Adaptive Brakes,

A Revolution in Safety

Presented by:
Dr.-Ing. Stefan Weigelt

© 2018 MHI® Copyright claimed for audiovisual works and sound recordings of seminar sessions. All rights reserved.
We set the Standards!

INTORQ Locations

❙ Market Leader Aerzen

Forklift Industry Atlanta Shanghai

❙ Worldwide Manufacturing Pune

❙ German Engineering
❙ Development Partner
❙ Atlanta GA U.S. Headquarters
The Idea!

A Device for Every Truck

Application …

Braking Situations
and
Performance
The Concept: Think different!

❙ Control the Deceleration Rate

❙ Torque Transfer – Brake And Drive
❙ Load-Dependent Braking
❙ Braking without
Blocking Drive Wheels
The Benefits!

❙ Intelligent Braking System

❙ Additional Performance Value
❙ Monitoring of all the Brake Safety Functions
e.g. Wear Monitoring
❙ Unique Technical Solution
Spring Applied Brake: Working Principle

1 = Armature plate
2 = Springs
FN = FF - FM FN FF 3 = Rotor
4 = Hub
M = 2 m rm FN 5 = Shaft
FM 6 = Flange
7 = Stator
FM = f(I,s) ~ I / s

Normal force FN , Magnetic force FM, Spring force FF ,

Mean friction radius rm, Friction coefficient m, Current I, Air gap s
The Perfect Solution!

Variation of the Brake Torque from 20% to 100% of the Rated Torque

Spring- Applied Brake Control

+ Ken
How to Simulate the Braking Behavior?
GUI Configuration Tool
Sensors Brake

CAN Adapter Control

PC
24V
Braking Test With and Without Controller
Emergency Stops Without Smart Control

Stopping Behavior Depended

of Load and Speed
VMax
Loaded
Truck

aLoaded < aUnloaded

V50%

Unloaded
Truck
t1 t2
Emergency Stops With INTORQ Control

Constant Deceleration Rate

Independent of Load and Speed
VMax Braking Process without Pedal
Loaded
Truck

aLoaded = aUnloaded
V50%
a 1 = a2

Unloaded
Truck
a 1 t1 a2 t2
Ramp Controlled Braking Concept

Time-Controlled Selection
M of Braking Torque
100%

Torque to Threshold at 100%

80%
Threshold
to 100%

20%

Dosing Start t1 Time [s]

Pedal Controlled Braking Concept

e.g.: 100% of Pedal Travel,

M Braking Torque will be 80%
100%

Torque to Threshold at 100%

80%
Threshold
to 100%

20%

Analog Input

Dosing Start 100% Position of Pedal

Torque Transfer Between Brake and Drive
Torque Transfer Between Brake and Drive
Acceleration Deceleration
n n

a Motor Brake
M M
a

Motor Designed for Deceleration Synchronization between ITC and Motor

n n
M
Motor
M M
Torque Transfer Between Brake and Drive

M
100%

65%
Maximum Motor Torque +
35%
Minimum Brake Control Torque
20%
Motor Torque Brake Torque
60% 100% Pedal
Control - Application

Load Dependent Braking

No Blocking of the Drive Wheel!

Control - Application

Future Application: AGV

Speed
Brake Drive n

Calculated
Speed
T n
s
Start of the
INTORQ Control Braking

Braking in a Defined Distance

Does our Safety Brake Fulfill Performance Level C?
Safety Brake, Performance Level C

B10d = 6 x 106

MTTFd = 94.6 Years

PFHd = 1.205 x 10-6

Safety Integrity Level (SIL) 1

Performance Level C,
Controller & Brake
Communication
Motor Controller

CAN External signal

Control Safety
Brake
Professional Forklift Maintenance

❙ Monitoring of Safety Functions

❙ Self-Diagnose in Case of Failure
❙ Parameterization of Brake System
❙ Function Monitoring of the CAN- Bus

> Monitoring of Safety Functions

Monitoring Functions

Shutdown

Relay

CAN alarm

Save status

Alarm
flag

Brake
action
Brake Coordination between
Load and Main Brake
Load Wheel Brake Concept

Control Mode 2 Control Mode 1

Load Wheel Brake Drive Wheel Brake

CAN-Bus
What Are The Advantages of Controller Use?
Benefits:

❙ Defined Braking Performance

❙ Motor Size Standardization
❙ Braking without Blocking Wheels
❙ Brake Torque Coordination
❙ Extensive Security Features
Questions?
 For More Information:
Speaker email: weigelt@intorq.com
Website: www.intorqusa.com

Or visit MODEX Booth HX53