Faster design braking.

Power Jacks Limited is an engineering specialist known for designing and manufacturing high-performance linear actuation systems. Serving demanding industries such as aerospace, renewable energy, civil engineering and industrial automation. Power Jacks has built a reputation for precision, reliability and bespoke engineering solutions. Their systems are often used in safety-critical and heavy-duty applications where accuracy and dependable performance are essential.

As Power Jacks continues to develop advanced mechanical systems, the need for robust, precisely specified braking solutions has become increasingly important across multiple projects.

Enhancing design efficiency.
To support these requirements, Power Jacks has been working closely with Mayr Transmissions, a global leader in safety brakes, torque limiters, and power transmission solutions. Central to this collaboration has been Mayr’s online product configurator, a powerful digital tool that allows engineers to quickly select, customise and download detailed 3D models of braking systems tailored to specific application needs.

The configurator enables design teams to:

• Rapidly configure brake solutions based on performance requirements
• Instantly access accurate 3D CAD models for integration into assemblies
• Reduce design time and eliminate guesswork during early development stages
• Move more efficiently from concept to prototype

For Power Jacks, this has translated into faster design cycles, improved accuracy in system layouts and smoother progression from concept through to prototype orders.

The value of both the technology and the technical support behind it has been clear throughout the collaboration. As one Power Jacks representative shared: “I’m really pleased with Mayr level of service and ease of 3D models downloading. Currently we are working on a few projects where brakes are required and a couple projects have now turned to the orders of prototype systems. I would like to say thank you to Mayr team for ongoing excellent support. Their technical support and design flexibility makes our design process much easier and makes Mayr our primary choice when it comes to brakes.”

From digital design to real-world results.
By combining Mayr’s advanced configurator with responsive technical expertise, Power Jacks has been able to confidently specify braking systems that align perfectly with their demanding engineering standards. The ability to download ready-to-use 3D models has not only accelerated internal workflows but also reduced risk during the design and prototyping stages.

What began as digital configuration has already progressed into prototype system orders. A clear demonstration of how smart engineering tools, backed by expert support, can drive real-world project success.

Supporting engineering teams.
The success of the collaboration between Power Jacks and Mayr Transmissions reflects a wider commitment to helping engineers work smarter, faster, and with greater confidence. Through intuitive digital tools such as the online configurator, combined with expert technical support, Mayr enables customers to rapidly specify reliable braking solutions tailored to their exact application needs.

Whether supporting early-stage design, accelerating prototyping or optimising final system performance, Mayr works closely with engineering teams to remove complexity from the selection process. The result is shorter development cycles, reduced risk and solutions that perform in the most demanding environments. For companies facing tight timelines, evolving design requirements and the need for dependable safety components, this technology and expertise can turn ideas into proven engineering outcomes.

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@mepaxIntPR @PowerJacksLtd #mayr® #TandM #Manufacturing #Britain

Precision meets safety.

Lightweight couplings, safety brakes and intelligent monitoring for test stand technology

Test stand technology for automotive drives is undergoing fundamental change. The rise of e-mobility is profoundly changing test routines, speed profiles and requirement landscapes. What remains unchanged: Precision, reliability and process safety are indispensable in measurement technology. mayr® power transmission presents its coordinated portfolio for test stand technology – from the lightweight coupling ROBA® DS Type 9120, through proven safety brakes, to intelligent monitoring solutions.

Shaft misalignment compensation couplings are essential components in test stands. Based on the proven ROBA® DS steel disk pack coupling, mayr® power transmission offers a weight-optimized aluminum variant with the ROBA® DS Type 9120. Compared to the steel version, the outside diameter is reduced by up to 10 mm; mass and mass moment of inertia are 40% to 60% of the steel version, depending on the design and size – with unchanged performance density.

The development has incorporated extensive knowledge gained over many years in test stand technology, where high speed ranges have previously been the norm. The ROBA® DS 9120 is therefore also suitable for speeds of up to 32,000 rpm. Thanks to its lightweight construction, low mass inertia and high performance density, the aluminum coupling offers measurable advantages. The balance between rigidity and elasticity ensures the lowest possible restoring forces on the system. A balance quality of G 2.5 at 5,000 rpm ensures the necessary smooth running and low-vibration operation – a decisive basis for high measurement accuracy across all speed ranges.

As standard, the coupling features manufacturing tolerance IT6. A nickel-plated surface, disk packs made of stainless steel and galvanized connecting screws provide comprehensive corrosion protection. Backlash-free shaft connections via shrink disk hubs or external shrink disk hubs ensure reproducible measurement results. The coupling is compatible with all common torque transducers as standard.

