Quality products for demanding

applications

BRAKE SYSTEMS
SOLUTIONS SINCE 1946
APPLICATIONS BRAKE SYSTEMS
In many mechanical drives, vehicles and machines, brakes are a crucial safety element.
Their reliability and longevity are decisive for the security and quality of the complete
system.

Brake systems ensure the controlled

deceleration and secure standstill
of a complete system respectively
of its moving components. As secu-
rity-relevant elements, they have to
meet very high requirements. These
depend on the particular range of ap-
plications. Brake systems thus have
to be designed specifically for the in-
tended service surroundings.
Hydraulically actuated brakes are
particularly suited when high yet sen-
sitively controlled braking forces have
to be exerted within tight spatial lim-
its. For applications with especially
high safety requirements - e.g. for ve-
hicles or cableways – brake systems
with additional equipment such as
redundant valves and switching posi-
tion monitoring are deployed.
For wind generators, hydraulically ac-
tuated brake systems are used for the Typical application areas for hydrau-
azimuth orientation and fixing. Espe- lic brake systems are, among others:
cially in the case of high wind speeds,
the system must feature the ability • Rail vehicles
to be turned out of the wind and be • Mobile work machines
brought to a standstill in a controlled • Winches
way in order to avoid damage to the
gearbox and the generator. • Wind generators

Also in the case of stationary ma- • Material lifts

chines such as in the manufacturing • Textile machines
process of textiles, brake systems
• Cableways
play a decisive role. In these appli-
cations, fast-turning drums have to • Cranes
be decelerated within milliseconds
without the textile thread to become
entangled or even to get ripped apart.

PAGE 1 | BRAKE 
SYSTEMS | BRANCHES | APPLICATIONS
BRANCHES REQUIREMENTS
Brake systems have to ensure a fast, reliable and controlled braking action. In order to
fulfil these requirements, the designer has to take into account a number of guidelines.
A decisive prerequisite for a sensitive control is that the hydraulic action on the brake
system itself is exerted as linearly as possible and with a small hysteresis.

Decisive features of brake systems: Modern hydraulic brake systems are order to ensure good controllability of
actuated using proportional valves. the system, these valves have small
CONTROL These are equipped with solenoids hysteresis, and their linearity can be
In order to achieve a controllable exactly controlling spool positions precisely adjusted. Their frequent use
braking action, a steadily changeable and thus hydraulic pressures, result- in accumulator unloading systems
braking force is a crucial factor. ing in a linear increase of the braking makes small leakage and pilot oil
force. Such systems are often fitted volumes of hydraulic valves manda-
SPEED with proportional pressure valves. tory. In spring-loaded brake systems,
The response time of the hydraulic Increasingly, closed control circuits a pressure relief down to nearly zero
valve used as an actuator has to be are used with proportional throttles bar is of prime importance to prevent
short for the brake effect to set in and the corresponding electronics. In the brake from dragging.
fast.

SAFETY
In order to secure an all-time reliable
functioning of the system, its compo-
nents have to meet stringent require-
ments.

EFFICIENCY
The amount of energy released has
to be minimized in order to avoid high
temperatures in the hydraulic system.

LONGEVITY
Hydraulic brake systems are made of
modern high performance materials
for high durability and low mainte-
nance.

COMPACTNESS
Hydraulic brakes distinguish them-
selves by their high power density.
This makes compact dimensions and
space saving solutions possible.

BRAKE 
SYSTEMS | BRANCHES | REQUIREMENTS | PAGE 2
HYDRAULIC BRAKE SYSTEMS
Brake systems are either active or passive. Operational brakes are often designed as
active systems. Safety brakes are always passive systems whose braking action is acti-
vated by spring forces. For both types, there are a number of different hydraulic control
method. Controlled hydraulic solutions are realised using pressure relief or pressure
reducing valves. In the case of closed hydraulic pressure controls either pressure relief
valves or throttle valves are used. For both cases, electronics optimised for the valves is
a crucial factor.

