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Introducing the TS1200-IB: A Simpler, More Powerful 4th-Axis Braking System
- 6 hours ago
- 3 min read
In 4th-axis machining, rotation gets most of the attention. But the real challenge often happens after the index—when the rotary must hold position against cutting forces.
When parts are mounted far from the centerline of rotation, or when aggressive tools and deep cuts are involved, the built-in brake of a standard rotary table may not provide enough holding torque. That’s where a dedicated braking system makes the difference.
At Martin Trunnion Tables, our TS1200 braking system has long been a trusted solution for increasing rigidity and eliminating unwanted movement during machining. Now, we’re excited to introduce the TS1200-IB, a major upgrade designed to simplify installation while delivering the same powerful clamping performance.
Why Add a Braking System to a 4th Axis?
Most CNC rotary tables include an internal brake. For many applications, that brake is sufficient. But as machining setups grow larger and more complex, additional holding torque becomes critical.
A dedicated braking system provides several key advantages:
Increased rigidity during heavy machining
Reduced risk of rotary movement under load
Improved surface finish and dimensional accuracy
Greater confidence when machining off-center or with large fixtures
The TS Series braking systems are designed to work in tandem with the rotary table’s internal brake, dramatically increasing the total holding torque available in the system.
This is especially important for trunnion setups where parts may be mounted well away from the rotary faceplate.
The TS1200: Proven Rigidity
The original TS1200 brake uses a hydraulically actuated squeeze bushing that clamps evenly around the rotary shaft.
This collet-style design delivers full 360° contact around the shaft, ensuring balanced clamping and eliminating play.
When engaged, the brake adds significant holding power to the rotary table—allowing shops to machine more aggressively without worrying about axis movement.
In many cases, this added rigidity can mean the difference between:
chatter vs. clean cutting
conservative feeds vs. optimized cycle times
unreliable positioning vs. repeatable accuracy
The Challenge: External Boosters
While the TS1200 performed exceptionally well, the traditional system required an external air-over-oil booster.
In a typical configuration:
Air pressure from the rotary table brake was sent to an external booster.
The booster converted that air pressure into hydraulic pressure.
That hydraulic pressure activated the squeeze bushing brake.
The system worked extremely well—but it introduced a few complications:
Additional plumbing and fittings
External booster components
More complex installation
Extra space requirements inside the machine
For many customers, the next logical step was clear: integrate the hydraulic booster directly into the brake system itself.
Enter the TS1200-IB
The TS1200-IB (Integrated Booster) is the next evolution of our braking technology.
Instead of relying on an external air-over-oil system, the TS1200-IB features a fully integrated hydraulic piston that generates the pressure needed to actuate the squeeze bushing.
Air from the rotary table’s internal brake now feeds directly into the TS1200-IB, where the integrated piston converts that air pressure into hydraulic force.
The result is a dramatically simpler system.
Key Advantages of the TS1200-IB
1. No External Booster or Pump All hydraulic amplification happens inside the brake assembly itself.
2. Cleaner Machine Installations With fewer hoses and components, the installation is far more streamlined.
3. Faster Response Time Shorter fluid paths allow the brake to engage and release more quickly.
4. True Plug-and-Play Integration The system works directly with the rotary table’s existing air brake signal.
5. Proven Clamping Performance The TS1200-IB still delivers up to five times the clamping torque of a standard rotary table brake.
How the TS1200-IB Works
The TS1200-IB mounts to the outboard support of a trunnion system and clamps directly onto the trunnion shaft.
When the rotary table’s brake signal is activated:
Air pressure is sent from the rotary table.
The TS1200-IB’s integrated piston converts that air into hydraulic pressure.
The hydraulic pressure compresses the squeeze bushing.
The bushing contracts evenly around the shaft, locking the axis in place.
At the same time, the rotary table’s internal brake engages, meaning both systems work together to hold the axis rigidly during cutting.
This synchronized braking dramatically increases stability and machining confidence.
Ideal Applications for the TS1200-IB
The TS1200-IB is particularly valuable in setups where rigidity is critical:
Large trunnion tables
Long fixtures or tombstones
Heavy off-center parts
Deep drilling operations
Aggressive roughing
Hard materials
High-torque tooling
In these situations, the extra holding torque helps prevent axis movement that could otherwise compromise part quality.
Simpler Hardware. Stronger Performance.
At Martin Trunnion Tables, we’re constantly refining our designs to make machining simpler, stronger, and more reliable.
The TS1200-IB represents exactly that philosophy.
By integrating the hydraulic booster directly into the brake system, we’ve eliminated unnecessary components while maintaining the powerful clamping force that machinists rely on.
The result is a braking system that is:
Easier to install
Easier to maintain
Cleaner inside the machine
And just as powerful as ever
For shops pushing the limits of their 4th-axis machining, the TS1200-IB delivers the rigidity needed to cut with confidence.
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