Thanks to the modular construction system, the ROBA® DS 9120 can be flexibly configured from a variety of connection variants and modules, from high-performance test stands in research and development to end-of-line testing.

Safety brakes for test stands: Reliable protection for people and equipment.
In addition to coupling technology, mayr® power transmission is also presenting its extensive portfolio of safety brakes for test stand applications at Automotive Testing Expo. Test stands for automotive drives frequently include vertical axes and linear movements that must be reliably secured, whether during ongoing test operation, during maintenance work or in the event of a fault.

The ROBA® guidestop® profiled rail brake, for example, acts directly on the moving masses of the vertical axes and clamps them into position in a backlash-free manner and with high rigidity. It is available in hydraulic, pneumatic and electromagnetic designs and is compatible with all common linear guides. The ROBA® linearstop piston rod brake secures linear movements on round rods. It is a safety brake based on the fail-safe principle, meaning it is closed in the de-energized state, and is designed for dynamic emergency braking. The series comprises six sizes with forces ranging from 70 to 17,000 N.

The ROBA-stop M® series also provides a robust motor brake for compact protection directly at the drive motor. As a holding brake, it clamps reliably and holds the system in position; as a dynamic brake, it brings the load to a standstill in the shortest possible time.

The brake speaks: Smart modules for intelligent monitoring.
Constant, meaningful data streams are now indispensable in modern test environments. The ROBA® brake-checker® module monitors safety brakes sensorless and simultaneously supplies them with power. By means of an advanced analysis of current and voltage, it detects the switching condition of the brake and issues a warning before the brake can no longer release under the current operating conditions. This facilitates planned maintenance and enables the user to specifically investigate critical boundary conditions such as supply voltage that is too low, incorrectly dimensioned supply lines, elevated coil temperature and an enlarged air gap.

In combination with the ROBA® gateway module, the solution becomes network-compatible: The brake data can be continuously read out via an Ethernet connection and displayed visually on a dashboard. Anomalies in the test process can be detected at an early stage, maintenance becomes plannable, and downtime can be specifically minimized. Integration into remote maintenance systems is also possible.  

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@mepaxIntPR #mayr® #TandM #Manufacturing

Innovative brake system increases safety of vertical axes

Due to their adapted flange dimensions,

ROBA®-topstop brakes can be integrated

problem-free in pre-existing

constructions between the

servomotor and the counter-flange.

If there is a danger of falling loads on vertical axes in areas where personnel have to work, additional measures must be taken to minimise the risk of accidents. The Mauerstetten brake specialist mayr® power transmission has developed brake systems which are capable of providing safety in any critical situation occurring during vertical axes operation.

Vertically-moved masses, in particular when they are heavy parts such as motors or gear boxes, become a serious safety hazard if, on power failure, their movement is inadvertently accelerated or if they drop uncontrollably.

mayr® power transmission offers the ROBA®-topstop, a modular construction brake Type series with individual brakes and redundant dual-circuit brake modules for the prevention of any critical danger situations which can occur during vertical axes operation and which are defined in the DIN EN 954-1, Categories 1-3.

The aspect of safety was not the only target criterion during development of the ROBA®-topstop. The constructional conditions for drive elements in vertical axes were also considered carefully. Due to their adapted flange dimensions, ROBA®-topstop brakes can be integrated problem-free into pre-existing constructions between the servomotor and the counter flange. The modular assembly is flexible enough to allow many different designs, for example with a shaft; with a hollow shaft; with a flexible coupling; with an additional safety clutch for torque limiting or with two individual brakes.

Using a ROBA®-topstop brake system with a hollow shaft and an integrated, insertable shaft coupling means that the separate compensation coupling and the coupling housing usually necessary are no longer needed. A drive line with this brake system is only minimally longer than the usual axis with servomotor and shaft coupling for connection to a spindle or to a gearbox shaft. ROBA®-topstop designs with shafts are principally conceived for installation between the servomotor and the hollow shaft gearbox.

As an independent module, the ROBA®-topstop is capable of holding the vertical axis in any required position. Additional measures for axis support - for example during transport and machine maintenance – are unnecessary.

This advantage means considerable savings in terms of cost and time; for example when replacing the drive motor, and reduces the downtimes during repairs. In addition to this, the device can guarantee the „safe brake“ function, if the units are equipped with the correct functional and wear monitoring systems.