Regal Rexnord Corp. Launches Integrated Position Brake (IPB) by Warner Electric

Regal Rexnord Corp. has introduced the Integrated Position Brake (IPB) by Warner Electric. The solution combines a high-performance brake with an integrated position sensor into a single component to deliver space savings and enhanced functionality for electrified and automated systems.

As original equipment manufacturers (OEMs) face packaging challenges due to space constraints in electric systems, the integration of speed or position sensors, which typically require 25–35mm of axial length, can be difficult. The IPB is designed to address this by combining a spring-applied, electrically released parking brake with an embedded position sensor in one compact unit.

“The drive toward electrification requires utilizing every millimeter of space to maximize power density,” said Jon Volk, global product manager, Electrification at Regal Rexnord. “By eliminating the need for separate sensors and providing an output signal immune to magnetic interference, we are saving space and also providing OEMs with a more robust, reliable system that simplifies the entire assembly process.”

Features of the Integrated Position Brake include:

• Offers a choice of 0–5V SIN/COS analog absolute position output or a digital quadrature encoder with resolutions from 64 to 1,024 pulses per revolution.
• Reduces overall drivetrain length by up to 25 mm, enabling OEMs to either shrink the package size or add motor windings for increased power.
• Eliminates the need for a separate encoder or resolver, reducing the total number of components in an assembly.
• Features an integrated sensor immune to common external magnetic disturbances, is unaffected by air gap variations, and does not rely on rotating permanent magnets.

By integrating the sensor directly into the brake assembly, the system provides accurate and repeatable feedback without increasing system dimensions or complexity. This makes the IPB suitable for space-constrained designs where packaging efficiency and reliability are critical.

Key applications and markets include farm and agriculture, forklift trucks, autonomous guided vehicles (AGVs) and compact off-highway equipment.