HYSTERESIS BRAKESAND CLUTCHES

PROVIDING TECHNICAL SOLUTIONS TO YOUR TENSION CONTROL PROBLEMS

Frictionless

n

Longer Expected Life

n

Superior Repeatability

n

Less Maintenance

n

Less Downtime

HYSTERESIS BRAKESAND CLUTCHES

Pioneers in Hysteresis Torque ControlFounded 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 Magtrol’s 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 Magtrol’s 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 14–15

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

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

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

3 MAGTROL

Hysteresis PrinciplesPRINCIPLES OF HYSTERESIS

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.

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 assembly–fastened 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, providing a braking action between the pole structure and rotor.

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.

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. Adjustability from a minimum value (bearing drag) to a maximum value of rated torque is possible. Additional torque in the range of 15-25% above rated torque may be 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 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.

AIR GAP

FIELD COIL

BALL BEARINGS

SHAFT

POLE STRUCTURE

HUB

ROTOR(Drag Cup)

4 MAGTROL

HB SeriesHysteresis Brakes

HB SeriesData Sheet

RATINGS

DESCRIPTIONPure 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.

BrakeModel

Minimum Torque

at Rated Current

Number 1 Coil Number 2 Coil Number 3 Coil

Rated Current

Res. at 25°C ±10%

VDC Watts (Nom.)

Rated Current

Res. at 25°C ±10%

VDC Watts (Nom.)

Rated Current

Res. at 25°C ±10%

VDC Watts (Nom.)

oz·in mA Ω At Rated I mA Ω At Rated I mA Ω At Rated IHB-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

BrakeModel

Maximum Speed

Kinetic Power Rating*watts

Drag Torque**De-energized

External Inertia

Angular Acceleration Model Weight

rpm 5 Minutes Continuous oz·in lb·in·s² rad/s² lbHB-2.5 20,000 20 5 0.05 3.8 × 10-6 41,100 0.24HB-8 20,000 60 15 0.10 3.3 × 10-5 15,200 0.49HB-16 20,000 75 20 0.10 5.6 × 10-5 17,900 0.65HB-32 15,000 90 25 0.20 8.6 × 10-5 23,300 1.06HB-50 15,000 90 23 0.20 1.478 × 10-4 21,000 1.72HB-140 12,000 300 75 0.70 9.1 × 10-4 9,620 4.06HB-250 10,000 450 110 1.00 2.75 × 10-3 5,680 7.73HB-450 8,000 670 160 2.00 6.55 × 10-3 4,290 12.90HB-750 7,000 1,000 200 7.00 1.283 × 10-2 3,450 28.30HB-840 6,000 1,340 300 4.00 1.31 × 10-2 4,010 26.30HB-1750 6,000 2,400 350 13.00 5.28 × 10-2 2,070 54.00HB-3500 6,000 4,800 600 19.20 1.056 × 10-1 2,070 110.00

* Kinetic power ratings are maximum values based on limiting coil and/or bearing temperature to approximately 100ºC, 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.

5 MAGTROL

HB SeriesDimensionsBRAKE DIMENSIONS

PILLOW BLOCK DIMENSIONS

BrakeModel ØA ØB ØC D E F G H I J K L M N Solid

ModelHB-2.5 1.250 0.1250 0.375 0.012 0.030 0.73 1.564 0.29 0.94 0.29 #4-40 × 0.16 0.750 --- --- 3

