Innovative brake solutions for complex drive trains – from conception to implementation
What is meant by a distributed brake system for multi-axis automation?
A distributed brake system is a decentralized safety concept, where braking functions are implemented and coordinated directly at the individual axes of a machine or system. Instead of a central brake, multiple interconnected intelligent brake modules, which particularly leads to higher precision and fault tolerance .
What are the main advantages of distributed brake systems?
The main advantages are increased safety through redundancy, as the failure of a single brake does not shut down the entire system. They also enable improved machine dynamics and precision through axis-specific brake force control. Their modularity allows for high flexibility and scalability for adjustments and expansions.
How do distributed brake systems contribute to safety, especially on vertical axes?
Distributed systems significantly increase safety by enabling redundant brake concepts. On vertical axes, where loads must be held against gravity, for example, ermöglichen. An Vertikalachsen, wo Lasten gegen die Schwerkraft gehalten werden müssen, können beispielsweise multiple independent safety brakes (e.g. motor holding brake plus external spring pressure brake) can be used. If one brake fails, the others can safely hold or control the load, in compliance with regulations such as the DGUV.
Can distributed brake systems also be integrated into existing systems (retrofit)?
Yes, retrofitting is often possible. It requires a careful analysis of the existing mechanics, drives, and control. Companies like ATEK Drive Solutions offer support in planning and selecting suitable components, to ensure optimal integration and functionality.
What role do sensors and communication protocols play in these systems?
Sensors (e.g. torque, speed, position sensors) provide precise data for intelligent control of braking processes and condition monitoring. Fast and reliable communication protocols such as EtherCAT or PROFINET IRT are crucial for the real-time synchronization of the brake modules and secure data transmission to the higher-level control.
What is condition monitoring in the context of distributed brake systems, and what benefits does it bring?
Condition monitoring continuously monitors the state of the brake components using integrated sensors and intelligent algorithms. It allows for the early detection of wear or potential malfunctions. This leads to predictive maintenance, reduces unplanned downtime, and can significantly lower maintenance costs (e.g. by up to 25%).
Are there specific brake types recommended for distributed systems?
The choice of brake type (e.g. electric spring pressure brakes, permanent magnet brakes, hydraulic or pneumatic brakes) heavily depends on the specific requirements of the respective axis – such as holding function, dynamic braking, or emergency stop. Often, combinations of different types are used to optimize safety and performance. ATEK Drive Solutions offers a wide range of brakes and supports the application-specific selection..
What future developments can be expected in distributed brake systems?
Trends are moving towards increased use of artificial intelligence (AI) for adaptive, self-optimizing braking strategies and more precise predictive maintenance. Digital twins are being used for simulation and optimization before commissioning. In addition, energy efficiency through recuperation and optimized actuation as well as integration into comprehensive Industry 4.0 concepts are the focus.
Distributed brake systems increase safety through redundancy und enhance efficiency in multi-axis automation, by reducing the mechanical stress by up to 15% und and can shorten cycle times by up to 10%. Intelligent functions like
Intelligente Funktionen wie condition monitoring enable maintenance cost reduction of up to 25%, while optimized system integration and precise control shorten commissioning times by about 15%. Future innovations such as AI and digital twins promise further optimizations, such as a Intelligent functions like
Zukünftige Innovationen wie KI und digitale Zwillinge versprechen weitere Optimierungen, etwa eine extension of brake pad lifespan by up to 20% and a reduction in development costs by up to 30%, with ATEK Drive Solutions as a system supplier actively shaping these developments.Learn how distributed brake systems are revolutionizing safety and efficiency in multi-axis automation. Discover the advantages, application areas, and latest technologies.
Multi-axis automation places high demands on safety and precision. Distributed brake systems offer innovative solutions here. Would you like to learn more about the optimal braking solution for your application? Contact us now with our experts!
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Understanding the basics: What is a distributed brake system for multi-axis automation?
The core idea: intelligence instead of centralization
Ein a distributed brake system is a networked safety concept where each axis reacts independently. Unlike central systems, such decentralized brake concepts, for example in 6-axis robots in the multi-axis automation, allow for more precise, fault-safe reactions. Modern safety brakes are key elements.
More than redundancy: coordinated brake force
Decentralization works through coordinated brake task distribution, often via EtherCAT. This allows for finer brake torque tuning and optimized overall system response. Handling applications can thus reduce mechanical stress by up to 15%. It is important to integrate the drive systems.
Differences from traditional approaches
Traditional single brakes are risky in case of failure. Distributed brake systems for multi-axis automation offer higher safety and flexibility through decentralization and brake type combinations. Example: The combination of motor holding brakes with external safety brakes increases fault tolerance in accordance with DGUV.Leverage the decisive advantages: redefine safety and efficiency
Maximum safety through intelligent redundancy
Distributed brake systems enable redundancy: other parts compensate for failures or secure shutdown. In case of multiple brakes on vertical axes (e.g. mayr® solutions for lifting axes), intact brakes compensate for a failure, increasing safety. See multi-axis automation kompensieren intakte Bremsen einen Ausfall, was die Sicherheit erhöht. Siehe Safety brakes for vertical axes..
Increase productivity: improved machine dynamics and precision
Precise brake force distribution through a distributed brake system enables more dynamic processes and more accurate positioning in multi-axis automation, shortening cycle times. A packaging machine can reduce cycle times by up to 10% as axes decelerate optimally. Beneficial in robotics and automation..
