Products
Rotary Motion Control
All Rotary Motion Control
Rotary Indexers
Rotary Indexers
Roller Pinion Gears
Geared Bearings
Gears
Precision Brakes
Ball Screw Brakes
Shaft Brakes
Servomotor Brakes
Gearheads
Gearheads
Rotary Motion Control
Rotary Motion Control including Rotary Indexers, Roller Pinion Gears, Precision Brakes and Harmonic Gearheads.
Rotary Indexers
Based on Nexen’s innovative Roller Pinion technology, Nexen Ring Drive (Compact Precision Ring Drive and Precision Ring Drive) systems come complete with a precision grade bearing and drive mechanism in a rigid housing to simplify the selection process. With all the features of our other advanced Roller Pinion System technology, Nexen's Ring Drives open up new design possibilities for the next generation of machines.
Rotary Indexers
Based on Nexen’s innovative Roller Pinion technology, Nexen Ring Drive (Compact Precision Ring Drive and Precision Ring Drive) systems come complete with a precision grade bearing and drive mechanism in a rigid housing to simplify the selection process. With all the features of our other advanced Roller Pinion System technology, Nexen's Ring Drives open up new design possibilities for the next generation of machines.
Rotary Indexers
Based on Nexen’s innovative Roller Pinion technology, Nexen Rotary Indexer Systems come complete with a precision grade, high capacity bearing and drive mechanism in a rigid housing.

With options for high speed, high torque and zero backlash, Nexen Ring Drives can be optimized for every application. With accelerations up to twice as high as other indexing technologies, Nexen Ring Drive systems provide more productivity while boasting low maintenance, high efficiency and long life.
Roller Pinion Gears
Nexen’s patented rack and roller pinion design maintain high repeatable accuracy with zero backlash over longer distances with quieter operation - even at high speeds.
Geared Bearings
Nexen's Geared Bearing solution is ready to be integrated into a machine with its full ring gear and a high-capacity cross-roller bearing.

Based on Nexen's innovative Roller Pinion technology, the Roller Pinion System Geared Bearings come complete with a precision zero backlash gear mounted on a precision grade, high capacity bearing. Geared Bearings can be incorporated into any precision rotary motion control application with a number of possible sizes and gear ratios, all with zero backlash.
Gears
Nexen's Roller Pinion Gear System (RPG) is based on an innovative pinion consisting of bearing-supported rollers and a unique tooth profile. Gears, Gear segments and geared bearings can be configured to meet the application needs.