HB-8 1.800 0.1875 0.500 0.021 0.096 0.82 2.120 0.50 1.00 0.50 #4-40 × 0.19 0.687 0.375 0.025 3

HB-16 1.970 0.1875 0.500 0.015 0.096 0.81 2.109 0.51 0.95 0.55 #4-40 × 0.19 0.750 0.375 0.025 3

HB-32 2.155 0.2500 0.625 0.025 0.094 1.25 3.000 0.56 1.69 0.63 #6-32 × 0.25 0.906 0.375 0.025 3

HB-50 2.360 0.2500 0.625 0.033 0.096 1.56 3.000 0.56 1.69 0.63 #6-32 × 0.25 0.906 0.375 0.025 3

HB-140 3.624 0.3750 0.875 0.025 0.140 1.53 3.968 1.00 2.00 0.80 #8-32 × 0.37 1.500 0.625 0.060 3

HB-250 4.437 0.5000 1.125 0.035 0.156 1.98 4.718 1.06 2.53 0.93 #10-32 × 0.50 1.750 0.625 0.060 3

HB-450 5.420 0.5000 1.125 0.035 0.156 2.06 5.156 1.06 2.87 1.03 #10-32 × 0.37 1.750 0.625 0.060 3

HB-750 6.220 0.6250 1.375 0.035 0.163 2.87 6.930 1.50 3.74 1.50 1⁄4-20 × 0.44 2.750 0.750 0.060 3

HB-840 5.485 0.5000 * * * 4.13 7.750 1.00 * 1.00 * * 0.625 0.060 3

HB-1750 8.900 1.0000 2.000 0.056 0.250 3.00 8.312 2.04 4.18 1.79 1⁄4-20 × 0.50 3.000 keyway 3

HB-3500 8.900 1.0000 * * * 6.00 12.460 2.04 * 2.04 * * keyway 3

Pillow Block Model

For BrakeModel

O P Q R S T ØU V ØW X Y SolidModel

4736 HB-2.5 1.75 1.500 0.31 1.000 1.500 0.25 0.750 #4-40 0.125 0.125 0.25 3

4702 HB-8 2.50 2.125 0.37 1.437 2.120 0.38 0.687 #4-40 0.201 0.187 0.38 3

4703 HB-16 2.50 2.125 0.37 1.437 2.120 0.38 0.750 #4-40 0.201 0.187 0.38 3

4705 HB-32 2.50 2.125 0.37 1.437 2.120 0.38 0.906 #6-32 0.201 0.187 0.38 3

4705 HB-50 2.50 2.125 0.37 1.437 2.120 0.38 0.906 #6-32 0.201 0.187 0.38 3

4711 HB-140 4.00 3.500 0.37 2.000 3.190 0.50 1.500 #8-32 0.201 0.250 0.504714 HB-250 4.00 3.500 0.37 2.375 3.690 0.50 1.750 #10-32 0.201 0.250 0.504717 HB-450 4.62 4.000 0.50 3.000 4.310 0.56 1.750 #10-32 0.201 0.250 0.504720 HB-750 5.25 4.500 0.75 3.250 5.125 0.75 2.750 1⁄4-20 0.343 0.375 0.75 3

4722 HB-1750 7.50 6.500 1.00 5.000 7.000 1.00 3.000 1⁄4-20 0.328 0.500 1.00

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

* 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.

ØL Bore Circle

K (3) Mounting Holes - equally spaced IJ

F

H

MM

ØBØCØA

N N

ØB

D

G

E

T

P

O

R

Q

S

X

Y

ØW (holes thru)(Drill Thru andCounter-bore for3 Socket HeadCap Screws)

V

ØU

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

6 MAGTROL

HB SeriesApplications

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.

Magtrol Hysteresis Brake used for holding of backdriving load.

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

Brake RollerRibbons

Idler Rollers Slitter Blades

SlittingTension Brake

Motor

UnwindTension HoldingHysteresis Brake

Motors

Hysteresis BrakesMotor

Motor

Ball Screw

Ball Screw

Load

Load

Hysteresis Clutch

Hysteresis Brake

7 MAGTROL

HB SeriesApplications

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

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

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

WireMagazine

HysteresisBrake

WireMagazine

Control Panel

HysteresisBrake

Armature

Wire Spool

Wound Coil

Hysteresis Brakes

GapPhoto Eye

Controller/Power Supply

HoldbackHysteresis

Brake

Follower Arm

HysteresisBrake

Controller/Power Supply

Potentiometer

8 MAGTROL

HCS SeriesHysteresis Clutches

HCS SeriesData Sheet

RATINGS

DESCRIPTIONLike Magtrol’s 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.

ClutchModel

Minimum Torque

at Rated Current

Number 1 Coil Number 2 Coil Number 3 Coil

Rated Current

Res. at 25°C ±10%

VDC Watts (Nom.)

