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Industrial Analytical Instrumentation

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Machine tools and general engineering

Smart switching - adapted braking. New electronic
braking torque regulation for ROBA-stop® safety brake

The new, intelligent braking torque control module by mayr® power transmission makes it possible to decelerate devices and machines evenly and gently. This innovative and economically attractive solution is pre-destined for application in smart, interconnected machines. Nobody would even think of using the handbrake or parking brake when a car is going at full speed. In order to decelerate the car as required, a driver would use the foot brake. Gradual, even deceleration is also often desired for devices and machine applications with dynamic braking actions. However, as safety brakes - in contrast to car brakes - can only distinguish between two operating conditions due to their design, namely »braking torque present» and »no braking torque present», every braking procedure is carried out with the maximum braking torque available. With the new, intelligent braking torque control module, mayr® power transmission offer an economically attractive solution to generate a variable braking torque for ROBA-stop® safety brakes, making it possible to decelerate machines evenly and gently.

Continuous braking torque changes when in operation
Up to now, brakes have been dimensioned with regard to the maximum load where devices with variable loads, for example forklift trucks, are concerned. However, it is not always expedient to work with the full braking torque. In case of partial loads, a stronger deceleration than necessary can lead to damage to the transported goods or even to sliding of the wheels. If, however, the system detects the operating conditions and converts this information into a default signal for the new, intelligent control module by mayr® power transmission, electronic braking torque regulation is possible. Using the new system, the brake specialists have succeeded in continuously changing the contact force on the brake linings and therefore also the braking torque during operation. In this way, machines can be decelerated gently, adapted to the respective system requirements. Furthermore, the new braking torque regulation makes it possible to compensate for negative influences on the braking torque consistency in applications requiring a constant braking torque within narrow tolerance limits.

Prerequisites for a smart machine
The new, intelligent switching device by mayr® power transmission, which is operated with 24V or 48V DC voltage, can control brakes with a coil nominal current of 10A or 5A. In addition, the resulting clamping force for the brake rotor can be specified to 25%, 50% or 75% of the nominal spring force by means of two digital inputs. Alternatively, a continuous, analogue default signal from 0 to 10V is possible. The switching device determines without using a sensor whether the armature disk is attracted or has dropped. This makes it possible to adjust the over excitation time automatically as desired. Due to the fact that the intelligent switching device registers the switching condition of the brake, no microswitches or proximity sensors including the respective cabling are necessary as would normally be the case. The device also takes possible wear reserves into account, and, if required, recognises unpermitted high temperatures. With its compact dimensions of 30 mm in height, 69 mm in width and 103 mm in length, it can easily be integrated into control cabinets.

With the new braking torque control module, mayr® power transmission provide the possibility to build up control circuits and brake movements intelligently - ideal prerequisites for application in the smart, interconnected machines of the future.

Fig. 1: With the new, intelligent braking torque control module, mayr® power transmission offer an economically attractive solution for the generation of a variable braking torque for ROBA-stop® safety brakes.

Fig. 2: The new, intelligent control device makes targeted braking torque regulation possible. The device can be operated with 24V or 48V DV and can control brakes with a coil nominal current of 10A or 5A.

For further information, view website: www.mayr.co.uk or e-mail: andrew@mayr.co.uk 

A permanent overview of the brake operating
conditions: Innovative monitoring solutions for safety brakes

The monitoring of electromagnetic safety brakes is an increasingly important topic. mayr® power transmission is therefore setting new standards with the new, intelligent brake control module ROBA®-brake-checker. This module is not only able to energise brakes, but can also monitor them without the use of sensors. It is flexible and easy to integrate into existing systems.

As the amount of networking between people, processes and machines increases, the requirements on the individual components of a drive line also rise. mayr® power transmission has therefore risen to the current challenges set by the Industry 4.0. and has already incorporated into its range intelligent products which can communicate with the superordinate controls. The latest developments include an intelligent brake control module, the ROBA®-brake-checker, which is not only able to energise safety brakes, but also to monitor them without the use of sensors. It recognizes the switching condition of the actuator and the wear on the brake linings, and thus detects safety-critical conditions prior to their occurrence. Any changes in the braking torque can thus be instantly detected and countermeasures initiated - for maximum functional and operational safety.

Higher performance, less inconvenience
The new module ROBA®-brake-checker serves to operate safety brakes at reduced power while simultaneously monitoring their switching condition. It is designed for an input voltage of 24V or 48V DC, and can control brakes with a coil nominal current of 10A or 5A. In comparison to the previous fast acting rectifiers, the new module is characterised by its higher performance and also by a larger input voltage range of 18-30 VDC or 42-54 VDC and a controlled output voltage at reduction. In addition, a higher cycle frequency is possible. The module ROBA®-brake-checker reliably detects when the brake condition changes; i.e. whether the armature disk has been attracted or released. The module emits the respective switching condition of the brake via a signal output. With the ROBA®-brake-checker, the switching condition of safety brakes can therefore be recorded in machines and systems even without the usual microswitches or proximity sensors.

Fig 1: The module ROBA®-brake-checker not only energises brakes, but also monitors them without the use of sensors. This opens up new possibilities for the monitoring of safety brakes.

Fig 2: The targeted braking torque control is carried out using the new module ROBA®-torqcontrol. The device can be operated with 24V or 48V DC voltage, and is able to control brakes with the coil nominal voltage of 10A or 5A.

Fig 3: Using the new, intelligent module ROBA®-torqcontrol, mayr® power transmission provides an economically attractive possibility to generate a variable braking torque on ROBA®-stop safety brakes.

The module functions highly reliably without mechanical contacts and is wear-free, independent of the cycle frequency and count. The additional wiring and possible sealing of switches and sensors is therefore no longer required. In addition, it is possible with the sensorless condition monitoring to adapt the overexcitation time automatically if required. Here an integrated automatic system regulates the voltage to the set lowering voltage after a brake-specific overexcitation time. Using a DIP switch, the automatic system can be switched off, after which it is possible to set certain, specified values manually.

Detect errors before they occur
Through the comparison of tightening current and holding current, the module ROBA®-brake-checker is able to detect a possible wear reserve or line breakage, or, if applicable, to detect unpermitted heat-up. In this way it can reveal safety-critical conditions and errors prior to their occurrence, and thus guarantee maximum operational safety for machines and systems. The new monitoring module can be used for a wide range of ROBA-stop® brakes, and can be easily, quickly and inexpensively integrated, also into existing systems. With its compact dimensions of 30 mm in height, 69 mm in width and 73.6 mm in length, it can easily be integrated into control cabinets.

Braking movements with intelligent systems
For applications which require braking torque control in addition to condition monitoring, mayr® power transmission provides the braking torque control module ROBA®-torqcontrol. It features the properties of the ROBA®-brake-checker, and is additionally able to change the level of braking torque during operation through the targeted influencing of current and voltage. In this way, devices and machines can be evenly and gently decelerated. The module ROBA®-torqcontrol allows control circuits to be constructed and movements to be braked intelligently - ideal prerequisites for use in smart, networked machines.

The targeted braking torque control is carried out using the new module ROBA®-torqcontrol. The device can be operated with 24V or 48V DC voltage, and is able to control brakes with the coil nominal voltage of 10A or 5A.

Using the new, intelligent module ROBA®-torqcontrol, mayr® power transmission provides an economically attractive possibility to generate a variable braking torque on ROBA®-stop safety brakes.

For further information, view website: www.mayr.co.uk or e-mail: andrew@mayr.co.uk 
Refer to page 424

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