This unique drive system provides high positional accuracy, zero backlash, no cumulative error, low-velocity ripple, high speeds, rigidity, low noise, low maintenance, corrosion resistance, and long life. This opens up new machine design possibilities and provides the capability to achieve much higher performance levels.
Precision Brakes
Nexen’s Ball Screw / Shaft Brake / Servomotor Brake is a high-torque, spring-engaged, air-released brake. It serves as a redundant safety brake in the event of a mechanical defect in the drive line, particularly in the Z-axis. These brakes provide high accuracy for holding the position in power-off situations.
Ball Screw Brakes
The Nexen Ball Screw Brake is a high-torque, spring-engaged brake acting on the machined end of a ball screw. It serves as a primary or redundant safety brake to prevent back driving if a power loss or mechanical defect occurs in the driveline.
Shaft Brakes
Nexen's Shaft Brake has several bore sizes available, offering an off-the-shelf, zero-backlash braking solution for shaft-holding applications. These spring-engaged, air-released brakes offer outstanding holding for consistent, long-lasting performance.
Servomotor Brakes
Nexen’s Eclipse® spring-engaged, air-released servomotor brakes offer a powerful, high-torque and no-slip holding option. The Eclipse Servo Motor brake is installed between the motor and the linear device, providing improved safety with low inertia.
Gearheads
Nexen’s Harmonic Gearhead is the perfect combination of size and precision. When combined with Nexen’s Poller Pinion System, a true backlash-free solution from the motor to the driven load can be achieved. Machine designers will have up to a 70% reduction in length over standard gearheads, gaining increased space in a design.
Gearheads
Nexen’s Harmonic Gearhead is the perfect combination of size and precision. When combined with Nexen’s Poller Pinion System, a true backlash-free solution from the motor to the driven load can be achieved. Machine designers will have up to a 70% reduction in length over standard gearheads, gaining increased space in a design.
Gearheads
Harmonic Gearheads offer true zero backlash, high reduction ratios of 50/80/100/120:1, and high load capacity in a very compact package. Gearheads utilize the best cross-roller-bearing technology for the highest rigidity and load capacities.
Linear Motion Control
All Linear Motion Control
Roller Pinion Racks
Roller Pinion Racks
Linear Precision Brakes
Profile Rail Brakes
Rod Locks
Roller Pinion Racks
Nexen’s Roller Pinion System (RPS) patented rack and roller pinion design maintains high repeatable accuracy with zero backlash over longer distances with quieter operation - even at high speeds.
Roller Pinion Racks
Nexen’s Roller Pinion System (RPS) patented rack and roller pinion design maintains high repeatable accuracy with zero backlash over longer distances with quieter operation - even at high speeds.
Roller Pinion Racks
Nexen’s patented rack and pinion system with bearing-supported rollers engaging two rack teeth simultaneously, allowing for greater efficiency, longer life and outstanding accuracy.
Linear Precision Brakes
Nexen’s Profile Rail Brakes and Rod Locks are compact and powerful, delivering precision holding and locking at an affordable price.
Profile Rail Brakes
Nexen’s linear profile guide rail brakes use spring force to secure the load in holding applications. Superior response time and high force for stopping and holding in e-stop and power-off situations. Each rail brake clamps directly onto the guide rail to provide positive braking and holding in all axes, with no effect on bearing surfaces
Rod Locks
Nexen’s Spring Engaged, Air Released Rod Locks offer precision holding with guide rod systems and NFPA or ISO cylinders. A large clamping surface ensures consistent performance, ideal for accurate positioning.
Power Transmission
All Power Transmission
Clutches
Friction Clutches
Tooth Clutches
Friction Brakes
Rotary Brakes
Drum Brakes
Caliper Brakes
Friction Clutch-Brakes
Friction Clutch-Brakes
Torque Limiters
Pneumatic Torque Limiters
Mechanical Torque Limiters
Tension Control
Tension Control Brakes
Tension Control Clutches
Web Controls
Clutches
Multiple or single-position tooth clutches are positive engagement devices having open or nickel-plated, enclosed housings. Tooth clutch designs include a pilot-mount version (accepts sprockets or couplings), a flange-mount version that connects to bearing-supported devices and integral sprocket versions. Air-engaged tooth clutches produce up to 60,000 in-lbs. torque. Spring engaged tooth clutches, with up to 72,000 in-lbs. torque, are the ultimate holding device. Single and double-flex couplings, specifically designed for high-torque tooth clutches, are used for inline shaft connections.
Friction Clutches
Nexen’s single-disc, self-adjusting Clutches mount on a driving or driven shaft. They cover transmitted horsepower ratings from fractional to 25 hp, torque ratings to 5000 in-lb with thermal capacities to 2.5 thermal horsepower, and maximum operating speeds to 3600 rpm. Most are available in Sheave, Pilot, or Coupling Mount versions.
Tooth Clutches
Available in a variety of Single or Multiple Position Models, as well as a Sprocket Tooth design, there are Standard and Metric Models available. Most can be used with a Single or Double Flex Coupling Assembly for in-line coupling applications.
Friction Brakes
Friction brakes have a stationary pad (friction facing) and a rotating wear surface. Common configurations include drum brakes, caliper disc brakes and shaft-mounted brakes with an integral disc and rotor. Friction brakes provide controlled deceleration, stopping, holding, and tension control. Air and spring-engaged versions are available in all brake configurations.
Rotary Brakes
Air or spring-engaged, shaft-mounted friction brakes come with tapered bores to accept QD bushings or straight, bored and keyed-to-size disc hubs. Bushings are available to reduce the size of the standard, straight-bore models. Air-engaged brakes are used for stopping, holding, controlled deceleration, and tension control. Spring-engaged brakes are excellent stopping and holding devices. Multiple sizes provide torque up to 10,000 in-lbs.
Drum Brakes
Nexen's drum brakes are actuated with a diaphragm-sealed actuator that forces a brake shoe on a drum surface to provide the braking torque. Brake drums are bored and keyed to fit standard shafts. The brake shoes are clamped on the outside of the drum to provide brake torque up to 3750 in-lbs. Hinge top models offer a convenient feature to change rolls when the brake is used in tension control applications.
Caliper Brakes
