Smart braking technology for predictive maintenance, optimized processes, and highest safety in connected production environments.
What is a digitally controlled brake in the context of Industry 4.0?
A digitally controlled brake is a brake component that is precisely controlled via digital signals and provides data on its condition and operation. As part of the Industry 4.0 integration it enables intelligent networking, process optimization, and predictive maintenance.
What specific benefits does the integration of digitally controlled brakes in Industry 4.0 systems offer?
The integration offers increased precision in movements, improved system safety through rapid response times and fail-safe functions, as well as reduced downtime through data-driven, predictive maintenance. This can lead to a decrease in maintenance costs of 10-15% resulting.
How does data generation work with digitally controlled brakes for predictive maintenance?
Many digitally controlled brakes, especially electromagnetic variants, use their integrated coil as a sensor.Changes in magnetic flux or the analysis of current flow during switching provide data on wear (e.g., air gap) and condition, without additional sensors being required.
Can digitally controlled brakes be easily integrated into existing systems and control systems?
Yes, the data generated by the brakes can often be processed by existing inverters or motion controllers. ATEK Drive Solutions also supports with modular evaluation modules for systems without direct controller access, which facilitates the integration and minimizes additional hardware.
What role does data security play in connected, digitally controlled brakes?
Data security is crucial.Robust measures such as encryption (e.g., according to IEC 62443),authentication, and authorization are needed to protect the brake systems and the entire industrial network against cyberattacks, especially in the Industry 4.0 integration.
Are digitally controlled brakes suitable for safety-critical applications?
Absolutely. Many digitally controlled brakes, such as spring-applied brakes or permanent magnet brakes, are fail-safe designed,meaning they fall into a safe, braked state in the event of a power failure. This makes them ideal for safety-critical applications,such as in robotics or vertical axes.
What new business models can emerge from the data generated by digitally controlled brakes?
The captured operating data enables data-based services such as predictive maintenance as a service, performance-based contracts (pay-per-use), or remote monitoring services that strengthen customer loyalty and create new revenue streams for providers like ATEK.
How does ATEK Drive Solutions assist companies in integrating digitally controlled brakes?
ATEK Drive Solutions offers comprehensive consulting as a system provider, supports in the design and optimization of drives, and develops, unterstützt bei der Auslegung und Optimierung von Antrieben und entwickelt custom solutions.With our modular system and expertise in the Industry 4.0 integration we help to fully exploit the advantages of digitally controlled brakes.
Digitally controlled brakes are key components of Industry 4.0,which significantly increase precision and safety through intelligent data utilization and enable predictive maintenance, which can reduce unplanned downtimes by up to 18%. vorausschauende Wartung ermöglichen, was ungeplante Stillstände um bis zu 18 % reduzieren kann.
Die Seamless integration of these brakes into existing systems and cloud platforms minimizes hardware effort, can reduce integration costs by up to 25% and opens up potential for innovative, data-driven services..
As part of data ecosystems like Manufacturing-X, digitally controlled brakes promote the sovereign data exchange,supporting more efficient value chains with potential efficiency increases of up to 10% and enabling the development of new, data-driven business models..Learn how digitally controlled brakes enhance the efficiency and safety of your Industry 4.0 applications. Discover the benefits of predictive maintenance, real-time data analysis, and seamless system integration.
The digital transformation encompasses the entire industrial drive train. Digitally controlled brakes are a key building block for Industry 4.0, opening up new possibilities for process optimization and predictive maintenance. Want to learn more? Contact us now Contact with our experts!
Are you interested in the integration of digitally controlled brakes into your Industry 4.0 environment? Talk to our experts!
Get advice now!
Introduction to digitally controlled brakes for Industry 4.0.
Precision and safety through digital control.
Digitally controlled brakes enable more precise control and improved safety in Industry 4.0-environments. Their seamless integration into connected production processes is a crucial factor for success. For example, modern systems achieve positioning accuracy of less than 0.1 degrees. Digital control offers high accuracy and responsiveness, which enhances product quality.
Predictive maintenance through data analysis.
These intelligent brakes use captured data for performance optimization and prediction of maintenance intervals, which is a key element of the Industry 4.0 integration For example, maintenance needs can be detected four weeks in advance through current flow analysis. Data-based predictions, such as with sensor-monitored brakes for condition monitoring,reduce unplanned downtimes.
Performance optimization and minimization of downtimes.
The intelligent use of operating data obtained through the integration of digitally controlled brakes in Industry 4.0-systems minimizes downtimes. For example, brakes with integrated logic dynamically adapt to load changes, reducing energy consumption by up to 15%. Continuous performance optimization, with digital servo gear motors with predictive maintenance sensors,reduces total operating costs.Functionality and data generation.
Operating principles of electromagnetic brakes.
Electromagnetic brakes (spring-applied/permanent magnet brakes), a core component of many digitally controlled brake systems,often utilize the integrated coil as a sensor without additional hardware. This is an advantage in the integration in complex Industry 4.0-systems. For example, changes in magnetic flux induce voltage for insights into the brake condition (e.g., air gap). This use of physical principles provides data directly.
Current flow analysis for wear prediction.
The current flow analysis during switching of the digitally controlled brake provides insights into wear, which is essential for predictive maintenance in the Industry 4.0 and the system integration of maintenance functions. For example, peak current during the opening of spring-applied brakes shows the operating air gap. This method enables precise, predictive maintenance with controllable brakes..
