Clutch/brake combination: High availability, low operating costs

The modernization of the clutch and brake technology that was completed a few years ago represented a milestone for the entire Hatebur hot forming range. Our state-of-the-art solutions enable customers to enjoy a wide range of benefits, most notably high system availability and a significant reduction in operating costs.

As part of the development process for these new concepts, our specialists took existing concepts from leading providers and adapted them to the typical requirements of Hatebur products and the specific needs of our customers. Equipping new machines and retrofitting existing systems were given equal emphasis as part of this.

The HOTmatic AMP 20, AMP 30, HM 35 and AMP 50 models use a pneumatically controlled clutch/brake combination with a friction block design, which has proven its effectiveness in cold forming applications over many years. These compact units are arranged on the flywheel side of the main drive shaft and are therefore situated completely outside of the press body.

Personnel safety

In all of the new solutions, the flywheel is mounted directly on the bearing housing and not on the drive shaft, which significantly improves safety for personnel. This arrangement ensures that the flywheel is held safely against the bearing housing even in the unlikely event of the drive shaft breaking.

Technical aspects

The use of a clutch/brake combination with friction blocks in-stead of friction disks provides several crucial benefits at once. A design using friction blocks enables the unit to be rigidly fitted to the flywheel and flywheel housing. The axial movement during the switching process occurs between the friction blocks and their steel supports, eliminating the need for wear-prone slide bearings. As the friction blocks are arranged on the very outside of the unit far away from the center of rotation, a relatively low force is applied to the individual friction blocks. This minimizes wear, particularly in comparison to conventional disk systems, which are designed such that the torque transfer occurs near to the center. By replacing the costly brake and clutch disks with simple friction blocks, we have laid the foundation for reliable, low-maintenance and cost-effective operation.

Availability and costs

During the technical design process in conjunction with suppliers, our development team decided to cleverly employ current technology and standard components. This guarantees the best possible availability of wear and spare parts at typical market prices.

Production and maintenance

A reliable clutch/brake system with a short braking angle plays a crucial role in ensuring safety for personnel as well as an efficient production facility. The new solutions offer impressive benefits for the maintenance of these units. As the clutch/brake combination is located on the flywheel on the outside, it is easy to access and simple to maintain and repair thanks to the use of friction blocks. Relocating the braking function outside of the press bodies also makes it easier to protect against contamination by lubricating oil and substantially improves the accessibility of the crank drive. As both functions are combined in a single unit, only one press safety valve is now required, which makes electrical and pneumatic installation noticeably easier. 

A wide variety of customers across the world have already converted their production facilities to use the new solutions, and are enjoying the benefits of lower operating costs and high availability of wear and spare parts.

Conversion example: HOTmatic AMP 20

In principle, any AMP 20 can be retrofitted to the clutch/brake combination. It is not necessary to rework the machine body, and the position of the V-belt remains unchanged. Smaller adjustments to the pneumatic system, electrical system, guards and control system are required. The costs of implementation depend on the technical standard, age and general condition of the machine, and are clarified in detail with the customer in the preliminary stages of the retrofitting process.

Cost-benefit analysis 
(Return on Investment)

If larger repairs or overhauling work in the area of the flywheel shaft are necessary, we highly recommend working with us to calculate how quickly conversion to the new clutch/brake combination will pay off. Depending on production numbers and machine utilization, we work on the assumption that the brake and clutch disks as well as the hubs of a conventional solution will wear out within three to five years. Our experience has shown that, taking material and personnel costs and machine downtimes into account, a return of investment of at most three to four years can be achieved for most customers.

Your advantages at a glance

• Modern technical solution with the latest components

• Higher system availability thanks to robust solution and simple troubleshooting

• Significantly lower maintenance costs thanks to simple construction with cost-effective friction blocks

• Actuated via a modern press safety valve

• Simple installation with easy access for quick maintenance and repair

• Return of investment costs within a few years

• Flywheel mounted directly on the bearing housing (ensuring safety in the event of the drive shaft breaking) 

• Brake outside of the press body = reduced risk of contamination and easier access to the crank drive

Our service

• Professional advice and expert implementation of the retrofitting

• Quick implementation thanks to pre-assembled components kept in stock

• Conversion of mechanical, pneumatic, electrical and control systems as a complete package from a single source

• High availability of wear and spare parts

• Support for individual calculation of the ROI period


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