Rated Current

Res. at 25°C ±10%

VDC Watts (Nom.)

Rated Current

Res. at 25°C ±10%

VDC Watts (Nom.)

oz·in mA Ω At Rated I mA Ω At Rated I mA Ω At Rated IHCS-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

ClutchModel

Maximum Speed

Kinetic Power Rating*watts

Drag Torque**De-energized

External Inertia

Angular Acceleration Model Weight

rpm 5 Minutes Continuous oz·in lb·in·s² rad/s² lbHCS-8 3,600 60 15 0.1 3.3 × 10-5 15,200 0.33

HCS-16 3,600 75 20 0.1 5.6 × 10-5 17,900 0.94

HCS-32 3,600 90 25 0.1 8.6 × 10-5 23,300 1.56

HCS-120 3,600 300 75 0.7 9.1 × 10-4 8,240 4.78

HCS-210 3,600 450 110 1.0 2.75 × 10-3 4,700 9.15

HCS-420 3,600 670 160 2.0 6.55 × 10-3 4,010 19.50

* Kinetic power ratings are maximum values based on limiting coil and/or bearing temperature to approximately 100ºC, 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.

9 MAGTROL

HCS SeriesDimensionsCLUTCH DIMENSIONS

PILLOW BLOCK DIMENSIONS

ClutchModel ØA ØB ØC ØD ØE F G H I J K ØL M N

HCS-8 1.88 0.1875 0.375 0.8750 1.56 0.100 0.897 0.69 1.156 0.750 #4-40 × 0.19 1.250 0.37 0.02

HCS-16 2.00 0.1875 0.375 0.8750 1.67 0.100 1.062 0.75 1.321 0.875 #6-32 × 0.22 1.250 0.37 0.02

HCS-32 2.09 0.2500 0.500 1.1250 1.67 0.212 1.603 * 0.87 2.006 0.740 #6-32 × 0.28 1.437 0.37 0.03

HCS-120 3.62 0.3750 0.625 1.6250 3.20 0.312 1.430 1.00 2.625 0.952 #10-32 × 0.25 2.750 0.50 0.06

HCS-210 4.47 0.5000 0.750 2.1654 3.96 0.312 1.912 1.10 2.975 1.312 #10-32 × 0.39 3.000 --- ---

HCS-420 5.72 0.7500 1.000 2.6772 5.07 0.375 2.449 1.25 3.811 1.686 #10-32 × 0.38 3.875 --- ---

Pillow Block Model

For ClutchModel

O P Q R S T ØU V ØW X Y Z AA BB ScrewNumber

BearingNumber

4742 HCS-8 2.625 2.250 0.38 1.437 2.25 1.94 1.250 #4-40 0.201 1.531 0.38 1.906 1.156 1.88 50-5729 50-6432

4744 HCS-16 2.625 2.250 0.38 1.437 2.25 1.94 1.250 #6-32 0.201 1.696 0.38 2.071 1.321 1.88 50-5707 50-6432

4753 HCS-32 2.625 2.250 0.38 1.437 2.31 2.06 1.437 #6-32 0.201 2.381 0.38 2.756 2.006 1.88 50-5707 50-6460

4755 HCS-120 4.250 3.750 0.50 2.000 3.62 3.20 2.750 #10-32 0.204 3.125 0.50 3.625 2.625 3.25 50-5731 50-6460

4760 HCS-210 5.000 4.500 0.50 3.000 4.88 4.25 3.000 #10-32 0.266 3.470 0.50 3.970 2.970 4.00 50-5770 50-6192

4759 HCS-420 6.000 5.500 0.50 3.500 5.88 5.12 3.875 #10-32 0.266 4.436 0.62 5.061 3.811 5.00 50-5770 50-6432

* 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.

K (3) Mounting Holes - equally spacedIJ

F G

H

M

ØDØE

N

ØB

ØA

ØC

Input Shaft

Coil Assembly

Output Shaft

Lead Wires (2)12” Lg. Standard

ØL Bore Circle

ZX

AAY Y

Bearing

P

R

O

Q

ØW(4) Thru Holes

BB

TS

REAR VIEW SIDE VIEW FRONT VIEW

(Drill Thru andCounter-bore for3 Socket HeadCap Screws - equally spaced)

V

ØUBore Circle

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

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

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.

