Robotics

Automated Precision

Precision Brake Technology for Robotics – Safe, Energy-Efficient and Highly Dynamic

Why Robotic Applications Require Specialised Brake Systems

Robots move workpieces, tools and assemblies quickly, with high repeatability and often within very confined spaces. They grip, rotate, lift, pivot, position and assemble. In doing so, multiple axes must work together with precision while loads, speeds and directions of movement continuously change.

Modern robotics places demanding requirements on both dynamic performance and safety. A robot must achieve short cycle times while still responding in a controlled manner to collisions or unexpected loads.

Vertical axes and moving tools must be held securely. At the same time, components should be lightweight, compact and energy-efficient in order to preserve the agility of the overall system.

Couplings, brakes, overload protection systems and actuators therefore perform important functions. They transmit torque, secure positions, limit forces, switch tools and enable precise linear and rotary movements. In robotics, every eliminated inaccuracy has the potential to improve motion performance.

When Dynamics and Safety Must Work Together

Mönninghoff components can be used in a wide variety of robotic applications, including

Industrial and articulated robots
Handling and pick-and-place systems
Assembly and feeding robots
Welding, machining and tool-handling robots
Collaborative robotic systems
Mobile robots and automated guided vehicles (AGVs)
Grippers and tool changers
Vertical lifting and positioning axes
Pivoting and rotary modules
Automated testing and measurement systems
Robotics for medical, laboratory and service applications
Special-purpose machinery with robotic motion sequences

The requirements vary according to the type of robot. A pick-and-place system demands high dynamics and short cycle times. A gripper must securely hold workpieces. A tool changer requires defined switching and locking states. A vertical axis must remain secured even during standstill or power loss.

What all applications share is that motion and safety cannot be considered separately. A robot must be fast, but it must always know when to stop.

Requirements for Couplings, Brakes and Overload Protection Systems

Robotic systems place specific demands on drive technology.

High dynamic performance Axes and tools must accelerate, decelerate and change direction rapidly.
High positioning accuracy Movements must be highly repeatable and as backlash-free as possible.
Low moving mass Couplings, brakes and actuators should have minimal impact on the dynamic behaviour of robot axes.
Compact design Components must fit into joints, grippers, tool modules and confined axis spaces.
Reliable holding function Vertical axes, tools and loads must remain securely positioned.
Collision and overload protection Unexpected forces or blockages should be accommodated by controlled limitation or interruption of power transmission.
Fast response times Safety and switching functions must react rapidly to commands and fault conditions.
Minimal backlash Backlash in couplings and connections can directly affect path accuracy and positioning precision.
High repeatability Every cycle should operate under consistent mechanical conditions.
Energy efficiency Mobile and highly dynamic robots benefit from low energy consumption and reduced additional mass.
Long-term durability Many robots operate with extremely high cycle counts and short takt times.
Low-vibration performance Vibrations can affect path accuracy, tool life and product quality.
Safe behaviour during power failure Moving or elevated assemblies must be brought into a defined state.
Easy integration Mechanical, electrical and diagnostic interfaces must suit the robot architecture.
Maintenance-friendly design Wear points and maintenance tasks should be easily accessible and predictable.

The challenge lies in combining lightweight design, dynamic performance, precision and safety. Every component must deliver high performance without unnecessarily limiting the robot's mobility or motion characteristics.

Grip, Engage and Hold Securely

Mönninghoff develops clutch, brake and actuator systems tailored to the torque, speed, force, stroke, load profile, switching frequency and installation space of the specific robotic application.

Electromagnetic Tooth Holding Brakes

Electromagnetic tooth holding brakes can positively lock axes in a precise and defined position. This is particularly relevant for vertical axes, pivoting modules and tool carriers.

Potential applications include

Holding vertical robot axes
Securing grippers and tool carriers
Holding pivoting and positioning axes
Protection during standstill and power failure
Holding functions during tool changes and maintenance
Support of redundant safety concepts
Securing loads in defined positions

The positive-locking principle can provide compact, backlash-free holding functionality. Holding torque, switching time, load direction, positioning accuracy and safety requirements must all be considered together.

Overload Couplings

Overload couplings can limit or disconnect power transmission when a defined torque threshold is exceeded. In robotic systems, they can help protect axes, gearboxes, tools and workpieces from damage caused by blockages or unexpected forces.

Potential applications include

Protection of robot axes
Safeguarding grippers and tools
Tool and process protection during collisions
Torque limitation in auxiliary axes
Relieving drivetrain loads during blockages
Reducing consequential damage to gears and shafts
Supporting rapid return to operation

Design considerations include release torque, response characteristics, reset behaviour, operating speed and overload detection methods. While an overload coupling is not a complete safety function on its own, it can form an important part of an integrated protection concept.

Electromagnetic Tooth Clutches

Electromagnetic tooth clutches provide positive-locking engagement with exceptional repeatability. They can be used whenever tools, drive branches or robotic functions must be connected and disconnected with precision.

