How innovative braking technologies make your robotics safer and more efficient – including predictive maintenance
What is a remote-controlled safety brake and why is it crucial for modern industrial plants?
A remote-controlled safety brake enables the immediate stopping of industrial robots from a distance. This is crucial to protect personnel, avoid costly collisions and maximize the safety in dynamic production environments, especially in human-robot collaboration (HRC).
How does the fail-safe principle ensure the reliability of these brakes?
The fail-safe principle ensures that the brake automatically transitions to a safe, braked state during power failure or signal interruption. Spring-applied brakes, such as those offered by ATEK Drive Solutions, use pre-tensioned springs to generate braking force and require energy to release – a key feature for maximum operational safety.
What role do communication protocols play in the remote control of safety brakes?
For reliable activation, robust communication protocols such as PROFINET Safety or EtherCAT FSoE are essential. These ensure a high signal integrity and fast response times, which is critical for safety. The choice depends on the existing infrastructure and the specific requirements of the facility ab.
In which areas do remote-controlled safety brakes provide the greatest benefit?
They are particularly valuable in collaborative robotics (cobots), in handling heavy loads e.g., automotive industry, in complex manufacturing lines and wherever a fast, remote-controlled emergency stop increases safety and productivity. ATEK Drive Solutions offers solutions for various industries, from mechanical engineering to medical technology.
What advantages do these braking systems offer beyond mere safety functionality?
In addition to the significant increase in facility safety , intelligent remote-controlled braking systems enable condition monitoring and predictive maintenance resulting in a reduction of unplanned downtimes by up to 70%. This leads to increased efficiency and productivity.
What are the main criteria for selecting a remote-controlled safety brake?
Important criteria include the required static and dynamic braking torque, the response time of the overall system, the suitability for environmental conditions e.g., IP protection class, the compatibility with control systems and maximize the compliance with relevant safety standards such as ISO 13849.
How is cybersecurity ensured in remote-controlled braking systems?
Securing remote control against unauthorized access is critical. Measures include the use of VPN connections, firewalls, intrusion detection systems and adherence to standards such as IEC 62443. This protects the integrity of the safety function..
Can remote-controlled safety brakes be easily integrated into existing robotic systems?
Yes, modern systems are often designed for easy integration. Standardized interfaces, compatibility with common PLCs and communication protocols, as well as. Standardisierte Schnittstellen, Kompatibilität mit gängigen SPS und Kommunikationsprotokollen sowie configuration software facilitate implementation.ATEK Drive Solutions supports customers in design and integration..
Remote-controlled safety brakes significantly increase facility safety, allowing for fast, remote-controlled stopping of industrial robots and often based on a fail-safe principle. This can reduce safety-related incidents by up to 25%..
Intelligent remote-controlled braking systems provide operational advantages beyond safety , such asreducing unplanned downtimes by up to 70% Reduktion ungeplanter Stillstände um bis zu 70 % through predictive maintenance and condition monitoring, which improves the overall equipment effectiveness..
The correct selection, based on braking torque, response time and environmental conditions, as well as the safe integration and adherence to standards (e.g., ISO 13849) and cybersecurity measures are crucial for the reliability and benefit of remote-controlled safety brakes.Learn how remote-controlled safety brakes are revolutionizing the safety of industrial robots while increasing productivity. Discover the latest technologies and application areas.
Industrial robots are indispensable in modern production facilities. But safety is the top priority. Remote-controlled safety brakes provide an innovative solution. Want to learn more about custom drive solutions? Contact us at ATEK Drive Solutions..
Do you need a custom safety brake solution for your industrial robots?
Get a free consultation now!
Revolutionizing robot safety: Understanding the need for remote-controlled brakes.
A remote-controlled safety brake for industrial robots provides an additional layer of safety, allowing operators to stop machines from a distance. Such remote-controlled safety systems are crucial during unforeseen events or to avoid costly collisions, especially in large facilities.
For human-robot collaboration (HRC), where humans and machines work closely together, such systems are also relevant. A quick, remotely activatable stop function is central. A worker can therefore stop the robot using a remote control in case of danger. The response time of the overall system, including signal transmission and brake activation, is a critical factor and should not exceed a few hundred milliseconds.
Standards like ISO 13849 define requirements for functional safety. Safety functions, including emergency stop systems, often need to achieve a certain performance level (PL). The correct design and implementation of such a remote-controlled safety solution is crucial for compliance and safe operation. ATEK Drive Solutions supports the selection of standards-compliant safety brakes..Securing precision in critical situations: Deciphering the operation of modern braking systems.
Many safety brakes utilize the fail-safe principle: In case of power failure or signal interruption, the brake automatically transitions to the braked state. Spring-applied brakes fulfill this criterion as they generate braking force through pre-tensioned springs and require energy to release. For example, they keep a vertical axis with a load of 300 kg even in the event of the robot’s power failure. Our industrial brakes are based on this principle.