10 MAGTROL

HCS SeriesApplications

HysteresisClutches

Bottleswithcaps

Bottleswithout

caps

Motor

HysteresisClutch

Controller/Power Supply

Potentiometer

Dancer Roll

Motor

Motor

Ball Screw

Ball Screw

Load

Load

Hysteresis Clutch

Hysteresis Brake

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

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

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

11 MAGTROL

MHB SeriesMatched Hysteresis Brakes

MHB SeriesData Sheet

RATINGS

DESCRIPTIONIn 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

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.

BrakeModel

Minimum Torque

at Rated Current

Number 1 Coil Number 2 Coil Number 3 Coil

Rated Current

Res. at 25°C ±10%

VDC Watts (Nom.)

Rated Current

Res. at 25°C ±10%

VDC Watts (Nom.)

Rated Current

Res. at 25°C ±10%

VDC Watts (Nom.)

oz·in mA Ω At Rated I mA Ω At Rated I mA Ω At Rated IMHB-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

BrakeModel

Maximum Speed

Kinetic Power Rating*watts

Drag Torque**De-energized

External Inertia

Angular Acceleration Model Weight

rpm 5 Minutes Continuous oz·in lb·in·s² rad/s² lbMHB-2.5 20,000 20 7 0.05 3.8 × 10-6 41,100 0.24MHB-10.5 20,000 60 15 0.10 3.3 × 10-5 19,900 0.49MHB-38 15,000 90 25 0.20 8.6 × 10-5 27,600 1.06MHB-50 15,000 90 23 0.20 1.478 × 10-4 21,000 1.72MHB-140 12,000 300 75 0.70 9.1 × 10-4 9,620 4.06MHB-250 10,000 450 110 1.00 2.75 × 10-3 5,680 7.73MHB-450 8,000 670 160 2.00 6.55 × 10-3 4,290 12.90MHB-750 7,000 1,000 200 7.00 1.283 × 10-2 3,450 28.30MHB-1750 6,000 2,400 350 13.00 5.28 × 10-2 2,070 54.00

* Kinetic power ratings are maximum values based on limiting coil and/or bearing temperature to approximately 100ºC, 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.

12 MAGTROL

MHB SeriesDimensionsBRAKE DIMENSIONS

PILLOW BLOCK DIMENSIONS

BrakeModel ØA ØB ØC D E F G H I J K L M N Solid

ModelMHB-2.5 1.250 0.1250 0.375 0.010 0.030 0.73 1.564 0.30 0.94 0.29 #4-40 × 0.16 0.750 --- --- 3

MHB-10.5 1.800 0.1875 0.500 0.015 0.096 0.82 2.159 0.50 1.00 0.55 #4-40 × 0.19 0.687 0.375 0.025

MHB-38 2.155 0.2500 0.625 0.032 0.096 1.25 3.000 0.56 1.69 0.63 #6-32 × 0.25 0.906 0.375 0.025

MHB-50 2.360 0.2500 0.625 0.033 0.096 1.56 3.000 0.56 1.69 0.63 #6-32 × 0.25 0.906 0.375 0.025 3

MHB-140 3.624 0.3750 0.875 0.025 0.140 1.53 3.968 1.00 2.00 0.80 #8-32 × 0.37 1.500 0.625 0.060

MHB-250 4.437 0.5000 1.125 0.035 0.156 1.98 4.718 1.06 2.53 0.93 #10-32 × 0.50 1.750 0.625 0.060

MHB-450 5.420 0.5000 1.125 0.035 0.156 2.06 5.156 1.06 2.87 1.03 #10-32 × 0.37 1.750 0.625 0.060

MHB-750 6.220 0.6250 1.375 0.035 0.163 2.87 6.930 1.50 3.74 1.50 1⁄4-20 × 0.44 2.750 0.750 0.060 3

MHB-1750 8.900 1.0000 2.000 0.056 0.250 3.00 8.312 2.04 4.18 1.79 1⁄4-20 × 0.50 3.000 keyway

