Brakes and Friction Linings for Wind Turbine Rotor and Yaw Applications
For over 50 years Carlisle Industrial Brake & Friction (CIBF) has produced a wide range of brake systems for the world’s most recognised OEMs in the mining, agricultural, military, industrial and construction industries. Beginning in the 1950s, Carlisle developed off-highway brakes for the first mining trucks. Over the intervening decades, the company has expanded into new markets in new countries with innovative braking solutions. As the demand for wind energy has increased around the globe in the last few years, Carlisle has focused its attention on meeting the needs of the industry’s biggest turbine manufacturers and operators. With global supply chains strained in 2007 and 2008, wind turbine manufacturers turned to Carlisle for assistance with brakes for both rotor and yaw applications; the calliper disc brakes and friction material used in these applications are the fundamental components in which Carlisle has many years of expertise.
By Colm Gallagher, Marketing Manager, and Phil Rhead, Business Development Manager (Wind Energy), Carlisle Industrial Brake & Friction, UK .
Carlisle entered the off-highway braking market in 1990 with the acquisition of BF Goodrich’s pioneering off-highway division in Bloomington, Indiana, USA. BF Goodrich created the first braking solutions for large mining vehicles in the 1950s, thereby paving the way for today’s trucks, which can in some cases reach weights of over 100 tonnes with payloads of up to 400 tonnes. Soon after BF Goodrich produced its first brake for the mining industry, Goodyear, which was subsequently acquired by Rockwell and then Arvin Meritor, also entered the off-highway braking market. Carlisle went on to acquire Arvin Meritor’s off-highway braking division in 2005. The resulting merger helped Carlisle grow to be the largest off-highway braking company in the world, boasting unrivalled engineering competencies and a full suite of braking products and technologies. Over the years, the iterations of the modern Carlisle expanded into adjacent off-highway markets, such as the construction and agricultural industries.
Earlier in this decade, as wind-powered generation grew in importance around the world, Carlisle discovered that the yaw and rotor braking systems in wind turbines were very similar to its standard brake for off-highway applications. Thus, with its proven expertise in large calliper braking, and engineering and manufacturing facilities in North America, Asia and Europe, Carlisle was able to meet the needs of wind customers who sought solutions during that time; and it is well positioned to meet global supply requirements as potential customers expand over the coming years.
The Company Today
Today Carlisle is solving braking problems for many different industries, including wind, construction, industrial, agricultural, military and, of course, mining. Headquartered in Bloomington, Indiana, USA, Carlisle Industrial Brake & Friction employs 300 people worldwide with manufacturing in the USA, UK, China, Japan and the Netherlands. It also has distribution networks established on all six inhabited continents. Carlisle Industrial Brake & Friction is part of the Carlisle Companies, an industrial conglomerate that had a turnover of US$ 2.97 billion in 2008.
Over 20 braking and friction engineers work with customers to develop brake solutions from the initial customer concept, through the validation and test phases all the way to serial production. Carlisle products are designed and supplied to safety critical applications in some of the world’s harshest environments. Therefore, product reliability and performance are foremost in the minds of Carlisle engineers and customers during the design and test phases. As a result, Carlisle has established a dedicated test and validation facility to enable the company to simulate the wide range of conditions that braking products experience during operation.
Carlisle’s facilities include three inertia dynamometers to enable replication of customer drive train torques in both high speed and low speed shafts, multiple torque flex stands for calliper fatigue testing, a yaw brake simulation stand, side load test stands for lining evaluation, corrosion and climatic testing chambers, drag dynamometers, a complete materials lab and pilot production sample lab, to name a few.
Although engineering commands significant attention, adherence to manufacturing excellence is paramount to Carlisle’s past and continued success. In order to ensure this excellence, all of Carlisle’s facilities are certified to IS0 9001:2000 and the company has embraced lean manufacturing through its Carlisle Operating System. In addition, Carlisle has implemented stringent incoming, machining, assembly and equipment process controls.
