Precise Control for Highest Demands: Servo Drives with Brake and Encoder Feedback

Maximum performance and safety in your drive systems – thanks to the intelligent combination of brake and encoder.

What are the main advantages of a brake with encoder feedback for servo drives?

The combination allows highest precision in positioning and motion control as well as reliable holding of loads, especially with vertical axes or in emergency stops. This leads to improved product quality und increased machine safety.

When is an absolute encoder preferable to an incremental encoder in servo applications?

Ein Absolute encoder is preferred, when the position information must be retained even after a power failure, to avoid reference runs. This is typical for CNC machines or complex robotics applications, where rapid re-commissioning is crucial. ATEK often recommends encoders with ≥17 bit resolution for high precision.

What advantages do integrated servo drive systems (motor, encoder, brake in one unit) offer?

Integrated systems, like the SOMANET Circulo, significantly reduce the required installation space (up to 60%), simplify wiring and installation, and can reduce overall costs. They provide a compact and powerful solution for servo drives with brake and encoder feedback.

What safety functions do servo drives with brakes and encoder feedback typically support?

Modern systems support certified safety functions such as STO (Safe Torque Off) und SBC (Safe Brake Control), often up to SIL3/PL-e. These are essential for human-robot collaborations (HRC) and ensure compliance with standards such as ISO/TS 15066.

How does ATEK Drive Solutions assist in selecting and configuring such drive systems?

ATEK offers comprehensive technical consulting as a system provider and uses a modular system design, to configure custom solutions. Our expertise helps to find the optimal system for your specific needs for brakes with encoder feedback for servo drives and to shorten the commissioning time by up to 30%.

What impact does the encoder resolution have on system performance?

The encoder resolution (e.g. 17-bit, 20-bit) determines the fineness of position detection. A higher resolution enables a more precise control of the servo drive, resulting in more accurate movements and better surface quality in machining machines.

Are there specific requirements for wiring servo motors with brake and encoder?

Yes, the correct cable selection is important. For dynamic applications, cable suitable for drag chains is required. Depending on the plug type (e.g. HFO, 4-PIN), integrated or separate brake cables are necessary. ATEK advises you in choosing the suitable wiring.

How can predictive maintenance be implemented for servo drives with brakes and encoders?

By analyzing operational data such as encoder error codes, vibration patterns, or brake current curves , algorithms can predict wear. This enables a demand-based maintenance, can increase machine availability by up to 10% and reduce downtime.

The combination of brake and encoder feedback in servo drives is fundamental for maximum precision and safety in industrial applications, which can result in a positioning accuracy of ±0.5 mm .

Integrated systems that combine motor, encoder, and brake provide significant advantages through reduced installation space (up to 60%) und simplified installation, contributing to lower system costs .

The correct selection and configuration, supported by expert knowledge like that of ATEK Drive Solutions, is crucial to fully exploit the full performance potential, meet safety standards and commissioning time by up to 30%.Learn how to optimize your machine performance with the integration of brakes and encoders in servo drives, increase safety, and benefit from precise control options.

Servo drives with brake and encoder feedback are essential for demanding applications. They offer maximum precision and safety. Discover the advantages and find the optimal solution for your requirements. Do you need individual consulting? Contact us at ATEK Drive Solutions.

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Introduction to brakes with encoder feedback for servo drives

The necessity of precise feedback and safe holding

In packaging technology, accurate position feedback and reliable holding brakes are essential to avoid errors and downtimes. Such systems, often realized as brake with encoder feedback for servo drives , are crucial. ATEK Drive Solutions offers integrated solutions for this, such as integrated encoder motors.

Synergy for performance and safety

Servo drives achieve maximum precision and safety, for example, when holding loads over 100 kg, through the precise coordination of motor, encoder, and brake. This combination, often referred to as a system with brake and encoder feedback for servo drives , allows safe utilization of performance limits. High torque servo motors with encoders are particularly suitable for this.

Cornerstones of modern automation

Short manufacturing cycles in modern automation require absolutely reliable drives. A precise brake with encoder feedback for servo drives enables dynamic and safe movements, as required in robotic gripper arms, for example. For further information, see: sensor-monitored brakes for condition monitoring.Fundamentals of encoder technology in servo drives

Encoder types: Incremental vs. Absolute – A matter of application

Absolute encoders offer the crucial advantage that they retain their position information (e.g. in CNC machines) even during a power failure. This allows for immediate operation without a reference run – a clear advantage over incremental types. Modern 20-bit absolute encoders deliver over a million positions per revolution, which is significant for the encoder feedback in servo drives is of great importance. Precise gear motors with encoder utilize this technology.

