by what are torque limiter?
overload clutchs are mechanical devices that are used to protect mechanical systems from overloading or over-torquing. They are designed to slip or disconnect the drive train if the torque exceeds a predefined limit, preventing damage to the machinery.
Types of torque limiter
there are different types of overload clutchs available depending on the application:
friction disc limiters friction disc limiters are one of the most commonly used types. They contain a set of friction discs that are designed to slip and allow relative movement between the input and output shafts when a preset torque limit is reached. This stops the transfer of torque and prevents component failure.
Clutch limiters clutch limiters use a similar slip mechanism as friction discs but instead use clutch plates that engage and slip to control torque transfer. They offer features like adjustable torque settings and quick disengagement times.
Overrunning clutches overrunning clutches only allow Torque Limiter transfer in one direction. If back torque is applied from the output, the clutch disengages automatically to protect downstream components.
Hydrokinetic limiters these limiters use hydraulic fluid coupling and viscous shearing of the fluid to control torque transfer. The fluid coupling slips and disengages smoothly when torque limits are exceeded.
Electronic limiters: advanced electronic limiters have sensors and controllers that can precisely measure torque and disconnect power electronically using techniques like braking if limits are reached. This provides highly responsive limiting.
Where are overload clutchs used?
overload clutchs find application in various industries where machinery safety is critical:
material handling equipment conveyor systems, cranes, winches and other material handling machinery use overload clutchs on motors and drivetrains to prevent overloading.
Automated processes robots, assembly lines and cnc machines integrate overload clutchs to protect gearboxes and motors from sudden impact loads or positional feedback errors.
Printing presse large commercial and industrial printing presses require careful torque control to smoothly handle heavy rolls and avoid jams or tears. Limiters protect drive mechanisms.
Textile machinery looms, knitting machines and other textile equipment are prone to yarn breaks and knots which can overload drives if not protected by torque limiting couplings.
Packaging lines from filling machines to case packers to palletizers, packaging overload clutchs avoid damage from missed picks, jammed products or unequal load distribution across lines.
Benefits of using overload clutchs reliability: overload clutchs prevent costly damage to gearboxes, shafts and motors from over-torquing incidents. They improve the service life of machinery.
Safety: by preventing mechanical failures, limiters enhance safety for operators and nearby personnel as loads are controlled smoothly under faults.
Uptime: downtime for repairs is reduced since components are shielded from failures. Production processes have higher availability with limiters in place.
Control: precise torque limiting prevents instability in closed-loop processes due to load variations or feedback errors, maintaining output quality.
Efficiency: smooth limiting extends component life cycles, reducing long-term maintenance and replacement costs for drives, couplings and gearboxes.
How do overload clutchs work?
overload clutchs function using principles of slippage and controlled disengagement between an input and output shaft. When torque rises above the pre-set limit during operation, this is what typically happens:
– sensing elements: torque is accurately measured by strain gauges, current/voltage sensors for electronic types or mechanical designs.
– slip mechanism: devices like friction discs, clutches or fluid couplings start slipping proportionally as torque exceeds limits, restricting further transfer.
– disengagement: at a predetermined overload threshold, the slip elements fully activate to break the drive connection, de-clutching the input from output.
– re-engagement: once the drive load reduces, the limiter automatically re-couples the shafts to resume normal operation without stalling machinery.
Precise components and calibration allow limiters to smoothly transition between engaged, slipping and disengaged states to avoid drive train shocks and alarms. They reset for continuous duty cycles.
Proper sizing and maintenance
for optimal performance, overload clutchs must be correctly specified to match the torque and speed capabilities of the driven system components. Manufacturers help with sizing tools. Regular inspection and lubrication as per oem guidelines also maintain limiter accuracy over years of operation. Proactively replacing wear parts prevents untimely failures.
overload clutchs are an essential safety device across industries that require motion control and power transmission in machinery. By preventing over-torquing related accidents and extending mechanical life, they optimize uptime and total cost of ownership for all types of motorized applications and automated production processes. Correct application and maintenance ensures long term limiting reliability
*Note:
1. Source: Coherent Market Insights, Public Source, Desk Research
2. We have leveraged AI tools to mine information and compile it
Money Singh
Money Singh is a seasoned content writer with over four years of experience in the market research sector. Her expertise spans various industries, including food and beverages, biotechnology, chemical and materials, defense and aerospace, consumer goods, etc. LinkedIn
