High-efficiency IE5 synchronous motors are growing in importance and placing new demands on braking technology. As power density increases, holding brakes must deliver greater braking torque without taking up additional installation space
Kendrion’s BFK558 Sync meets these changing requirements by delivering more braking torque at the same brake size as conventional standard brake series, while maintaining reliable performance over a long service life.
As high-efficiency IE5 synchronous motors gain ground, their higher power density is changing the demands placed on braking technology, requiring greater braking performance without increasing installation space. Kendrion developed the BFK558 Sync with this in mind.
At the same brake size, the BFK558 Sync can provide up to 30% more braking torque than previous standard brake series. Depending on the version, the increase is at least 25%. This braking performance is achieved without relying on a higher friction coefficient. In the BFK558 Sync, the additional braking torque comes primarily from increased spring force, enabling selection of the friction lining for the application, with a range of options available in the Kendrion portfolio. The design also helps ensure reliable braking torque over a long service life.
Dr Tobias Engelke, product manager at Kendrion, said, “With the BFK558 Sync, we are responding to the increasing power density of modern synchronous motors. Our goal was to provide significantly more braking torque within the existing installation space while retaining the proven characteristics of our BFK platform.”
For integration, Kendrion expands on proven dimensions and established design principles. The BFK558 Sync utilises the installation dimensions of the BFK series and provides comparable options, enabling motor manufacturers to integrate the new performance level into existing motor concepts with minimal modifications.
The precisely preset air gap also simplifies installation, requiring no readjustment during assembly. The modular design lets users configure the brake flexibly for different applications and motor variants.
The BFK558 Sync suits a range of modern drive concepts. Sizes 08, 10, and 12 will be available at market launch, with additional sizes based on the existing BFK series to follow. Depending on application requirements, the BFK558 Sync can be used with IE3 and IE4 motor concepts, as well as IE5 synchronous motors.
The BFK558 Sync is ideal for intralogistics and material-handling applications where compact drives must operate reliably and brake safely in an emergency. As a fail-safe spring-applied brake, it is designed for holding and emergency-stop functions. Typical applications include lifting equipment such as hoists and cranes, storage and retrieval systems, automated guided vehicles, gantries, and conveyor systems.
The BFK558 Sync is developed and assembled in Germany, combining higher performance with a proven platform. In addition to increased braking performance, the design focuses on easy integration, a range of variants, and short lead times.
Kendrion will present the new brake to a wider audience for the first time at SPS in Nuremberg, Germany, from 24 to 26 November, 2026. Kendrion will be located at Hall 4, Booth 418.