For over 50 years Carlisle has aligned itself with the world’s leading OEMs in off-highway vehicle construction. That focus on serving the best and most innovative OEMs in the world remains a core pillar of Carlisle today. To achieve that end, the company recently added Phil Rhead as Business Development Manager (Wind Products). Phil joined Carlisle after 6 years with Insensys Limited, the leading supplier of blade load measurement technology for the wind energy industry.
The Products
Carlisle engineers were literally at the forefront of dry calliper braking invention, the same technology so ubiquitous in wind turbines today. Its current portfolio of products includes multiple options for wind energy application, including hydraulic active brakes, spring applied (failsafe brakes), and split calliper, single calliper and sliding calliper models, which enables Carlisle to provide specific solutions for both the rotor (high and low speed shafts) and nacelle yaw control applications. In addition, Carlisle also boasts braking products such as disc and drum brakes for park, emergency, full circle and service applications. Moreover its portfolio includes hydraulic valves, actuators, master cylinders, boosters and friction materials.
Carlisle is focused on the future and is constantly developing better solutions for its customers. Recent and future innovations for wind turbine braking systems include a one-piece calliper, lighter-weight callipers, new friction compounds for linings, and a new coating for pistons that utilises QPQ technology compared to the former and environmentally harmful chrome over nickel coated.
The ability to design and manufacture friction linings in house is a key differentiator for Carlisle. This advantage enables Carlisle to work in partnership with its customers to create the complete brake systems matched to the application requirements. With over 100 friction compounds to choose from, engineers have multiple options while designing a new wind turbine brake, or simply optimising an existing model to the performance requirements of an individual turbine manufacturer’s designs. Significantly, this experience with friction has already enabled Carlisle to solve several lining problems for turbine manufacturers, ranging from noise to concerns about accelerated wear.
Carlisle Industrial Brake and Friction and the Wind Industry
Today Carlisle is partnering and supplying rotor and yaw brakes to leading wind OEMs around the globe. Bringing decades of braking experience, Carlisle has been able to offer innovative and cost-reducing features on next-generation brakes, friction and hydraulic systems combined with the ability to supply and engineer brakes from its facilities on three continents. As Carlisle expands further into the wind power industry, it will continue to push the envelope on brake system solutions designed specifically for the needs of the industry.{/access}
For over 50 years Carlisle Industrial Brake & Friction (CIBF) has produced a wide range of brake systems for the world’s most recognised OEMs in the mining, agricultural, military, industrial and construction industries. Beginning in the 1950s, Carlisle developed off-highway brakes for the first mining trucks. Over the intervening decades, the company has expanded into new markets in new countries with innovative braking solutions. As the demand for wind energy has increased around the globe in the last few years, Carlisle has focused its attention on meeting the needs of the industry’s biggest turbine manufacturers and operators. With global supply chains strained in 2007 and 2008, wind turbine manufacturers turned to Carlisle for assistance with brakes for both rotor and yaw applications; the calliper disc brakes and friction material used in these applications are the fundamental components in which Carlisle has many years of expertise.By Colm Gallagher, Marketing Manager, and Phil Rhead, Business Development Manager (Wind Energy), Carlisle Industrial Brake & Friction, UK .
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Company RootsCarlisle entered the off-highway braking market in 1990 with the acquisition of BF Goodrich’s pioneering off-highway division in Bloomington, Indiana, USA. BF Goodrich created the first braking solutions for large mining vehicles in the 1950s, thereby paving the way for today’s trucks, which can in some cases reach weights of over 100 tonnes with payloads of up to 400 tonnes. Soon after BF Goodrich produced its first brake for the mining industry, Goodyear, which was subsequently acquired by Rockwell and then Arvin Meritor, also entered the off-highway braking market. Carlisle went on to acquire Arvin Meritor’s off-highway braking division in 2005. The resulting merger helped Carlisle grow to be the largest off-highway braking company in the world, boasting unrivalled engineering competencies and a full suite of braking products and technologies. Over the years, the iterations of the modern Carlisle expanded into adjacent off-highway markets, such as the construction and agricultural industries.
Earlier in this decade, as wind-powered generation grew in importance around the world, Carlisle discovered that the yaw and rotor braking systems in wind turbines were very similar to its standard brake for off-highway applications. Thus, with its proven expertise in large calliper braking, and engineering and manufacturing facilities in North America, Asia and Europe, Carlisle was able to meet the needs of wind customers who sought solutions during that time; and it is well positioned to meet global supply requirements as potential customers expand over the coming years.