Caliper brakes are used in controlled deceleration, cyclic stopping, holding, emergency stops, and tension control applications. Nexen offers a wide variety of caliper brake designs, including air actuated/spring-released, spring engaged/air-released, and spring engaged/hydraulic-released models. Several disc diameters up to 24-inches are offered to provide torque up to 50,000 in-lbs. Multiple calipers can be used on a single disc to increase torque and accommodate various disc thicknesses.
Friction Clutch-Brakes
Nexen’s Friction Clutch-Brakes combines the features of a Friction Clutch with a Friction Brake into a single unit. Standard models offer pilot mount, sheave mount and pilot mount with coupling half options. Pilot Mount units are available in various standard bores sizes with customization possible with bushings and couplings.
Friction Clutch-Brakes
Nexen’s Friction Clutch-Brakes combines the features of a Friction Clutch with a Friction Brake into a single unit. Standard models offer pilot mount, sheave mount and pilot mount with coupling half options. Pilot Mount units are available in various standard bores sizes with customization possible with bushings and couplings.
Friction Clutch-Brakes
Conveniently packaged clutches and brakes for a start and stop applications. Clutch-brake combinations have mounting features that make them adaptable to NEMA and IEC motor frames. All clutch-brakes operate on static air pressure.
Torque Limiters
A torque limiter protects mechanical equipment or its work from damage by mechanical overload. A torque limiter may limit the torque by slipping a friction plate clutch or disconnecting the load entirely. The action of a torque limiter is useful to limit any damage to the machine or product due to mechanical failures or product jams in the machine and is typically installed on the output side of gear reducers to protect the gear set.
Pneumatic Torque Limiters
Nexen’s pneumatically engaged, single-position torque limiters are the best overload protection devices available. The “TL” Series units are ball/detent clutches equipped with overload sensors.
Mechanical Torque Limiters
Nexen’s Torque Limiters protect the drive and driven components from damage associated with torque overloads caused by material jams, operator error, or various unforeseen reasons that pose a significant threat to machine downtime.
Tension Control
Precise tension control is vital to any web or strip-fed operation, and the product must be fed under tension, processed under tension and wound up again under tension. Tension controllers are an integral part of maintaining this set tension. Nexen tension controllers range from simple systems with diameter feedback (open loop) to dancer control systems and the highest precision systems using web tension sensor feedback (closed loop).
Tension Control Brakes
Nexen’s Tension Control brakes offer precise control over the full operating range – from the high torque needed to manage a large roll, to the lower torque requirements for more delicate materials and demanding applications.
Tension Control Clutches
Nexen's line of Modular Tension Control Clutches is designed to be the most flexible, maintenance-free pneumatic units available for continuous winding operations. Ruggedly built to endure the continuous drag and high heat load that tension control demands, yet extremely sensitive and responsive to a wide range of torque requirements.
Web Controls
Nexen’s Web Controllers are a closed-loop, load cell-based tension control products which use torque to control the tension of paper, film, foil, or fabric in all zones of web processing machines.
NexSafe® Safety Certified
All NexSafe® Safety Certified
Servomotor Brakes
Servomotor Brakes
Profile Rail Brakes
Profile Rail Brakes
Rod Locks
Rod Locks
Servomotor Brakes
Nexen’s Spring Engaged, Air Released Servomotor Brakes are available safety certified to comply with international safety standard ISO 13849-1. Category Level up to 4 and Performance Level up to e, can be achieved using NexSafe® products in recommended configuration.
Servomotor Brakes
Nexen’s Spring Engaged, Air Released Servomotor Brakes are available safety certified to comply with international safety standard ISO 13849-1. Category Level up to 4 and Performance Level up to e, can be achieved using NexSafe® products in recommended configuration.
Servomotor Brakes
Nexen’s Spring Engaged, Air Released Servomotor Brakes are available safety certified to comply with international safety standard ISO 13849-1. Category Level up to 4 and Performance Level up to e, can be achieved using NexSafe® products in recommended configuration.
Profile Rail Brakes
Nexen’s Rail Brakes Series of linear profile guide rail brakes uses spring force to secure the load in holding applications. Superior response time, high force for stopping and holding in e-stop and power-off situations. Each Rail Brake clamps directly onto the center of the guide rail to provide positive braking and holding in all axes, with no effect on bearing surfaces. These profile rail brakes hold position accurately by reducing drive train backlash and elasticity.
Profile Rail Brakes
Nexen’s Rail Brakes Series of linear profile guide rail brakes uses spring force to secure the load in holding applications. Superior response time, high force for stopping and holding in e-stop and power-off situations. Each Rail Brake clamps directly onto the center of the guide rail to provide positive braking and holding in all axes, with no effect on bearing surfaces. These profile rail brakes hold position accurately by reducing drive train backlash and elasticity.
Profile Rail Brakes
Nexen’s Spring Engaged, Air Released Rail Brakes are safety certified to comply with international safety standard ISO 13849-1. Category Level up to 4 and Performance Level up to e, able to be achieved using NexSafe® products in recommended configuration.
Rod Locks
Nexen’s Static Rod Locks deliver precision holding with virtually no backlash, providing high accuracy in demanding applications. These spring-engaged, air-released units come in both ISO and NFPA sizes. The Rod Lock’s large clamping surface ensures high clamping/holding force, and Nexen offers models for use on a pneumatic cylinder or as a stand-alone unit on a guide rod. The design is sealed and features a natural brushed aluminum finish or a corrosion-resistant, anodized finish.
Rod Locks
Nexen’s Static Rod Locks deliver precision holding with virtually no backlash, providing high accuracy in demanding applications. These spring-engaged, air-released units come in both ISO and NFPA sizes. The Rod Lock’s large clamping surface ensures high clamping/holding force, and Nexen offers models for use on a pneumatic cylinder or as a stand-alone unit on a guide rod. The design is sealed and features a natural brushed aluminum finish or a corrosion-resistant, anodized finish.
Rod Locks
Nexen’s Spring Engaged, Air Released Rod Locks are safety certified to comply with international safety standard ISO 13849-1. Category Level up to 4 and Performance Level up to e, can be achieved using NexSafe® products in recommended configuration.

