released just as smoothly. This not only reduces mechanical wear but also prevents dangerous oscillations or uncontrolled overruns. The advantage is clear: better protection for equipment and a safer working environment for personnel. An example of this approach is the SOBO iQ intelligent braking controller from Svendborg Brakes, part of the Regal Rexnord group. The system monitors variables such as line pull and conveyor speed, adjusting brake torque in real time to maintain controlled operation under changing conditions. When a braking command is issued, the controller energises or de-energises valves to modulate hydraulic pressure and follow predefined braking ramps. Integrated pressure feedback provides accurate control of brake torque, helping to deliver a consistent and predictable stopping sequence. At a major copper mine in Chile, this technology was applied to a take-up winch on a 2.65-kilometre conveyor transporting more than 11,000 tonnes of ore per hour. By enabling controlled release of belt tension, even during a power failure, the SOBO iQ system prevented damage to both the belt and mechanical components, marking what was described as the industry’s first “smart” take-up winch. New generation of brake pads Beyond control, braking systems in mining must also address health and safety challenges that extend beyond machinery. Dust, for example, is a persistent hazard in mining environments, contributing to respiratory risks and harmful working atmospheres. Brake pads can be a surprisingly significant source of airborne dust. Recognising this, Svendborg Brakes has developed a proprietary range of environmentally friendly brake pad materials that drastically reduce dust emissions without compromising performance. Designed, manufactured, and tested in-house, these pads can be tailored to the specific requirements of each application, combining operational SPECIAL REPORTS 36 HYDRAULICS & PNEUMATICS March 2026 www.hpmag.co.uk In mining, the scale of machinery is immense, and so are the risks. Conveyors stretch for miles across rugged landscapes, bucket wheel excavators move thousands of tonnes per hour, and hoists pull ore from deep underground. Similar high-inertia machinery can also be found in large construction and quarrying operations. Each of these systems relies on braking and clutch technologies to protect operators, safeguard equipment, and ensure continuous production. The difference between downtime and reliability often comes down to how intelligently these systems are designed and controlled. Hydraulic brakes have long been the standard for large-scale mining equipment because they deliver the force and reliability required for high-inertia machines. But modern mines demand more than brute stopping power. They need systems that can react smoothly, adapt to changing load conditions, and safeguard components during emergencies such as power failures. Intelligent hydraulic braking is no longer an optional upgrade, it has become a crucial element of safety, efficiency, and uptime in the mining industry. Controlled braking One of the key advances in this field is the development of programmable soft braking control. Unlike conventional braking methods that can place enormous stresses on belts, shafts, and bearings, soft braking allows torque to be applied gradually and Smart hydraulic braking improves safety and reliability in mining equipment Mining machinery operates under extreme loads where reliable braking is essential for safety and equipment protection. Advances in hydraulic braking control, combined with intelligent monitoring and improved component design, are helping operators manage high inertia systems more smoothly while reducing wear, downtime and maintenance demands. H&P reports.
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