The Company Today
Today Carlisle is solving braking problems for many different industries, including wind, construction, industrial, agricultural, military and, of course, mining. Headquartered in Bloomington, Indiana, USA, Carlisle Industrial Brake & Friction employs 300 people worldwide with manufacturing in the USA, UK, China, Japan and the Netherlands. It also has distribution networks established on all six inhabited continents. Carlisle Industrial Brake & Friction is part of the Carlisle Companies, an industrial conglomerate that had a turnover of US$ 2.97 billion in 2008.
Over 20 braking and friction engineers work with customers to develop brake solutions from the initial customer concept, through the validation and test phases all the way to serial production. Carlisle products are designed and supplied to safety critical applications in some of the world’s harshest environments. Therefore, product reliability and performance are foremost in the minds of Carlisle engineers and customers during the design and test phases. As a result, Carlisle has established a dedicated test and validation facility to enable the company to simulate the wide range of conditions that braking products experience during operation.
Carlisle’s facilities include three inertia dynamometers to enable replication of customer drive train torques in both high speed and low speed shafts, multiple torque flex stands for calliper fatigue testing, a yaw brake simulation stand, side load test stands for lining evaluation, corrosion and climatic testing chambers, drag dynamometers, a complete materials lab and pilot production sample lab, to name a few.
Although engineering commands significant attention, adherence to manufacturing excellence is paramount to Carlisle’s past and continued success. In order to ensure this excellence, all of Carlisle’s facilities are certified to IS0 9001:2000 and the company has embraced lean manufacturing through its Carlisle Operating System. In addition, Carlisle has implemented stringent incoming, machining, assembly and equipment process controls.
For over 50 years Carlisle has aligned itself with the world’s leading OEMs in off-highway vehicle construction. That focus on serving the best and most innovative OEMs in the world remains a core pillar of Carlisle today. To achieve that end, the company recently added Phil Rhead as Business Development Manager (Wind Products). Phil joined Carlisle after 6 years with Insensys Limited, the leading supplier of blade load measurement technology for the wind energy industry.
The Products
Carlisle engineers were literally at the forefront of dry calliper braking invention, the same technology so ubiquitous in wind turbines today. Its current portfolio of products includes multiple options for wind energy application, including hydraulic active brakes, spring applied (failsafe brakes), and split calliper, single calliper and sliding calliper models, which enables Carlisle to provide specific solutions for both the rotor (high and low speed shafts) and nacelle yaw control applications. In addition, Carlisle also boasts braking products such as disc and drum brakes for park, emergency, full circle and service applications. Moreover its portfolio includes hydraulic valves, actuators, master cylinders, boosters and friction materials.
Carlisle is focused on the future and is constantly developing better solutions for its customers. Recent and future innovations for wind turbine braking systems include a one-piece calliper, lighter-weight callipers, new friction compounds for linings, and a new coating for pistons that utilises QPQ technology compared to the former and environmentally harmful chrome over nickel coated.
The ability to design and manufacture friction linings in house is a key differentiator for Carlisle. This advantage enables Carlisle to work in partnership with its customers to create the complete brake systems matched to the application requirements. With over 100 friction compounds to choose from, engineers have multiple options while designing a new wind turbine brake, or simply optimising an existing model to the performance requirements of an individual turbine manufacturer’s designs. Significantly, this experience with friction has already enabled Carlisle to solve several lining problems for turbine manufacturers, ranging from noise to concerns about accelerated wear.
Carlisle Industrial Brake and Friction and the Wind Industry
Today Carlisle is partnering and supplying rotor and yaw brakes to leading wind OEMs around the globe. Bringing decades of braking experience, Carlisle has been able to offer innovative and cost-reducing features on next-generation brakes, friction and hydraulic systems combined with the ability to supply and engineer brakes from its facilities on three continents. As Carlisle expands further into the wind power industry, it will continue to push the envelope on brake system solutions designed specifically for the needs of the industry.{/access}