The remote-controlled activation of such braking mechanisms requires reliable communication. Modern systems use robust, often redundant transmission paths, such as wired solutions with fail-safe protocols (e.g., PROFINET Safety, EtherCAT FSoE). These protocols ensure high signal integrity (often >99.999%). The choice of communication protocol depends on the infrastructure and requirements. An electronic braking system integrates this logic.
Ein Remote-controlled braking system includes brake unit, control, sensors for status monitoring, and communication interface. The redundant design of critical components, common in SIL 2 systems, minimizes the risk of failure.Dual sensor technology can monitor the braking state and alert in case of deviations.Maximizing deployment potentials: Utilizing remote-controlled brakes across industries.
In collaborative robotics (cobots), remote-controlled safety brakes enable new application scenarios. If an employee unexpectedly enters the work area of a cobot, neue Einsatzszenarien. Betritt ein Mitarbeiter unerwartet den Arbeitsbereich eines Cobots, it can be stopped within milliseconds by a quickly responding, remotely activatable brake., often before a collision occurs. This enhances safety without compromising the flexibility of HRC. Many robotics applications benefit from these advanced remote safety brakes.
- Increasing safety in human-robot collaboration (HRC) through quickly responding remote brakes.
- Enabling new application scenarios for cobots through flexible and safe stop functions.
- Reliable securing of heavy loads against uncontrolled descent during emergency stops, e.g., in the automotive industry.
- Adaptability to specific industry requirements such as hygiene standards in food production.
- Ensuring robust and reliable braking functions even in harsh industrial environments like foundries.
- Protecting personnel and facilities through cross-industry applications of remote-controlled brakes.
These systems are also useful in handling heavy loads, such as in the automotive industry or mechanical engineering. Robots that move heavy body parts require brakes with high holding torque. A remote-controlled emergency stop function, a core feature of the remote-controlled safety brake for industrial robots, secures the load against uncontrolled descent during unforeseen stops. A special flange brake for robot axes can be a solution.
Special applications can be found, for example, in food production, where hygienic, easy-to-clean components (stainless steel design, IP69K) are required. Even in harsh environments like foundries, robust braking solutions ensure reliable function and protect personnel and equipment. ATEK Drive Solutions also offers gear boxes in hygienic design for this purpose.Generating added value: Achieving superior safety and efficiency through intelligent brakes.
A main advantage is the increased safety. The ability to remotely control robots and quickly stop them using a reliable remote-controlled brake reduces the consequences of accidents. Companies report up to 25% fewer safety-related incidents after implementing such systems.. A modern digitally controlled brake contributes to this.
Another advantage is the reduction of downtimes through predictive maintenance. Intelligent braking systems with sensors monitor their condition (e.g., brake material wear, temperature). This data enables early maintenance planning and can reduce unplanned downtimes by up to 70%. An Servo motor with integrated safety brake can provide such functions.
Compliance with standards (ISO 13849, IEC 62061) is required for safe operation. Cybersecurity is also important. Measures such as VPNs, firewalls, and intrusion detection systems are necessary to safeguard the integrity of the remote control of such safety systems. zu sichern and to prevent manipulations. Cyberattacks incur high costs in the industry every year.Implement securely for the future: select and integrate the optimal brake solution.
When selecting a remotely controlled safety brake , several factors must be considered, such as the required braking torque. In addition to the static holding torque, dynamic braking work in emergencies is an important criterion.. A robotic arm (2m reach, 50kg payload) requires at least 1000 Nm braking torque, for example. An energy-efficient brake reduces operating costs.
- Careful selection based on critical parameters such as braking torque and dynamic braking work.
- Consideration of the static holding torque to secure loads at rest.
- Simplified integration into existing systems through standardized interfaces and communication protocols.
- Reduction of implementation effort through suitable configuration software and tested PLC compatibility.
- Focus on maintenance friendliness, including easy replacement of wear parts and long-term support.
- Ensuring future viability through modular and upgradeable brake systems for long-term economic efficiency.
Integration into existing controls requires planning. Standardized interfaces and protocols (EtherNet/IP, CANopen Safety) facilitate integration of systems such as a remote-controlled safety brake for industrial robots. Configuration software can reduce effort by up to 30%. PLC compatibility (e.g., Siemens, Rockwell) must be checked. For complex systems, a distributed braking system can be sensible.
Maintenance and future viability are also relevant. Easy replacement of wear parts and long-term support are important. Modular braking systems, especially those for remote control, with easy maintenance and upgrade options are often more economical. A system for 5s cycle time can later be optimized for 3s, ensuring adaptability.
