History of CD Brakes by Bill Hipp 11/5/02

The CD disc brake is a direct current DC operated brake, originally developed around 1958. It began with size CD-1 and continues on through size CD-6ADD. The CD-1 is only good for a maximum of approximately 10 ft. lbs. but the CD-6ADD is good for a maximum of 428 ft. lbs. of torque. Since the early CD brakes were not adjustable, various springs and spacers had to be used to vary the torque setting. See Fig. 2 below for spring (14) and spacer (15). The adjustable CD disc brake was introduced around 1989. To set this brake to a desired torque, a plug in the center of the brake pot is turned in/out (18). This increased or decreased the spring (12) compression, thus increasing or decreasing brake torque. The CD-1 disc brake became obsolete around 1989. It was replaced by the adjustable disc brake (SD-1). The SD-1 brake used most of the same brake parts that were in the old Zip II hoist. The CD disc brake typically consisted of: 1. A bill of material for the basic mechanical parts (armature, disc, pins, disc hub etc.). 2. The brake pot (brake coil item 19 - Fig.1) 3. The spring (item 12 - Fig. 1 - various springs were used to provide different torque values) 4. Spring guide (item 13 - Fig. 2) and sometimes spacers ( item 15 Fig. 2 - to provide different torque values). When the adjustable disc brake was introduced it eliminated the need for all the different spacers and spring combinations. 5. Identification label. The brake coil typically called the brake pot was always a separate item because it frequently changed. For each CD brake size there are two basic brake coil sizes a short coil (lower torque capability) and a longer coil (higher torque capability). The short coil would be the CD-2 through the CD-6. The long (thicker) coil has a D added to the brake PN f or example CD-2D through CD-6D. This means the cover has to be longer.

Figure 1 Adjustable Disc Brake

Since the CD disc brake is a DC operated brake, it does not buzz or hum like an AC brake when energized. There are two types of CD brake coils- SHUNT and SERIES. SHUNT coils are connected to a fixed supply voltage. SERIES brakes are only used on DC powered cranes and Hoists. SERIES coils are connected in series with the DC motor. The majority of the CD brake coils are the SHUNT type. The early SHUNT coils were 18VDC but in about 1972 the standard was changed to 100VDC. This eliminated a step down transformer for the brake. SHUNT Brakes typically get their DC operating power from a separate RECTIFIER in the Control. SERIES brakes are not used much today, since most DC motors have been replaced with AC motors.

The CD disc brake typically has two lining discs in it (item 10 Fig.2), but there are some CD-2 brakes that only have only one disc. Additionally all CD brakes ending in DD have three discs. Example CD-3DD, CD-4DD, CD-5DD and CD6DD. In general, the more discs the higher the brake torque as each disc adds more braking surface area. All CD disc brakes used on the classic Hevi-lift and HL-300 hoist are NONADJUSTABLE brakes. For a given B, C, D, E or F hoist, the torque setting is either a 100% or 150% torque brake. The 100% torque brake was used for hoists having a mechanical load brake. Hoists without mechanical load brakes used 150% torque brakes. CD brakes used on motors are either nonadjustable or adjustable. Hoist brakes are 150% braking torque. Traverse motor brakes are typically between 50% to 100% of rated motor torque. On the traverse motion the lower torque settings are used to minimize hook swing on stopping. Early motors used nonadjustable CD disc brakes. Most of these brakes have an internal splined brake hub (item 8 Fig 2) which is held on to the end of the motor shaft with a snap ring (12). Because of this special splined motor shaft no other vendors brake can be used. The newer adjustable CD disc brakes were designed to fit on any motor build to standard NEMA FC dimensions. The disc hub (item 7 Fig. 1) for this brake is held on to the motor shaft with set screws. The installation procedure for the adjustable disc brake is found on drawing R30711. The attached adjustable disc brake tables show parts for NEMA FC sizes 180 through 400 frames. The attached tables of CD brakes show parts for both nonadjustable and adjustable brakes. There are many possible combinations of parts. The lists attached show some of the more popular combinations. Through the years various methods were used to attach the Brake studs (6) to the collar or hoist gear case (2). Early versions were knurled and pressed into the case, some are threaded and the most secure mounting has the studs pressed through the collar with a snap ring retaining them on the backside. When looking for CD brake parts always refer to the parts books.

Figure 2 Typical non-adjustable brake