Brake Motor
Precision stopping meets industrial safety.
Brake Motor
WhatsApp for 15-min engineer call
Warranty
1 Year Standard
Service
Covered by Warranty
Certified
ISO 9001:2015
Experience
24 Years
Product Overview
The Sun Star brake motor combines a robust AC induction motor with a disc-type electromagnetic brake mounted on the non-drive end. In the energised state, the brake coil creates a magnetic field that compresses the brake spring, releasing the brake disc and allowing the motor shaft to rotate freely. When power is cut — whether intentionally or due to a fault — the spring force instantly presses the brake disc against the friction lining, locking the shaft within milliseconds. This fail-safe principle means the motor defaults to a braked (safe) state, making it fundamentally different from externally applied braking systems.
Key Features
Technical Specifications
| Power Range | 0.5 HP to 20 HP |
| Brake Type | AC Brake | Fail Safe |
| Braking Torque | Up to 200 Nm |
| Duty Cycle | S4 - 40% |
| Mounting | Foot / Flange / Face |
| Protection | IP54 / IP55 |
Common Applications
Industries Served
Steel & Metal Processing
EOT cranes, ladle handling, coil lifting, and sheet metal stacking in steel mills and metal fabrication shops.
Construction & Infrastructure
Tower cranes, construction hoists, and material lifts on building sites and infrastructure projects.
Warehousing & Logistics
Overhead cranes, goods lifts, and automated material handling systems in warehouses and distribution centres.
Packaging & FMCG
Intermittent-duty indexing, conveyor positioning, and carton sealing machines requiring precise stop-start control.
Key Benefits
- Prevents load drop during power failures with spring-applied fail-safe braking that engages in under 30 milliseconds
- Reduces maintenance downtime — brake disc and friction linings are designed for 1 million+ operations before replacement
- Enables precise positioning for packaging machinery and automated lines with adjustable braking torque
Why Choose Our Motors
- AC fail-safe design — brake engages on power loss with zero external dependency, no separate DC rectifier needed
- Adjustable braking torque from factory — specify your exact holding torque requirement at order time
- Tested for 10,000+ braking cycles before dispatch — every brake motor undergoes extended endurance testing
Manufacturing & Quality
Manufacturing Process
Brake motor production involves parallel manufacturing of the motor and brake assemblies, followed by precision integration. The brake disc is ground to flatness tolerance within 0.02mm for uniform friction contact. The brake coil is vacuum-impregnated separately and tested for correct pull-in voltage.
Quality Standards
- Brake engagement time tested and recorded for every unit
- Brake disc flatness verified to ≤ 0.02mm tolerance
- 10,000+ cycle endurance test on sample basis
- Insulation resistance and high-voltage testing per IS 325
- Vibration testing with brake engaged and released
Certifications
Selection Guide
For crane and hoist applications, the critical selection factor is the duty cycle (S4 rating) — not just HP. A 5 HP brake motor rated S4-40% can handle intermittent crane hoist duty, but the same motor at S1 continuous duty should be derated to approximately 3.5 HP. Always specify the braking torque to be at least 1.5× the full-load torque for safe holding on inclines.
Recommended For
Comparison With Similar Motors
| Feature | Sun Star Motors™ | Typical Market Motor |
|---|---|---|
| Brake Type | AC fail-safe (spring-applied) | DC brake requiring separate rectifier |
| Engagement Time | < 30 milliseconds | 50–100 milliseconds |
| Manual Release | Optional lever included | Often not available or extra cost |
| Duty Rating | S4-40% rated and tested | S1 rated only (derate for crane duty) |
| Endurance Testing | 10,000+ cycle test before dispatch | No endurance testing |
| Brake Air Gap | Factory-set and documented on nameplate | Set during installation by end user |
Installation Guidelines
- Mount the brake motor on a rigid foundation — inadequate foundation rigidity causes vibration that accelerates brake lining wear
- Verify the brake air gap before first start-up using feeler gauges — the air gap should be as specified on the nameplate (typically 0.3–0.5mm)
- For crane and hoist applications, align the motor shaft to the gearbox input shaft within 0.05mm — use flexible couplings to accommodate minor misalignment
- Connect the brake coil leads to the motor contactor output — the brake must energise and de-energise simultaneously with the motor
Maintenance Tips
- Inspect brake friction lining thickness every 6 months — replace when worn to minimum thickness marked on the lining
- Check and readjust the brake air gap annually — as linings wear, the air gap increases, reducing braking torque
- Verify manual release lever operation quarterly — lubricate the lever mechanism with light machine oil
- Listen for brake chatter or squeal during engagement — this indicates contaminated friction surfaces requiring cleaning
Troubleshooting Guide
| Issue | Possible Cause | Solution |
|---|---|---|
| Brake does not release (motor hums but shaft does not rotate) | Brake coil not receiving power, faulty coil, or stuck brake disc due to corrosion | Verify voltage at brake coil terminals. Check coil continuity with multimeter. If disc is stuck, use manual release lever and clean friction surfaces. |
| Brake does not engage (shaft freewheels when power is cut) | Brake spring broken or weakened, excessive air gap, or worn friction lining | Inspect brake springs for breakage. Readjust air gap to nameplate specification. Replace friction linings if worn below minimum thickness. |
| Brake engages with a loud bang or chatter | Oil or grease contamination on brake disc, glazed friction linings, or uneven lining wear | Clean disc and linings with solvent (acetone or brake cleaner). If glazed, lightly sand the friction surfaces. Replace linings if unevenly worn. |
Warranty Information
All Sun Star Motors™ brake motors carry a 12-month warranty from the date of dispatch, covering manufacturing defects in motor and brake assembly components. Warranty includes brake coil, friction linings, and spring mechanism under normal operating conditions within the specified duty cycle.
Quality Assurance • Sun Star Motors™