• Encoder types: The choice between incremental and absolute encoders depends on the specific requirements of the application.
• Advantages of absolute encoders: They retain the position even during a power failure, allowing for immediate restart without a reference run – a clear advantage over incremental variants.
• High resolution for precision: Modern absolute encoders, such as 20-bit models, can capture over a million discrete positions per motor revolution.
• Accuracy factor resolution: The resolution of the encoder, specified in bits or pulses per revolution, is crucial for the overall accuracy of the drive system.
• Finer gradation through sin/cos encoders: This type of encoder allows an even finer resolution and thus more precise position detection through interpolation of the analog signals.
• Importance of communication protocols: Protocols such as EtherCAT, BiSS or EnDat are essential for fast and reliable data transmission between the encoder and servo amplifier.
• Minimal latency for control loops: A low delay in data transmission is critical for the performance and stability of the control loops.
• Tuning of protocol and control: The choice of communication protocol must be compatible with the deployed control hardware (e.g. Kinco FD423 with EtherCAT).

Functionality and resolution: The eye of the drive

The resolution of the encoder, specified in bits or pulses per revolution, is crucial for the accuracy of the entire drive system, especially in servo drives with precise encoder feedback. Sin/cos encoders allow for even finer gradations through interpolation of the analog signals. Many applications rely on encoders with ≥17 bit resolution. Flange gear motors with brake and encoder offer a variety of options here.

Communication protocols: The language of precision

A fast and reliable data transmission from the encoder to the servo amplifier is crucial for the performance of servo drives with encoder feedback is essential. Communication protocols such as EtherCAT, BiSS, or EnDat ensure minimal latency, which is crucial for the stability of the control loops. The choice of protocol must fit the control used (e.g. Kinco FD423 with EtherCAT). Servo motors with digital interfaces are well suited for this.Integration of brakes in servo drives

Types of brakes: More than just stopping

Not every brake in servo drives is designed for dynamic emergency stops. Many function merely as holding brakes, while working brakes are designed to absorb kinetic energy (e.g. 50 joules per cycle). ATEK Drive Solutions offers suitable solutions for the various requirements of brakes for servo drives . Energy-efficient disc brakes represent an interesting option.

Functionality and selection criteria: Making the right choice

In medical technology, for example, there may be special requirements for brakes for servo drives such as a holding torque of 3 Nm and the fulfillment of strict hygiene standards. Important selection criteria include the required holding torque, expected switching cycles, environmental conditions (e.g. protection class IP65) and operating voltage (often 24V DC). Stainless steel brakes are often a suitable solution here, which can also benefit from play-free planetary gears .

Drive control and monitoring: Control is better

Modern servo controllers (like the SOMANET Circulo) not only enable precise control of the brake in the servo drive, but also their condition monitoring using current measurement or additional sensors. This can increase plant availability by up to 15%. In this context, digital servo motors with predictive maintenance are also relevant.Applications and advantages of servo drives with brake and encoder feedback

Typical applications: Where precision and safety matter

Filling systems that require a positioning accuracy of ±0.5 mm at cycle rates of 120 bottles per minute typically rely on servo drives with brake and encoder feedback. Such systems are also essential in robotics for precise tool guidance and in machine tools. An example of this is the Bosch SE-B2040060-14000.

1. Filling systems: Ensuring highest positioning accuracy (e.g. ±0.5 mm) at high cycle rates (e.g. 120 bottles/minute) through systems with brake and encoder feedback.
2. Robotics: Precise guidance of tools and grippers in complex movements, secured by reliable brake and encoder systems in servo drives.
3. Machine tools: Precise control of axes for high-quality machining results, based on accurate encoder feedback and holding brakes.
4. Optimized positioning: The synergy of encoder feedback for control and brake for secure holding leads to superior accuracy.
5. Protection against load drop: Especially in vertical axes or in case of failure, the brake in the servo drive prevents uncontrolled movements.
6. Increased product quality and plant safety: Resulting from precise movements and reliable holding due to the combination of brake and encoder.
7. Potential for energy savings: The brake can hold loads, relieving the motor and saving energy, an advantage of servo drives with holding brake.
8. Implementation of certified safety functions: Necessary for human-robot collaborations (HRC) according to standards such as ISO/TS 15066, supported by precise encoder feedback and reliable brake functions like STO/SBC (e.g. in the SOMANET Circulo).