With superior performance, these spring-engaged, air-released units supplement air cylinders and guide rods for holding in power-off/e-stop situations. High clamping forces ensure positive holding with minimal air required for release.
Accessories
All Accessories
Pneumatic Control Accessories
Pneumatic Control Accessories
Linear Couplings
Linear Couplings
Pneumatic Control Accessories
Nexen offers a number of Pneumatic Accessories for our line of products.
Pneumatic Control Accessories
Nexen offers a number of Pneumatic Accessories for our line of products.
Pneumatic Control Accessories
Nexen offers a number of Pneumatic Control Accessories for our products that allow for easy connections, servicing, and trouble-free performance.
Linear Couplings
Nexen’s Linear Couplings protect valuable equipment by controlling misalignment in linear motors, ballscrew actuators, pneumatic cylinders, and rods or sensors.
Linear Couplings
Nexen’s Linear Couplings protect valuable equipment by controlling misalignment in linear motors, ballscrew actuators, pneumatic cylinders, and rods or sensors.
Linear Couplings
Nexen's Linear Coupling help prevent binding or premature wear, Providing zero backlash misalignment control between linear actuators, ballscrew actuators, pneumatic cylinders, and rods or sensors.
Resources
Contact

Tension Control Brakes

About our Tension Control Brakes

Designed to dissipate heat away from the unit, Nexen’s tension control brakes and clutches have high thermal capacities and long operating lives. Multiple actuators allow for versatile, precise tension control. Installation and maintenance are made easy by simple connections.

