Everything under control
Everything under control MOTION AND DRIVES The intelligent ROBA-brake-checker module by mayr power transmission is able to monitor and supply safety brakes without the use of sensors. It is delivered ready to install and can easily be integrated even into existing systems. For users, this means fewer components, maximum reliability and easy commissioning without additional effort. For decades now, brakes by mayr power transmission have safeguarded machine movements of this world. In the era of Industry 4.0, the technology and market leader for electromagnetic brakes is the only company to have an intelligent solution for the sensorless monitoring of electromagnetic brakes in its standard portfolio with its ROBA-brake-checker. “Users can integrate the module easily and quickly into machines and systems, without having to intervene with the ‘converter’ or ‘control’ components”, explains Andreas Merz, Product Manager at mayr® power transmission in Mauerstetten. “In this way they don’t take any risks as they don’t have to validate limit values and data themselves. We supply the ROBA®-brake-checker ready for installation and test all values beforehand. For users, this means a plug-and-play solution, so to speak.” New designs and brake sizes The ROBA-brake-checker module is now also available in an alternating voltage design. In an extended configuration level, the mod- 18 WORLD OF INDUSTRIES 3/2019
01 The intelligent ROBA-brake-checker module is able to monitor and supply safety brakes without the use of sensors 03 When monitoring using the ROBA-brake-checker, brakes in standard design are used. This not only holds advantages with regard to costs and delivery times, but also for example with regard to corrosion protection 02 The ROBA-brake-checker module is now also available in a design for AC voltage ule simultaneously also takes over control of the brake, thus replacing a rectifier. The switching condition monitoring and brake control are therefore combined in one device, and users do not need to procure additional components. In addition, small brake sizes from a braking torque of 0.7 Nm can now also be supplied and monitored using the ROBA-brake-checker. Sensorless brake monitoring The intelligent ROBA-brake-checker module works without the use of sensors. Instead, it detects the movements of the armature disk by analysing voltage and current, and knows what condition the brake is in at all times. In addition to switching condition, temperature and wear, it also monitors the tension path or tensile force reserve, i.e. whether the magnet is still able to attract the armature disk. With the new module, substantially more processes can therefore be depicted during monitoring than when using microswitches and proximity switches. On reaching the tensile force reserve, the ROBA-brake-checker emits a warning signal early enough so that a certain operating time is still possible for the brake. During this time, the system operator or manufacturer can undertake maintenance in a targeted manner, aligned to their own working process. Increased system availability The ROBA-brake-checker works without mechanical contacts with high reliability and wear-free, independently of the cycle frequency. “As the module works without sensors, i.e. no microswitch or proximity sensor has to be attached to the outside of the brake for monitoring of the switching condition, basic construction safety brakes can also be used”, adds Mr. Merz. “In addition, the extra wiring and any sealing of switches and sensors which may be required dependent on the aspired level of protection are no longer necessary. The risk of cable breakage is also excluded.” In contrast to solutions with switches and sensors, which are exposed to impacts and vibrations due to their installation situation, the monitoring process with the ROBA-brake-checker is carried out from the control cabinet, i.e. from a protected environment. Failures due to icing up and error signals caused by contamination such as friction dust are thus ruled out. Due to the electrical switching of the ROBA-brakechecker module in the DC version, the system availability can also be increased, as critical sparks can no longer form on the switching contactor, which in conventional wiring may lead to contact consumption. Reliable monitoring even in adverse conditions “The fact that brakes in standard design are used for monitoring with the ROBA®-brake-checker not only offers advantages in terms of costs and delivery time, but also for example with regard to corrosion protection”, Merz emphasises. “This is because the brakes can be painted over easily, quickly and safely – for example, if the corrosion risk is very high and protective measures are required in compliance with the DIN EN ISO 12944 standard Protective Measures (C5), for example on wind power plants or on applications in the maritime sector. In general, the ROBA-brakechecker represents a cost-effective solution, especially for small quantities, and even existing systems can be retrofitted without any problems.” Photographs: mayr power transmission www.mayr.com WORLD OF OF INDUSTRIES 3/2019 19