WITH PRESSURE RELIEF WITH PRESSURE REDUCING VALVES WITH ELECTRONIC PRESSURE
By means of a proportional pressure By means of a proportional pressure CONTROL
relief valve, the pressure within the reducing valve, the cylinder pressure As an actuator, a proportional pres-
cylinder is adjusted to the required is adjusted to the required braking sure relief valve is used. By means of
braking force. Additionally, the pres- force. The output pressure of the a pressure sensor, the brake pressure
sure in the brake system is monitored control valves is decoupled from the is fed back into the electronics which
using a pressure sensor. Usually, input pressure. Therefore higher input compare the feedback value and the
these are direct operated controlled pressures do not play any role with re- command value. As an alternative,
valves with compact dimensions and spect to the brake pressure. Such sys- the control can be realised using two
short response times. In the case tems are often selected for the accu- proportional throttles, one positioned
of active systems, reverse hydraulic mulator unloading operations in order in the pressure line and the other one
valves have usually to be selected. to achieve as long standstill intervals in the tank line. Proportional throttles
Inverse valves are spring loaded and of the motor pump unit as possible. distinguish themselves by their high
adjusted to the maximum pressure In the case of proportional control speeds as well as by an enhanced
value in a deenergised condition. This valves, only low leakages must occur. flexibility with respect to the opti-
maximum value can be adjusted by For active systems, a reverse valve mized adjustment of the controller.
means of an adjustment screw. function usually are required.

PAGE 3 | BRAKE SYSTEMS | PRODUCTS | HYDRAULIC BRAKING SYSTEMS

VALVE TECHNOLOGY
Depending on the brake system, different sizes of proportional valves are required. For
tight space conditions, small, compact, direct operated valves have been developed. For
large systems, pilot operated valves are used. In order to meet the different requirements,
more than 20 variants of valves are available for the selection of the most suitable valve.
The available bandwidth ranges from valves with low maximum output pressure to mod-
els with a maximum output pressure of 450 bar. Likewise, the flows can vary between
some 100 ml/min up to 40 l/min.

PRESSURE REDUCING VALVES PRESSURE RELIEF VALVES THROTTLE VALVES

MDPPM16 BDPPM18 DNPPM18 / DOPPM18
The small, compact solution The small, compact solution The small, compact solution
P max.: 40 bar P max.: 315 bar P max.: 250 bar
Q max.: 6 l/min Q max.: 8 l/min Q max.: 12 l/min
Size: M16 cavity Size: M18 cavity Size: M18 cavity
MGPPM16 BDPPM22 DNPPM22 / DOPPM22
The compact solution for higher The solution for large brake cylinders For fast movements of large brake
brake pressures P max.: up to 350 bar cylinders
P max.: 100 bar Q max.: 25 l/min P max.: 350 bar
Q max.: 6 l/min Size: M22 cavity Q max.: 25 l/min
Size: M16 cavity Size: M22 cavity
BSPPM22
MPPPU10 For high brake pressures, seat tight
The solution for larger brake cylinders execution
P max.: up to 350 bar P max.: up to 450 bar
Q max.: 20 l/Min Q max.: 2 l/min
Size: M22 cavity
Size: UNF 7/8-14 cavity
MQPPM22
For fast movements of large brake
cylinders
P max.: up to 350 bar
Q max.: 40 l/min
Size: M22 cavity

BDPPM22_W D_PPM22_ME

Control system Pressure relief Pressure reducing Electronic control

Pressure accuracy   

Space conditions   

Costs   

Tightness   

Response times and   

MDPPM16
hysteresis

BRAKE 
SYSTEMS | PRODUCTS | VALVE 
TECHNOLOGY | PAGE 4
ELECTRONIC DEVICES
The control of proportional valves is made using electronic control devices. These
control the solenoid current in the valve. Through pulse width modulation with a su-
perimposed dither signal, a very sensitive control of the valve with a small hysteresis is
ensured. Our control devices are equipped with microprocessors. This enhances their
functionality as well as their flexibility for use in different control systems. The various
electronic devices feature amplifying and control functionalities with an optional fieldbus
interface for easy connection to superordinate controls.

Decisive prerequisites for an opti- all types a fieldbus interface can be MOBILE ELECTRONICS MD2
mum electronic control of the pres- used (Profibus DP, CANopen, J1939 The digital amplifier and controller
sure are high-end signal processing or HART). Apart from the 24 VDC module MD2 for maximum 8 sole-
and control of the solenoids. Three execution, also a 12 VDC version is noids was especially developed for
different electronic control variants available. the control of hydraulic valves under
are available. A user-friendly para- extreme ambient conditions. This de-
metrising and diagnosis software fa- ON-BOARD ELECTRONICS DSV vice is suitable for use in conditions
cilitates adjusting the parameters of This digital controller module for the where moisture, vibrations, higher
the valve and the PID controller. control of maximum 2 solenoids is temperatures or fluctuating voltage
mounted directly onto the solenoid. supplies might occur. Thanks to its
SNAP-ON MODULE SD7
The “Digital Smart Valve” features large voltage supply tolerance range
Digital electronic controller for the digital electronics in an extremely (8…32VDC), the MD2 can be flexibly
control of maximum 2 solenoids for small space, making it the most com- integrated into various systems.
installation in control cabinets.
pact design currently available on the The module features digital inputs
The inputs and outputs can be freely market. These solutions have been and outputs as well as high-powered
assigned. This allows an optimised designed especially for demanding PWM outputs for the control of so-
utilisation of existing hardware and applications in block constructions lenoid valves. Its digital inputs can
enables a flexible adaptation to the solutions for stationary as well as easily process FM or PWM signals.
application even without program- mobile systems. The plug-and-play Instead of an analogous interface,
ming knowledge. valves distinguish themselves by the MD2 is also available with a CAN
Parameter adjustments are stored in simple commissioning. The easy re- fieldbus interface.
a non-volatile memory and are thus placement facilitates fast repairs and The MD2 is the ideal solution when
immediately available after switching thus short downtimes. Control can be several brake systems have to be
on the control system. made either by analogue signals or controlled by a single electronic cir-
Instead of an analogue interface, for via a CAN fieldbus. cuit board.