Benefits of the combination: More than the sum of the parts

The combination of precise encoder feedback for control and a reliable brake for secure holding in servo drives significantly improves positioning accuracy, reduces the risk of load drop, and thus increases product quality and plant safety. Energy savings are also possible as the brake can hold the load and relieve the motor.

Safety aspects and standards: Trust is good, certified safety is better

Especially in human-robot collaborations (HRC), certified safety functions (up to SIL3/PL-e), such as STO (Safe Torque Off) and SBC (Safe Brake Control), realized through reliable encoder feedback and safe brake control (e.g. in the SOMANET Circulo) are crucial. This supports compliance with relevant standards like ISO/TS 15066 and is a core aspect of systems with brake and encoder feedback for servo drives.Selection and configuration of servo drives with brake and encoder feedback

Criteria for selection: Finding the right system

When selecting servo drives with integrated brake and encoder feedback for vertical axes (e.g. 50 kg load, 1 m/s speed), factors such as load profile, dynamic requirements, environmental conditions, required precision (often realized by 17-bit encoders or higher) and the budget must be considered. ATEK’s modular system offers flexible configuration options. An often overlooked but important aspect is the selection of suitable cables, especially drag chain compatible variants.

Configuration and parameterization: Fine-tuning counts

Special software tools (like the Kinco software) simplify adjusting control parameters, selecting the correct encoder type, and configuring the brake control in the servo drive. This can shorten the commissioning time by up to 30%. Correct parameterization is crucial to fully utilize the servo drives with brake and encoder feedback .

Integration into existing systems: Seamless and efficient

Modern servo drives equipped with brake and encoder feedback, must be able to communicate seamlessly with higher-level controls (e.g., Siemens S7). The selection of suitable field buses (such as Profinet with the Kinco FD423) and standardized interfaces is crucial for this. Careful planning of the integration can significantly reduce the effort, which often accounts for up to 20% of the project time.Current trends and future developments

Integrated servo drives: Compact and powerful

A clear trend is moving towards integrated servo drives (like the SOMANET Circulo), which combine motor, encoder, brake and all control electronics in a compact unit. Such systems, which represent a complete solution for servo drives with brake and encoder feedback , reduce the required space (by up to 60%), installation time, and costs and significantly simplify the wiring.

• Trend towards integrated servo drives: These systems encapsulate motor, encoder, brake, and power electronics in a single, compact unit – a core component of modern servo drives with brake and encoder feedback.
• Benefits of integration: Significant reduction of required space (up to 60%), lower installation times and costs, as well as significantly simplified wiring.
• Potential of wireless encoders: In the future, wireless encoders could further reduce the complexity of systems with encoder feedback for servo drives and increase flexibility, especially in hard-to-reach or mobile applications.
• Current challenges with wireless technology: Their widespread industrial application is still limited by factors such as robustness against interference and battery life.
• Predictive maintenance through data analysis: The evaluation of operational data from the encoder (e.g. vibrations, error codes) and brake current enables algorithms to predict the wear of brakes and encoders in servo drives .
• Optimized maintenance and increased availability: Predictive maintenance allows demand-oriented service interventions, which can increase plant availability by up to 10%.
• Key component for Industry 4.0: Predictive maintenance is an integral part of modern, connected production environments in the sense of Industry 4.0, often based on data from encoders and brakes in servo drives.

Wireless encoders: Fewer cables, more flexibility

Wireless encoders, although not yet widely established in industrial applications, promise further reductions in system complexity and increased flexibility, especially for servo drives with encoder feedback in hard-to-reach or mobile applications. Current challenges with this technology are still robustness against interference and battery life.

Predictive maintenance: Acting proactively instead of reactively

The analysis of operational data, such as encoder data (e.g. vibrations, error codes) and the current flow of the brake, enables algorithms to predict the wear of components in servo drives . This predictive maintenance optimizes service interventions, can increase plant availability by up to 10%, and is an integral part of Industry 4.0 concepts.

The combination of brake with encoder feedback for servo drives is a fundamental building block for precision and safety in modern automation applications. This technology still holds significant potential for performance improvements and new functionalities. ATEK Drive Solutions is happy to provide detailed consulting and tailored solutions.