2017-1

Brake technology 4.0:
safety brakes fit for all challenges
Mayr power transmission’s approach towards
integrating the industry 4.0 technology with the
braking systems delivers utmost level of operational
and functional safety, at the same time its brake
monitoring modules increase the productivity through
preventive fault detection and maintenance.
The great challenge on the road to a “smart factory” is the digitalization
of the information flow in production and the use of the
collected data, not only to establish intelligent processes, for example
in planning and manufacturing, but also for preventive maintenance.
For safety brakes, this specifically means the realisation of
comprehensive monitoring using sensors. Here, Industry 4.0 comes
up against safety regulations and standards, which already demand
the monitoring of safety brakes with sensors. In addition to the tried
and tested brake control unit Roba-SBCplus, Mayr power transmission
has now developed a new, intelligent generation of monitoring
modules with the Roba-brake-checker and Roba-torqcontrol.
Condition monitoring without sensors
MACHINE ELEMENTS
Mayr power transmission’s brake technology 4.0 with a
advanced friction system and permanent brake monitoring,
making the safety brakes fit for the challenges
of the industry 4.0
The Roba-brake-checker module monitors the tension path reserve
as well as the switching condition without sensors and detects safety-critical
changes in voltage, air gap and temperature. On reaching
the tension path reserve, the Roba-brake-checker sends a warning
signal indicating that the brake can continue to be operated for a
certain amount of time. During this time, the machine owner can
undertake targeted maintenance – in coordination with their work
process. In addition, the module also simultaneously assumes
the control of the brake and therefore replaces a rectifier. Switching
condition monitoring and brake controls are thus combined
in one device. As the Roba-brake-checker works without sensors,
no microswitches or proximity sensors have to be attached to the
exterior of the brake for switching condition monitoring, and the
safety brakes can be employed in their basic design. Furthermore,
additional cables and sealing of the switches and sensors become
obsolete. This therefore ensures full design freedom. Unlike solutions
with switches and sensors, which, due to their installation
position on the brake are exposed to impacts and vibrations, monitoring
with this module takes place from the control cabinet, i.e. in a
protected environment. It works without mechanical contacts and
is highly reliable and wear-free.
For applications, which additionally require braking torque control
as well as status monitoring, Mayr power transmissions provides
the braking torque control module Roba-torqcontrol. It shares the
features of the Roba-brake-checker and can also change the level
of the braking torque in operation by influencing the current and
voltage. As a result, devices and machines can be evenly and gently
decelerated. The Roba-torqcontrol module permits the development
of control loops and brakes movements intelligently – the
ideal basis for its application in smart, interconnected machines.
Even more safety and reliability
One indispensable prerequisite for intelligent, automated processes
with permanently monitored safety brakes is however a reliable
brake technology, as it is of primary importance that brakes work
safely and reliably, and deliver the required torque over the entire
service lifetime. As a result, Mayr power transmission consistently
takes basic safety principles into consideration for development
and manufacture, as defined amongst other things in the standard
EN 13849-2: The electromagnetic Roba-stop safety brakes work
according to a fail-safe principle, and therefore they are closed in
de-energised condition. The braking torque is generated through
the force stored in the thrust springs. When the magnetic coil is
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017