Typical applications include

Automated tool changing
Engaging and disengaging tool drives
Synchronising drive stages
Defined locking and positioning functions
Switching gripper and auxiliary functions
Applications requiring minimal backlash

The positive-locking connection creates an unambiguous engagement state and precise torque transmission. This can be particularly beneficial in tool-changing and rotary applications where repeatable positioning is essential.

Torsionally Rigid Shaft Couplings

Torsionally rigid shaft couplings enable precise torque transmission while compensating for minor shaft misalignment. They are ideal where high torsional stiffness, minimal backlash and compact integration are required.

Potential applications include

Articulated and pivoting axes
Rotary grippers and tool modules
Motor-to-gearbox connections
Synchronised robotic movements
Positioning and testing axes
Applications with frequent direction changes

A precision shaft coupling helps translate motor movement directly into controlled robotic motion. This enhances path and positioning accuracy while reducing additional loads within the drivetrain.

Magnetorheological Fluid Brakes

Magnetorheological fluid brakes provide continuously adjustable braking torque and damping characteristics. They can be attractive for robotic applications requiring variable resistance, controlled deceleration or highly sensitive motion control.

Potential applications include

Dynamic pivoting and positioning movements
Motion and vibration damping
Variable load and resistance profiles
Sensitive gripping and handling applications
Robotic testing and simulation systems
Controlled deceleration of moving axes

The adjustable braking effect allows motion characteristics to be adapted to the specific process. Response time, braking torque, thermal behaviour and integration with the robot control system are key design considerations.

Linear Actuators

Linear actuators can provide short, dynamic and highly repeatable strokes. They are suitable where grippers, slides, locking mechanisms or compact positioning axes require direct actuation.

Potential applications include

Gripper actuation
Locking and unlocking movements
Short-stroke movements in tool changers
Linear positioning of assemblies
Fast switching operations
Compact auxiliary axes and actuation functions

Design considerations include force, stroke length, speed, acceleration, holding functionality and available installation length. Direct linear motion can help eliminate unnecessary mechanical elements and reduce moving mass.

Product overview >

Request a Robotics Drive Solution >

Drive Technology for Intelligent Motion

Whether for robot axes, grippers, tool changers, lifting modules, pivoting units or mobile platforms, Mönninghoff develops couplings, brakes, overload protection systems, shaft couplings and actuators for robotic applications that demand dynamic performance, precision, safety and compact integration.

Are you developing a new robot, optimising an existing axis or searching for a compact solution for engagement, holding, damping and overload protection? Speak with our experts about torque, speed, force, stroke, payload, cycle time, safety functions and installation space. Together, we can bring greater precision to your automated motion.

Dynamics Require a Stable Foundation

In robotics, even small mechanical inaccuracies can directly affect path accuracy and process results. Backlash, vibration, overshoot or excessive moving mass can all influence repeatability and cycle times.

The following parameters may be considered during system design

Torque and speed
Linear force and stroke
Acceleration and deceleration
Axis and tool inertia
Payload and centre of gravity
Cycle time and switching frequency
Path and positioning accuracy
Backlash and torsional stiffness
Vibrations, resonances and damping
Thermal loading during continuous operation
Behaviour during collisions and overload conditions
Response during power failure and emergency stop
Available installation space and connection geometry
Weight and power consumption
Requirements for controls, sensors and diagnostics
Tool changing, maintenance and recommissioning procedures

Mönninghoff develops customised solutions tailored to the specific axis, tool and motion sequence. The focus is always on reliable overall movement, from the drive itself right through to interaction with the workpiece.

Safety Is More Than an Emergency Stop

In robotics, safety must be considered across the entire motion task. What matters is how axes, tools and loads behave during collisions, sensor faults, blockages or power failures.

Depending on the application, the following functions may be relevant

Secure holding of axes and loads
Limitation or interruption of power transmission during overload
Controlled braking of moving assemblies

Monitoring of switching, braking and holding states
Protection of tools, workpieces and machine components
Integration into emergency-stop and safety circuits
Defined responses to sensor or control system failures
Safe recovery after collisions
Controlled resumption of operation
Diagnostics and documentation of safety-related conditions

The required safety functions must always be assessed together with the robot controller, sensor systems, mechanical design and overall risk assessment. In robotics, rapid movement is good. Controlled response is better.

Prototypes for Rapid Validation

For new robot axes, grippers and tool modules, prototypes and functional test units can help evaluate the interaction between couplings, brakes, overload protection systems and control systems at an early stage.

Potential evaluation criteria include

Switching times and response behaviour
Positioning accuracy and repeatability
Holding torque and holding accuracy
Behaviour under varying loads and payloads
Response during collisions and overload events
Acceleration and deceleration profiles
Vibrations and resonances
Temperature development during continuous operation
Wear across large numbers of motion cycles
Behaviour during power failure and emergency stop
Tool changing and restart performance
Integration with controls, sensors and diagnostics
Influence on cycle times and path quality
Performance of both individual components and the complete system

This enables optimisation measures to be incorporated early into the mechanical design and motion control strategy, reducing later modifications and providing a solid foundation for successful series production integration.