SD7 DSV MD2

PAGE 5 | BRAKE 
SYSTEMS | PRODUCTS | ELECTRONIC 
DEVICES
INDIVIDUAL SOLUTIONS
Wandfluh is offering its customers a large number of individual solutions based on exist-
ing components. Together with the customer, the specific requirements are defined prior
to the design of a product exactly matching these prerequisites. Thanks to the profound
experience of our engineers and the flexibility of our manufacturing organisation, we
achieve optimised solutions for your specific needs.

EXPLOSION PROTECTION
For equipment used in ambient condi-
tions where explosive liquids or gases
are present, special technologies are
mandatory. This particularly applies
to sectors such as the extraction or
processing of oil and gas, but also in
mines with dangerous dusts or gases
explosion protection valve technolo-
gy is required.
MQBPM22_M248

CORROSION PROTECTION
For valves operating in continuous
contact with salt water, a salty atmos-
phere or extreme weather conditions,
an enhanced corrosion protection is
required to enhance their service life.
For such applications, valves with a
zinc-nickel coating (> 800 h salt spray
test) or in stainless steel execution
(AISI 3162) are available.
MDIPM16

LOWTEMPERATURE APPLICATIONS
For application in cold conditions,
valves in two low temperature execu-
tions are available

Z604 (-40 °C):
Suited sealings, partly adapted fitting
tolerances
-25
-5 5 -4 5 -3 5 -15 -5 5 15 25 35
Z591 (-60 °C): -5 0 -3 0 -2 0 -1 0 10 20 30

Special materials, special sealings, -60 -40 0

increased fitting tolerances Z591 Z604

BRAKE 
SYSTEMS | PRODUCTS | INDIVIDUAL 
SOLUTIONS | PAGE 6
SWITZERLAND AUSTRIA
Wandfluh AG Wandfluh GmbH
Hydraulik + Elektronik Färbergasse 15
Helkenstrasse 13 6850 Dornbirn
3714 Frutigen Tel. +43 55 72 38 62 72 0
Tel. +41 33 672 72 52 office-at@[Link]
Fax +41 33 672 72 87 [Link]
sales-ch@[Link]
[Link] FRANCE CHINA
Wandfluh SARL Wandfluh (Shanghai)
SWITZERLAND Hydraulic System Co. Ltd.
Parc Technologique
Wandfluh Produktions AG Immeuble le Pôle No. 450 Beihengshahe Road
Parallelstrasse 42 333, Cours du Troisième Millénaire Minhang District
3714 Frutigen 69791 Saint-Priest Cedex Shanghai 201 108
Tel. +41 33 672 73 73 Tel. +33 4 72 79 01 19 Tel. +86 21 67 68 12 16
Fax +41 33 672 73 93 Fax +33 4 13 57 02 41 Fax +86 21 67 86 12 18
wapro@[Link] contact@[Link] sales@[Link]
[Link] [Link] [Link]

GERMANY UNITED KINGDOM AMERICA

Wandfluh GmbH Wandfluh UK Ltd. Wandfluh of America, Inc.
Friedrich-Wöhler-Strasse 12 Northfield Road 909 High Street
78576 Emmingen Southam CV47 0FG Mundelein, IL 60060, USA
Tel. +49 74 65 92 74 0 Tel. +44 1 926 81 00 81 Tel. +1 847 566 57 00
Fax +49 74 65 92 74 20 Fax +44 1 926 81 00 66 Fax +1 847 566 57 33
info@[Link] sales@[Link] sales@[Link]
[Link] [Link] [Link]

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