Warner XS-Series brake applications: Quiet and powerful braking in airline seats and more

XS-Series spring-actuated electrically released brakes from Warner Electric — part of the Altra Industrial Motion Corp. — are specifically designed to meet stringent compactness requirements in weight-sensitive applications. They boost reliable braking performance in a package weighing as little as 27 g. The XS brakes are  also statically engaged holding  so can stop moving loads in exceptional situations.

The Warner Electric brakes work with actuators that are usually stationary. So such actuators move a load into the desired position and then hold it there while a product or machine performs its job. Typical applications for motion control include position-adjustment systems in medical equipment and seats.

Here, it’s critical that the actuators maintain fixed positions regardless of changes in the applied load or power-supply interruptions. That means mechanical brakes are a leading choice. Because these applications are limited by stringent weight, space, and cost constraints, the brakes must be highly specialized designs.

Warner Electric XS brake delivers on power density

The most powerful XS-Series brake delivers holding torque to 0.5 Nm from a package weighing only 100 g.

Where minimum size and weight are top priority, equipment manufacturers need brakes that precisely match application requirements — and ones that easily integrate into the rest of the design. So to satisfy these demands, XS brakes come in six sizes with diameters of 22 mm, 29 mm, and 33 mm. Each diameter includes variants optimized for shortest overall length and minimum weight — and a slightly longer version optimized for greater torque. The most powerful brake in the series delivers holding torque to 0.5 Nm in a 100-g package. The three brake diameters accommodate maximum shaft diameters of 3.5, 4.5, and 6 mm respectively.

To maximize mounting flexibility, XS brakes come with a custom-designed mounting plate tailored to end-user application needs. The actuating coil runs off a 24-Vdc power supply as standard with other voltage options available to suit other applications. Operation of the brakes takes only 3 W of power for the smallest units (and only 7 W for the largest). Warner’s investment in flexible lean-manufacturing operations means it manufactures custom brakes with short lead times in volumes to suit customer requirements.

Warner Electric XS Series for first and business-class airline seats

XS Series brakes are available in six sizes with overall diameters of 22 mm, 29 mm, and 33 mm. One of the first customer applications for the new XS Series brakes is on actuators in first and business-class seats for a major global aerospace OEM. There were extremely stringent space and weight requirements, and the customer needed exceptionally quiet operation. Seat specifications called for a brake having characteristics exactly matching that of the model XSB29 brake.

Working closely with the aerospace OEM during seat development and testing, Warner Electric’s engineering team supplied an XS brake that met or exceeded all application requirements. Plus the design is more cost-effective than competing permanent-magnet brake variations.