Hydraulic brakes and clutches for modern mining

Hydraulic brakes have been the standard for large-scale mining equipment as they deliver the force and reliability needed for high-inertia machines

However, modern mines are beginning to require more than brute stopping power; they need systems capable of reacting smoothly, adapting to changing load conditions, and safeguarding components during emergencies. Intelligent hydraulic braking is no longer an optional upgrade; it is now a critical element of safety, efficiency, and uptime in the mining industry.

Controlled braking

A key advancement in this field is the development of programmable soft braking control. Unlike conventional braking methods, soft braking allows torque to be applied gradually and released just as smoothly. This reduces mechanical wear and prevents dangerous oscillations or uncontrolled overruns.

Svendborg Brakes, a Regal Rexnord brand, has developed this technology with is SOBO iQ intelligent braking controller. The SOBO iQ system monitors variables such as line pull and conveyor speed and adjusts brake torque in real time to maintain control under all conditions.

When the SOBO iQ receives a brake command, it energises/de-energises the valves to modulate the pressure to follow the predefined braking ramps. A unique pressure feedback feature ensures fast, accurate control of the braking system's torque output and helps maintain a predictable stopping sequence.

At a copper mine in Chile, this technology was applied to a take-up winch on a 2.65km conveyor transporting over 11,000 metric tonnes of ore per hour. By controlling belt tension release, the SOBO iQ prevented damage to the belt and mechanical components.

New brake pads

Mining braking systems need to address health and safety challenges that extend beyond machinery, as well as control. Dust is a persistent hazard in mining environments and contributes to respiratory risks and harmful working atmospheres. Brake pads can be a significant source of airborne dust.

In recognition of this issue, Svendborg Brakes has designed a proprietary range of environmentally friendly brake pad materials reduce dust emissions without compromising performance. Designed, manufactured, and tested in-house, these pads can be tailored to each application, combining operational reliability with enhanced workplace conditions.

Brake pads need to be optimised for shape, size, surface area, and contact points to ensure ideal braking force, effective heat dissipation, and uniform wear. Regulations on the registration, evaluation, authorisation, and restriction of chemicals (REACH) must also be followed to restrict the use of harmful substances.

Svendborg Brakes has eliminated the use of asbestos, nickel, and antimony, and has kept levels of mercury, chromium 6+, lead, and cadmium under 0.1%.

Integrating connectivity

The move to smart braking is about machine control, safety, and data. Mining is entering the era of predictive maintenance, where equipment health is monitored in real time, and potential failures are found before they lead to downtime.

Integrating industrial Internet of Things (IIoT) solutions with braking systems has helped Regal Rexnord brands to develop platforms that enable performance data to be accessed from anywhere, allowing mine operators to plan maintenance when needed.

This approach has delivered results at a European lignite mine, where a fleet of bucket wheel excavators was upgraded with Svendborg’s IIoT-enabled systems. Operators reported smoother performance, extended component lifespans, and halved regular inspection intervals, resulting in cost savings and higher uptime.

Reliability and durability

Complementary technologies across Regal Rexnord’s portfolio fortify these advantages. Steiber’s RDBK high-speed backstop protects conveyors from reverse rotation, while Industrial Clutch’s LKB multi-plate brakes bring compact, high-energy stopping capability to crushers and mills. For large rotating equipment, Svendborg Brakes and Twiflex offer hydraulic calliper brakes that combine fail-safe spring application with hydraulic release for dependable emergency and parking functions in demanding conditions.

Durability is also a defining requirement for mining machinery, often operating in corrosive environments where dust, humidity, and salt take their toll. To overcome this, Regal Rexnord braking systems are protected with advanced coatings, such as C5 medium-grade paint systems applied to non-functional surfaces. This can extend the service life and reduce the maintenance burden, reinforcing the equipment's reliability.

Regal Rexnord is helping mining companies to transition toward a future where safety, sustainability, and efficiency are essential. Hydraulic brakes and clutches are for more than just stopping machines; they enable smarter, safer operations that can withstand the pressure of modern mining. Whether on overland conveyors, bucket wheel excavators, or crushers and mills used in mineral extraction, Regal Rexnord brands provide solutions to keep mines running.