This airflow design uses fins on the rotor, hub back and calipers to throw dissipated heat into space, not into the brake or shaft. This design also helps draw cooler air around and over the brake. The one-piece lightweight rotor pulls cool air into the brake and draws it over the air hoses, so they don’t overheat and crack.

Contact a Nexen Engineer

Resources

Tension Control Brakes Technical Data

Air Champ Catalog

Tension Control Brakes Application Examples:

Compare our Tension Control Brakes

Multiple_Actuators_1 Multiple ACTUATORS

	STB	BTBA
Sizes Available	600, 940	10, 12
Max Dynamic Torque With All Calipers	Up to 258 Nm [2,284 in-lbs]	Up to 588 Nm [5,200 in-lbs]
Max Brake Continuous Thermal Dissipation	Up to 2.2 kW [3 hp]	Up to 7.5 kW [10 hp]
Purpose	Tension Control Brake Designed for High Thermal Constant Slip Operation and Highly Variable Torque	Tension Control Brake Designed for High Thermal Constant Slip Operation and Highly Variable Torque
Engagement Method	Air Engaged	Air Engaged
Braking	Holding, E-Stop, Continuous Slip	Holding, E-Stop, Continuous Slip
Mounting	Shaft Mount	Shaft Mount
Actuation Type	Multiple Actuators: 6 Diaphragm Actuators, 2 Small, 2 Medium, 2 Large	Multiple Actuators: 6 or 8 Equal Sized Diaphragm Actuators
Hub	Keyed Female Through Bore	Keyed Female Through Bore
Available Hub Bore Diameters	0.750 to 2.000 in, 19 to 50 mm	0.938 to 2.188 in, 20 to 55 mm
Outer Diameter	6.62 or 10.02 in, 168.1 or 254.5 mm	10.83 or 12.89 in, 275.1 or 327.4 mm
Housing	Open	Guarded
Finish	Bare Aluminum or Nickel Plated	Acrylic Paint or Bare Aluminum
Maximum Speed	Up to 3,600 RPM	Up to 2,500 RPM

XTB_Glyph Multiple CALIPERS

	XTB	XTB-Advanced
Sizes Available	10, 12, 14, 18, 22	10, 12, 14, 18
Max Dynamic Torque With All Calipers	Up to 3,986 Nm [35,280 in-lbs]	Up to 3,986 Nm [35,280 in-lbs]
Max Brake Continuous Thermal Dissipation	Up to 44.7 kW [60 hp]	Up to 44.7 kW [60 hp]
Purpose	Tension Control Brake Designed for High Thermal Constant Slip Operation and Highly Variable Torque	Tension Control Brake Designed for High Thermal Constant Slip Operation and Highly Variable Torque
Engagement Method	Air Engaged	Air Engaged
Braking	Holding, E-Stop, Continuous Slip	Holding, E-Stop, Continuous Slip
Mounting	Shaft Mount	Shaft Mount
Actuation Type	Multiple Calipers: Up to 9 Calipers Per Disc-Hub	Multiple Calipers: Up to 9 Calipers Per Disc-Hub
Hub	Keyed Female Through Bore	Keyed Female Through Bore
Available Hub Bore Diameters	1.000 to 5.000 in, 25 to 127 mm	1.000 to 5.000 in, 25 to 127 mm
Unit Outer Diameter	17.25 to 29.93 in, 438.2 to 760.2 mm (Dimension Includes Guard and Calipers)	17.25 to 29.93 in, 438.2 to 760.2 mm (Dimension Includes Guard and Calipers)
Guarding	Guards are Available - Sold Separately	Guards are Available - Sold Separately
Finish	Powder Paint	Powder Paint
Maximum Speed	Up to 3,400 RPM	Up to 3,400 RPM
Note	Dual Rotor Units are Available For Additional Thermal Work Capacity. Rotors are Available with Cooling Fins Optimized for Clockwise or Counterclockwise Rotation.	XTBA Rotors are Cross-Drilled for Even More Thermal Work Capacity than XTB Units. Dual Rotor Units are Available For Additional Thermal Work Capacity. Rotors are Available with Cooling Fins Optimized for Clockwise or Counterclockwise Rotation

