Monitoring and controlling brakes intelligently using new modules

5th July 2018
Posted By : Alex Lynn
Monitoring and controlling brakes intelligently using new modules

The safety brakes by mayr power transmission are equipped for the challenges of the Industry 4.0. The coordinated system aims for the utmost level of operational and functional safety, as well as increasing the productivity of machines and systems through predictive error detection and maintenance.

Brake technology 4.0 stands for intelligent monitoring modules, the modules such as the ROBA brake-checker and the ROBA torqcontrol monitor safety brakes easily and quickly to facilitate the even and smooth deceleration of machines and devices.

Permanent brake monitoring and predictive maintenance

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.

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.

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.

Braking movements gently and in a controlled manner

For applications which require braking torque control in addition to 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 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 a well suited basis for its use in smart, interconnected machines.

Reliable brake control 

Another module to continuously monitor the switching condition of the brakes is the safe brake control ROBA SBC plus. In this module, mayr power transmission offers safety brakes and safe brake control in a complete package. 

This module has been developed in collaboration with the company Pilz, especially for applications which have to fulfil requirements for the protection of people according to standards regarding functional safety. 

The ROBA SBC plus 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 semiconductors, and as a result achieves practically unlimited switching frequency and switching reliability. 

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. Which in turn permits creep errors which influence on the switching times, for example increasing wear, to be detected in due time. 

The reliable ROBA SBC plus brake control unit is type certified by TÜV Süd (Technical Inspectorate, Southern Germany) and can be used up to the highest Performance Level PLe and Safety Integrity Level (SIL) 3.


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Advanced Engineering 2020
4th November 2020
United Kingdom NEC, Birmingham