Ensure adaptability: flexibility and scalability
The modularity of distributed brake systems allows for adjustments to new tasks or axis expansions in multi-axis automation without a concept overhaul. A manufacturing line can be expanded with new modules and software adjustments, shortening changeover times by up to 30%. ATEK Drive Solutions offers customized drive system integration..Understanding technology in detail: cleverly applying components and functionality
Selecting suitable brake types: electric, mechanical, or combined?
The selection of brake types for a distributed brake system in multi-axis automation is based on axis requirements – from dynamically electric to mechanical safety brakes. Servo applications often use electric spring pressure brakes; static holding functions also employ mechanical solutions. ATEK offers electronic brake systems..
- Demand-oriented brake selection: The choice of brake type (electric, mechanical, combined) is based on the specific requirements of the respective axis in a decentralized brake concept..
- Specific brake applications: Frequent use of electric spring pressure brakes in servo applications and mechanical solutions for static holding functions, relevant for the multi-axis automation.
- Central role of control: Intelligent controls (PLCs, industrial PCs) coordinate all braking processes and evaluate sensor data – the heart of a distributed brake system..
- Precision through sensors: Torque sensors and encoders enable precise dosing and monitoring of braking force, crucial for performance in the multi-axis automation.
- Improved reaction times: Precise sensors can significantly shorten emergency reaction times (e.g. by up to 50ms), an advantage of such intelligent brake systems..
- Reliable communication: Industry protocols such as EtherCAT or PROFINET IRT ensure secure and fast data transmission, fundamental for networked safety concepts..
- System synchronization: Fast protocols (e.g. EtherCAT with sub-millisecond cycles) are crucial for synchronization in complex multi-axis systems and for collision avoidance.
Utilizing intelligent control and sensors: the brain of the system
Controls (PLCs, industrial PCs) coordinate brake processes in a distributed brake system and evaluate sensor data for safety and functionality. Torque sensors/encoders enable precise dosing and monitoring of braking force, which can improve emergency reaction times by up to 50ms. The digital interface of servomotors is important..
Mastering communication protocols: the nervous system of the system
Industry protocols (EtherCAT, PROFINET IRT) ensure data transmission between control, sensors, and actuators in a distributed brake system for multi-axis automation. EtherCAT enables sub-millisecond cycle times for synchronization in multi-axis systems (>16 axes) to prevent collisions. Part of the modern drive system integration..Mastering implementation: ensuring integration and intelligent monitoring
Retrofit or new system: choosing the right strategy
Integrating a distributed brake system requires a detailed analysis of mechanics and control for retrofits; for new systems in multi-axis automation, interfaces can be optimized. Example: Retrofitting a gantry robot system with external safety brakes increased personnel safety (ISO 13849-1, PL d). ATEK assists in the selection of suitable brakes.
Act proactively: Condition Monitoring and Predictive Maintenance
Integrated sensors and algorithms in a distributed brake system enable Condition Monitoring for early detection of wear or malfunctions. The ROBA®-brake-checker system (mayr®) monitors condition/wear sensorlessly for predictive maintenance, reducing costs by up to 25%. Supports Industry 4.0 brakes.
Seamless system integration: The whole is more than the sum of its parts
A successful implementation of a distributed brake system for multi-axis automation requires coordination of the brake system, drives, control, and the overall safety architecture. ATEK ensures that components work together, which can reduce commissioning times by about 15%. Part of our philosophy of drive system integration.Shaping the future: Actively utilizing trends and innovations in distributed brake systems
Incorporating artificial intelligence (AI): Adaptive and self-optimizing brake systems
AI algorithms allow distributed brake systems to learn from operational data, dynamically adjust braking processes, and accurately predict maintenance needs. Systems can optimize braking ramps (load/speed) for safety and wear reduction (brake pad lifetime +20%). Basis: digital control of brakes.
- Adaptive systems through AI: Utilization of AI algorithms so that distributed brake systems can learn from operational data, dynamically adjust braking processes, and predict maintenance needs.
- Optimization and wear reduction: AI-supported systems can optimize braking ramps depending on load and speed, which increases safety in multi-axis automation and can extend the lifespan of brake pads by up to 20%.
- Simulation with digital twins: Use of digital models to simulate the system behavior of decentralized brake concepts, which shortens development times and minimizes risks during commissioning.
- Pre-optimization and cost reduction: Digital twins enable the analysis and optimization of the interaction of components in complex scenarios of multi-axis automation, which can reduce development costs by up to 30%.
- Increase of energy efficiency: Focus on the use of energy-efficient components and intelligent control in distributed brake systems.
- Brake energy recovery: Implementation of systems that recuperate brake energy and make it reusable, an important aspect of modern brake systems for multi-axis automation.
- Minimization of energy consumption: Reduction of holding energy, for example, by servo motors with brakes that are powered only for ventilation, which can lower the energy requirement of the axis in multi-axis automation systems by up to 10%.
Use digital twins: Simulation and optimization before commissioning
Digital twins simulate the behavior of distributed brake systems, shorten development time, and minimize risks during commissioning in multi-axis automation. ATEK can analyze/optimize the interaction of components in multi-axis scenarios in advance, which reduces development costs by up to 30%. Expertise in drive system integration.
Increase energy efficiency: Sustainability in focus
Modern distributed brake systems utilize efficient components and controls, recuperate brake energy, and minimize holding energy in multi-axis automation applications. Servo motors with brakes, powered only for ventilation, reduce axis energy requirements by up to 10%. ATEK offers efficient servo motors.