Single ACTUATORS

	S Brake Advanced	T Brake Advanced	W1000
Sizes Available	450, 600, 800, 1000	450, 600, 800, 1000	1000
Max Dynamic Torque With All Calipers	Up to 331 Nm [2,933 in-lbs]	Up to 331 Nm [2,933 in-lbs]	Up to 339 Nm [3,000 in-lbs]
Max Brake Continuous Thermal Dissipation	Up to 4.1 kW [5.5 hp]	Up to 4.1 kW [5.5 hp]	Up to 6 kW [8 hp]
Purpose	Tension Control Brake Designed for Constant Slip Operation and Variable Torque	Tension Control Brake Designed for Constant Slip Operation and Variable Torque	Tension Control Brake Designed for Constant Slip Operation and Variable Torque
Engagement Method	Air Engaged	Air Engaged	Air Engaged
Braking	Holding, E-Stop, Cyclic Dynamic, Continuous Slip	Holding, E-Stop, Cyclic Dynamic, Continuous Slip	Holding, E-Stop, Cyclic Dynamic, Continuous Slip
Mounting	Shaft Mount	Shaft Mount	Shaft Mount
Actuation Type	Single Actuator	Single Actuator	Single Actuator
Hub	Keyed Female Through Bore	Keyed Female Through Bore	Keyed Female Through Bore
Available Hub Bore Diameters	1.000 to 2.938 in, 25 to 75 mm (Optional adapter bushings can reduce bore to as small as 0.500 in)	0.500 to 2.875 in, 13 to 73 mm Accepts required customer-supplied taper bushings between the following sizes	2.938 in (Optional adapter bushings can reduce bore to as small as 0.500 in
Unit Outer Diameter	5.94 to 11.88 in, 151 to 302 mm	5.94 to 11.88 in, 151 to 302 mm	11.88 in, 302 mm
Guarding	Open, Guards Available - Sold Separately	Open, Guards Available - Sold Separately	Open, Guards Available - Sold Separately
Finish	Black Oxide	Black Oxide	Black Oxide
Maximum Speed	1,800 RPM	1,800 RPM	1,800 RPM
Note	Optional Additional Compressed Air Cooling	Optional Additional Compressed Air Cooling	Water Cooled for More Thermal Work Capacity

Required Components and Accessories for our Tension Control Brakes

Listed below are some of the Required Components and Accessories for Tension Control Brakes. Use the filters above to find the complete list of Required Components and Accessories on the product page.

Required Components

3-Way Valves
Caliper Assemblies
Facing Kits

Accessories

Guards
Torque Pin Brackets
Control Kits
Filters
Flow Control Valves
Lubricator
Mufflers
Quick Exhaust/Shuttles
Regulators
Restrictor Valves
Dancer Controllers
Diameter-Based Tension Controls
Load Cell-Based Tension Controls

Applications

Nexen's Tension Control Brakes are designed for the following applications:

Converting
Printing
Unwinding
Winding

More Information

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Help with your application

Note: The technical data on this website is subject to change without notice. Please contact Nexen for help with your application, appropriate sizing, and configuration.

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Rotary Motion Control

Rotary Indexers

Rotary Indexers

Rotary Indexers

Roller Pinion Gears

Geared Bearings

Gears

Precision Brakes

Ball Screw Brakes

Shaft Brakes

Servomotor Brakes

Gearheads

Gearheads

Gearheads

Roller Pinion Racks

Roller Pinion Racks

Roller Pinion Racks

Linear Precision Brakes

Profile Rail Brakes

Rod Locks

Clutches

Friction Clutches

Tooth Clutches

Friction Brakes

Rotary Brakes

Drum Brakes

Caliper Brakes

Friction Clutch-Brakes

Friction Clutch-Brakes

Friction Clutch-Brakes

Torque Limiters

Pneumatic Torque Limiters

Mechanical Torque Limiters

Tension Control