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Brake technology 4.0

Brake technology 4.0

Monitoring and controlling brakes intelligently can lead to greater levels of safety and equip power transmission systems for the challenges of Industry 4.0. New monitoring modules are the enabler.

Mayr Power Transmission has introduced a new generation of monitoring modules for safety brakes. The perfectly-coordinated complete system guarantees the utmost level of operational and functional safety, and increases the productivity of machines and systems through predictive error detection and maintenance.

With these new modules, Mayr says it is delivering safety brakes that address the challenges of the fourth industrial revolution, and has coined the term ‘brake technology 4.0’. The modules such as the ROBA-brake-checker and the ROBA-torqcontrol monitor safety brakes easily and quickly or facilitate the even and smooth deceleration of machines and devices. The ROBA-brake-checker module operates without sensors. Instead, it analyses current and voltage and recognises the movement of the armature disk. Thus it knows the condition of the brake.

In addition to the switching condition, the module can also deduce the temperature, wear and tension path or tensile force reserve, ie whether the magnet still has sufficient force to attract the armature disk. Using the new module, a significantly larger number of processes can be depicted during the monitoring of the safety brakes than was hitherto the case.

On reaching the tensile force reserve, the ROBA-brake-checker emits a warning signal, early enough so that a defined operating time of the brake is still possible. Within this time, the machine operator can undertake specific maintenance in coordination with their work process – maintenance with foresight, so to speak.

The ROBA-brake-checker is now available in a design for AC voltage. In addition, another version of the module will also in future take on the supply of the brake, and as a result, replace the rectifier. Switching condition monitoring and brake control are therefore combined in one device.

For applications, which require braking torque control in addition to status monitoring, Mayr 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 through purposeful influencing of 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 use in smart, interconnected machines.

Another module to continuously monitor the switching condition of the brakes is the safe brake control ROBA-SBCplus. In this module, Mayr offers safety brakes and safe brake control in a complete package. This module has been developed in collaboration with Pilz, especially for applications which have to fulfil requirements for the protection of people according to standards regarding functional safety.

The ROBA-SBCplus module must reliably interrupt the current in the magnetic coil when the brake is switched off. For this purpose, the module operates with wear-free electronic semi-conductors, and as a result achieves practically unlimited switching frequency and switching reliability. This brake control module performs reliable switching time monitoring.

Furthermore, an integrated plausibility check is conducted through the evaluation of the release monitoring signals. The evaluations of the switching states and the return signal therefore permit reliable error diagnostics. This permits creep errors which influence on the switching times, for example increasing wear, to be detected in due time.

The reliable ROBA-SBCplus brake control unit is type-certified by TÜV SÜD and can be used up to the highest Performance Level PLe and Safety Integrity Level (SIL) 3.

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