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Brake technology 4.0:

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

01 The Roba-brake-checker module monitors the tension path reserve as well as the switching condition without sensors, and detects changes in safety- critical parameters like voltage, air gap and temperature 02 Engineers at Mayr, have developed a new friction lining technology through which the brakes achieve improved torque consistency and a higher performance density energised, a magnetic field builds up, which attracts the armature disk against the force of the springs and thus releases the rotor with the friction linings. The brake is released. In addition to the application of a fail-safe principle, all brake components are reliably dimensioned and produced only from high-quality, known and proven materials. The screw thrust springs used are made from rust-proof steel and are tested for a lifetime strength of 10 million load alternations. Advanced friction lining technology One key factor for the manufacture of reliable brakes is the use of high-quality friction linings. Mayr’s highly-qualified engineers and technicians have developed a new friction lining technology based on extremely complex parameters. A friction lining is not 100 % homogenous, but rather comprises of many components which react differently to external influences and environmental conditions. Engineers at Mayr, have managed to create a new friction lining technology through which the brakes achieve improved torque consistency and a higher performance density. Influences caused through environmental conditions, such as air humidity or temperature, have successfully been reduced, and this is further supported through the increasing use of enclosed brake designs, which are protected against external influences. Higher braking torques can be achieved with the new linings, this means, a smaller, lighter brake construction size can be selected for higher braking torques. This takes into account the general trend for machines and their components, for example engines, to be increasingly compact in construction, but with greater performance density. The company observes careful quality checks: This includes quality assurance measures during the design process and a comprehensive final inspection. Prior to delivery, all brakes are thoroughly tested on the test stands and function-relevant values are documented. An electronic database in which the measurement values are archived together with the corresponding serial numbers of the products ensures 100 % traceability. Controlling the brakes reliably In particular for applications which have to provide personal protection according to standards regarding functional safety, Mayr brakes are perfectly supplemented with the reliable brake control Roba-SBCplus. Together with the company Pilz, Mayr power transmission has developed this module which can control and monitor one or two Roba-stop safety brakes. The Roba-SBCplus module reliably interrupts the current in the magnetic coil on switching off the brake. For this purpose, the module operates using wear-free electronic semi-conductors, and as a result achieves practically unlimited switching frequency and switching reliability. In addition, a reliable integrated plausibility check is carried out through the evaluation of the release monitoring signals. The evaluations of the switching conditions and the return signal therefore enable reliable fault diagnosis. As a result, even creeping faults influencing the switching times, such as increasing wear for example, can be detected in good time. The reliable brake control Roba-SBCplus has been prototype-tested by the company TÜV Süd (Southern German Technical Inspectorate) and can be used up to the maximum Performance Level ‘PLe’ and Safety Integrity Level (SIL) 3. Brake technology 4.0 Brake technology 4.0 by Mayr power transmission is a concept which begins with the smart selection of the products. In order for a user to find the best or most reliable brake for their purpose, they require a comprehensive selection of products with the solutions appropriate for them. The brake technology 4.0 approach means a technologically leading friction system which, together with safety principles, stands for reliable braking with extremely high performance density. Innovative monitoring solutions are firmly integrated into this system, and as a result, Mayr’s brakes and the corresponding monitoring modules are able to master all challenges. They ensure the utmost operational reliability and enable preventive maintenance in the increasingly compact, higher performance density machines. Photographs: lead shutterstock/solarseven, 01-02 Mayr power transmission About Mayr Power Transmission The family-owned company, Mayr power transmission, founded in 1897, is a leading manufacturer of safety brakes, torque limiters and shaft couplings. These products are primarily used for electrically-powered machines in filling plants, machine tools, packaging and printing machines as well as in elevators, wind power plants and in stage technology. Approximately 600 employees currently work in the Allgäu-based Headquarters in Mauerstetten, Germany. Mayr power transmission has over 1000 employees worldwide. The company is globally established with plants in Poland and China, sales subsidiaries in the USA, France, Great Britain, Italy, Singapore and Switzerland and with representatives in 36 other countries. WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017