Pillow Block Model

For BrakeModel O P Q R S T ØU V ØW X Y Solid

Model

4736 MHB-2.5 1.75 1.500 0.31 1.000 1.500 0.25 0.750 #4-40 0.125 0.125 0.25 3

4702 MHB-10.5 2.50 2.125 0.37 1.437 2.120 0.38 0.687 #4-40 0.201 0.187 0.38 3

4705 MHB-38 2.50 2.125 0.37 1.437 2.120 0.38 0.906 #6-32 0.201 0.187 0.38 3

4705 MHB-50 2.50 2.125 0.37 1.437 2.120 0.38 0.906 #6-32 0.201 0.187 0.38 3

4711 MHB-140 4.00 3.500 0.37 2.000 3.190 0.50 1.500 #8-32 0.201 0.250 0.50

4714 MHB-250 4.00 3.500 0.37 2.375 3.690 0.50 1.750 #10-32 0.201 0.250 0.50

4717 MHB-450 4.62 4.000 0.50 3.000 4.310 0.56 1.750 #10-32 0.201 0.250 0.50

4720 MHB-750 5.25 4.500 0.75 3.250 5.125 0.75 2.750 1⁄4-20 0.343 0.375 0.75 3

4722 MHB-1750 7.50 6.500 1.00 5.000 7.000 1.00 3.000 1⁄4-20 0.328 0.500 1.00

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

ØL Bore Circle

K (3) Mounting Holes - equally spaced IJ

F

H

MM

ØBØCØA

N N

ØB

D

G

E

T

P

O

R

Q

S

X

Y

ØW (holes thru)(Drill Thru andCounter-bore for3 Socket HeadCap Screws)

V

ØU

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

13 MAGTROL

MHB SeriesApplications

Brake

PowerSupply

Transducer

Brake

Brake

Brake

Brake

PowerSupply

Transducer

Brake

PowerSupply

Transducer

Brake

PowerSupply

Transducer

Matched BrakesTypical

TYPICAL BRAKES VS. MATCHED

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-off tension within ±1% at matched point value.

MatchedHysteresisBrakes

Spool

PotFollower Arm

Multiple Pay-Off System

ThreadWires or

Extruder

Controller/Power Supply

MatchedHysteresis Brake

(Enlarged View)

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

Matched Large BoreHysteresis Brakes

sdna

rtScit

porebiF

14 MAGTROL

HPM Series PermanentMagnet Brakes & Clutches

HPM SeriesData Sheet

PERMANENT MAGNET BRAKE RATINGS

PERMANENT MAGNET CLUTCH RATINGS

DESCRIPTIONMagtrol 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.

BrakeModel

Rated Torque*

Maximum Speed**

Kinetic Power Ratings watts

External Inertia

Angular Acceleration

Model Weight

oz·in rpm 5 Minutes Continuous lb·in·s² rad/s² lb

HPM-2.5 2.5 10,820 20 7 3.8 × 10-6 41,100 0.17

HPM-8 8 10,140 60 15 3.3 × 10-5 15,200 0.49

HPM-16 16 6,340 75 20 5.6 × 10-5 17,900 0.65

HPM-32 32 3,800 90 25 8.6 × 10-5 23,300 1.06

HPM-120 120 3,380 300 75 9.1 × 10-4 8,240 4.06

HPM-210 210 2,900 450 110 2.75 × 10-3 4,770 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.

ClutchModel

Rated Torque*

Maximum Speed**

Kinetic Power Ratings watts

External Inertia

Angular Acceleration

Model Weight

oz·in rpm 5 Minutes Continuous lb·in·s² rad/s² lb

HPMC-2.5 2.5 10,820 20 7 3.8 × 10-6 41,100 0.17

HPMC-8 8 10,140 60 15 3.3 × 10-5 15,200 0.49

HPMC-16 16 6,340 75 20 5.6 × 10-5 17,900 0.65

HPMC-32 32 3,800 90 25 8.6 × 10-5 23,300 1.06

HPMC-120 120 3,380 300 75 9.1 × 10-4 8,240 4.06

HPMC-210 210 2,900 450 110 2.75 × 10-3 4,770 7.73

15 MAGTROL

HPM SeriesDimensionsPERMANENT MAGNET BRAKE DIMENSIONS

PERMANENT MAGNET CLUTCH DIMENSIONS

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

BrakeModel ØA ØB ØC D E F G H I J K ØL M N Solid

ModelHPM-2.5 1.250 0.1250 0.375 0.015 0.030 0.840 1.564 0.290 0.940 0.290 #4-40 × 0.16 0.750 --- --- 3

