Increasing consumer demand for frozen food items continues to generate
significant growth in cold storage capacity around the world. Harsh
environmental conditions in these facilities are challenging for both workers
and equipment, including forklifts. Besides exposure to the extreme cold
temperatures, forklifts are also subjected to damaging condensation that
occurs as the trucks move in and out of refrigerated areas.
Since cold storage facilities are costly to operate compared to typical
warehouses, facility managers are constantly focused on maintaining high
productivity levels. In response, many forklift truck manufacturers offer
special feature packages designed for forklifts that need to perform in cold
and wet conditions such as cold rooms and outdoor yard environments.
These features might include special wiring harnesses and
battery enclosures.
ELIMINATING A STICKY SITUATION
To provide reliable service braking as well as parking brake
functionality in these vehicles, spring-applied motor brakes are positioned
inline with the forklift’s motor or between the motor and the gearbox.
The problem is that in cold environments with high moisture levels standard
friction materials can, in some conditions, stick. This phenomenon often
appears after parking for a few hours. The friction material becomes
bonded to the counter-friction surface, locking up the brake, which blocks
the motor and prevents the truck from moving. If this occurs, maintenance
is required to unblock the brake. To eliminate the problem, Warner Electric
engineers have developed a proprietary friction material specifically
designed for cold room and outdoor environments with high moisture levels
and wide temperature differentials.
ADVANCED FRICTION MATERIAL TECHNOLOGY
MEETS THE APPLICATION CHALLENGE
Warner Electric is well recognized as the world leader in
advanced forklift braking solutions. In this application, the
challenge was to design a new friction material that would
retain stable torque in between static parking and highenergy
service and emergency stopping in tough cold and
wet environments.
The Warner engineering team was able to draw on its
extensive brake technology knowledge, combined with
vast forklift application experience, to develop the new
friction material.
PK enclosed design models are
offered for applications where
the brakes may be exposed to
excessive water, debris or dust.
IP67-rated models are also
available.
The new material was put through a rigorous battery of
in-house testing, including extreme temperature changes
in a climate chamber, endurance testing and spline
strength testing. Cold environment field tests were also
performed with the new material installed on a forklift truck.
Both the lab and field test results confirmed that there was
virtually no sticking, not even a tenth of a Nm drag torque.
The new material is currently available on all Warner
Electric PK motor brakes in different arrangements/
configurations depending on the application.
NEW FRICTION MATERIAL HELPS FORKLIFT OEM
IMPROVE RELIABILITY
Warner Electric PK motor brakes with the new friction
material are also ideal for use on other vehicles that
operate in cold and/or wet environments, including
aerial lifts and golf carts
A major global forklift truck OEM was looking for a more
reliable braking solution for its cold storage/outdoor option
package. Warner Electric supplied lab test reports along
with a sample PK brake with the new friction material
installed. After completing its own field testing, the OEM
specified the Warner Electric solution.