight, tension and displacement. Magtrol Inc, which is headquartered in the USA, is a leading manufacturer of motor test equipment and hysteresis brakes and clutches. Magtrol SA, located in Switzerland, also offers motor test equipment as well as products to measure, control and monitor load-force-weight and displacement. Magtrol offers customers a wide array of measurement and control solutions, combined with excellent worldwide sales and service.

Rotary Transmitters
Used for signal transmission of transducers on a rotating part (e.g. engine shaft) to a stationary system (measuring instrument or PC). Common applications include thermocouples and strain gauges, as well as piezo electric transducers to measure oscillation, acceleration, force and pressure. The transmitter can also provide the supply signal to each transducer. Features include: Noise 25 V; 1, 4, 8 or 12 channels; Speed up to 40,000 rpm; Resistance < 0.2 m; Very low inertia; No slip-rings. Due to the continual development of our products, we reserve the right to modify specifications without forewarning.
Magtrol SA ISO 9001:2000 certified

70 Gardenville Parkway Buffalo, New York 14224 USA Tel: +1 716 668 5555 Fax: +1 716 668 8705 E-mail: magtrol@magtrol.com

MAGTROL INC

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