HPM-8 1.750 0.1875 0.500 0.015 0.060 0.915 2.109 0.500 0.953 0.584 #4-40 × 0.16 0.687 0.375 0.025

HPM-16 1.970 0.1875 0.500 0.015 0.096 0.812 2.109 0.515 0.946 0.545 #4-40 × 0.25 0.750 0.375 0.025

HPM-32 2.250 0.2500 0.625 0.025 0.094 0.865 2.431 0.562 1.125 0.625 #6-32 × 0.20 0.906 0.375 0.030

HPM-120 3.625 0.3750 0.875 0.025 0.130 0.985 3.490 0.910 1.654 0.800 #8-32 × 0.25 1.500 0.625 0.060 3

HPM-210 4.437 0.5000 1.125 0.035 0.156 2.410 4.693 1.062 2.510 0.930 #10-32 × 0.38 1.750 0.625 0.060

IJ

F

H

MM

ØBØCØA

N N

ØB

D

G

E

ØL Bore Circle

K (3) Mounting Holes - equally spaced

ClutchModel ØA ØB ØC D E F G H I J K ØL M N Solid

ModelHPMC-2.5 1.250 0.1250 1.059 0.032 0.250 0.840 1.803 0.290 1.224 0.290 #4-40 0.750 --- --- 3

HPMC-8 1.750 0.1875 1.000 0.032 0.312 0.915 2.375 0.500 1.295 0.584 #4-40 0.687 0.375 0.025 3

HPMC-16 1.970 0.1875 1.000 0.032 0.312 0.812 2.350 0.515 1.290 0.545 #4-40 0.750 0.375 0.025

HPMC-32 2.250 0.2500 1.500 0.032 0.375 0.865 2.719 0.562 1.532 0.625 #6-32 0.906 0.375 0.030

HPMC-120 3.500 0.3750 2.000 0.032 0.375 1.150 3.732 1.000 1.932 0.800 #8-32 1.500 0.625 0.060

HPMC-210 4.437 0.5000 2.250 0.062 0.500 2.410 5.060 1.062 3.067 0.935 #10-32 1.750 0.625 0.060

IJ

F

H

MM

ØBØCØA

N N

ØB

D

G

E

ØL Bore Circle

K (3) Mounting Holes - equally spaced

16 MAGTROL

How to Select a Brake or ClutchTo 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.

Torque (T)

T = Force (lb) × Radius (in) T = F × (d/2) T = 2 lb × 3.5 in = 7 lb·in or T = 32 oz × 3.5 in = 112 oz·in

Slip Speed (RPM)

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

Kinetic Power (W) see notes at box in right

W = hp × 746 W = (torque (lb·in) × speed (rpm) / 63025) × 746 W = (T × RPM / 63025) × 746 W = (7 lb·in × 327 rpm / 63025) × 746 = 27 watts

SAMPLE PROBLEM

Full RollDiameter (d)

TotalWeb/StrandTension (F)

HysteresisBrake

Velocity/Feed Rate (v)

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.

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 oz·in, 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.

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.

NOTES

1 hp = 746 watts

Basic Horsepower Formula:hp = torque (lb·in) × speed of rotation (rpm) 63025

GIVEN: d Diameter = 7 in

F Tension/Force = 2.0 lb

v Linear Velocity = 600 ft/min

FIND: T Torque (lb·in)

RPM Slip Speed (rpm)

W Kinetic Power (watts)

17 MAGTROL

Application Data Sheet

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

Application Sketch

Company Information Application Specifications

Company Max. Torque Required

Address Minimum Torque

Normal rpm

Intermittent rpm

Contact Duty Cycle

Phone Anticipated Qty

Fax Target Price

E-mail

Electrical Specifications

Device Type Desired Volts, DC

r Hysteresis Brake Available DC Current

r Matched Hysteresis Brake Electrical Time Constant

r Large Bore Brake

r Hysteresis Clutch Ambient Conditions

r Permanent Magnet Brake Ambient Air Temperature

r Permanent Magnet Clutch Other Special Conditions

Application Description

18 MAGTROL

Special Designs and Modifications

METRIC HYSTERESIS BRAKES

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

Most of Magtrol’s Hysteresis Brakes and Matched Hysteresis Brakes are available in a metric design. For more details, please refer to Magtrol’s 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.

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.

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

HIGHER TORQUE CAPABILITYIt is Magtrol’s 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.

FORCED AIR COOLED BRAKES

Compressed Air Cooled

Blower Cooled

CURRENT

Maximum Torque

+15 to +25%

Rated Torque

TO

RQ

UE

19 MAGTROL

Options and AccessoriesBRAKE 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.

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 product’s dimension page for pillow block drawings and dimensions.

COUPLINGSAlthough 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 INFORMATIONSpecify 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.

FFGG HH

AAJJCC BB

DD

EEØKK (4)Thru Holes

AA BB CC DD EE FF GG HH JJ ØKK

HB-451 2.50 0.25 2.00 0.50 3.15 5.25 4.75 0.25 * 0.201

HB-840 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 * 0.406

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

All other dimensions per standard brakes

* Contact Magtrol for drawing.

Pillow Block # Fits Brake/Clutch Model(s)

4702 HB-8, HPM-8, HPMC-8, MHB-10.54703 HB-16, HPM-16, HPMC-164705 HB-32, HB-50, HPM-32, HPMC-32, MHB-38, MHB-504711 HB-140, HPM-120, HPMC-120, MHB-1404714 HB-250, HPM-210, HPMC-210, MHB-2504717 HB-450, MHB-4504720 HB-750, MHB-7504722 HB-1750, MHB-17604736 HB-2.5, HPM-2.5, HPMC-2.5, MHB-2.54742 HCS-84744 HCS-164753 HCS-324755 HCS-1204759 HCS-4204760 HCS-210

POWER SUPPLIES

For optimum torque stability, Magtrol offers four different power supplies for its Hysteresis Brakes and Clutches:

Model 6100 Closed Loop Speed Control/Power Supply

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.

HB

WW

W 0

1/05

For more information, contact your local sales agent:

Motor Testing EquipmentMagtrol offers three types of Dynamometers, each with a different braking system to absorb load: hysteresis, Eddy-current and powder. The dynamometers are complemented by DSP-based controllers, power analyzers and LabVIEW™ based motor test software. Magtrol’s 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 N·m to 1200 N·m; 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 TransducersHighly reliable systems to measure and monitor load, force and weight, commonly used to provide safety, control and overload protection. Typical applications requiring Load-Force-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, 0–10 V, 4–20 mA outputs or bus interface, and digital display.

Displacement TransducersProvides 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.

Rotary TransmittersUsed 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 µV; 1, 4, 8 or 12 channels; Speed up to 40,000 rpm; Resistance < 0.2 mΩ; Very low inertia; No slip-rings.

OTHER MAGTROL PRODUCTS

ISO 9001

CE

R

T IFIC ATI ON

SWISS

Magtrol SA ISO 9001:2000 certified

MAGTROL INC70 Gardenville Parkway

Buffalo, New York 14224 USATel: +1 716 668 5555Fax: +1 716 668 8705

E-mail: magtrol@magtrol.com

MAGTROL SARoute de Moncor 4B1701 Fribourg, Suisse

Tel: +41 (0)26 407 3000Fax: +41 (0)26 407 3001

E-mail: magtrol@magtrol.ch

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, load-force-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.

www.magtrol.com

For worldwide network of sales agents, visit our web site:

Subsidiaries in:France • Germany • U.K.

Due to the continual development of our

products, we reserve the right to modify

specifications without forewarning.