Switching cycles and total switching work for condition monitoring.
Monitoring of total switching work can reduce downtimes, an important aspect for efficiency in connected production (Industry 4.0); an intralogistics customer reported a 12% reduction. Pure switching cycles are often insufficient for a comprehensive condition assessment within the integration into higher-level monitoring systems. For example, in robotics, total switching time (from speed/torque) is more relevant. Capturing total switching work improves wear assessment.Integration into existing systems and cloud connectivity.
integration with inverters and motion controllers.
The data from digitally controlled brakes can often be processed by existing inverters/motion controllers (e.g., SEW, Lenze), making the Industry 4.0 integration significantly easier. For example, controllers support standardized field buses for simple data acquisition. This minimizes additional hardware, reduces integration costs by up to 25%, and simplifies drive system integration..
- Existing inverters and motion controllers can process data from intelligent brakes directly, minimizing additional hardware in system integration.
- The use of standardized field buses simplifies data acquisition and can reduce integration costs for the incorporation of digital brake systems in Industry 4.0-architectures by up to 25%.
- The cloud-integration based brake data enables proactive maintenance strategies and the improvement of service offerings, adding value to the digitally controlled brake in the Industry 4.0.
- For systems without direct controller access, modular evaluation modules provide a solution for cloud connectivity, facilitating the Industry 4.0 integration integration of digital brakes.
- Comprehensive data security measures, including encryption according to standards like IEC 62443, are critical for the secure integration. digitally controlled brakes.
- Strong authentication and authorization mechanisms are essential for protecting connected brake systems as part of the Industry 4.0 against cyber threats.
- Die integration simplifies the drive system integration. and promotes data-driven services enabled by digitally controlled brakes. in Industry 4.0-concepts.
Cloud-integration for intelligent maintenance.
Cloud-stored data from digitally controlled brakes enable proactive maintenance and service improvement, as shown by a machine tool manufacturer in the context of its Industry 4.0-strategy and the integration of smart components. For example, ATEK develops solutions for applications without controller access, modular evaluation modules. which ensure cloud connectivity for data-driven services.
Data security and protection measures.
Security measures protect connected brakes and industrial networks, especially in the integration of digitally controlled brakes in Industry 4.0-environments. For example, we implement encryption according to IEC 62443 and strong authentication for each digitally controlled brake. A security architecture with authentication/authorization is essential for safe operation in Industry 4.0.Application areas and benefits.
Safety-critical applications.
Spring-applied and permanent magnet brakes, often referred to as digitally controlled brake executed, securely stop in the event of a power failure. Their reliable integration in safety-relevant Industry 4.0-applications is therefore of great importance. For example, they hold heavy loads in vertical axes. This fail-safe property is ideal for safety-critical applications, such as remotely controlled safety brakes for industrial robots..
Predictive maintenance and reduced downtimes.
The continuous analysis of data generated through the integration of digitally controlled brakes can be won, optimized maintenance intervals in Industry 4.0-scenarios; a customer reduced downtimes by 18%. For example, deviations are detected early. Predictive maintenance reduces downtime and lowers maintenance costs by 10-15%.
New business models through data utilization
The data generated by digitally controlled brakes. enables new revenue streams and service offerings, especially in the context of the Industry 4.0 integration and digital transformation. For example, manufacturers offer pay-per-use contracts or remote monitoring. Data-driven services, enabled by intelligent brake technology, improve customer loyalty and create revenue streams.Manufacturing-X and data exchange
Manufacturing-X as a data ecosystem
Manufacturing-X (platform Industry 4.0) creates an interoperable data ecosystem for sovereign, secure data exchange, which facilitates the integration of components such as digitally controlled brakes in a smart factory. For example, this enables supply chain optimization with efficiency improvements of up to 10%. The ecosystem promotes resilience, sustainability, and competitiveness.
- Manufacturing-X serves as the foundation for an interoperable data ecosystem in the Industry 4.0, relevant for integrating diverse systems, including digitally controlled brakes.
- It enables sovereign and secure data exchange, which can increase efficiency, e.g., in supply chains, by up to 10% – an advantage also for data from intelligent brake systems in the context of the Industry 4.0 integration.
- The ecosystem aims to strengthen the resilience, sustainability, and competitiveness of participating companies in the era of the digital factory.
- A core principle is data sovereignty, which gives companies full control over their shared data, as in the exchange of quality data of electronic brake systems, which are often regarded as digitally controlled brake executed and whose data is valuable for integration into Industry 4.0-concepts.
- Clear usage terms for data promote trust and facilitate collaboration between partners, even in system integration in the context of the Industry 4.0.
- Practical use cases include optimizing parts traceability, which can lead to a reduction of scrap by up to 8% – here, precise data from digitally controlled brakes, as part of a comprehensive Industry 4.0 integration, contribute.
- Other important applications include ESG reporting, creating CO2 balances for decarbonization, product passport management, and capacity management, all areas that benefit from deep Industry 4.0 integration and data from smart components like digital brakes.
Data sovereignty and secure data exchange
Manufacturing-X enables data exchange with full control, as suppliers safely share quality data from electronic brake systems (often digitally controlled brakes.) securely with OEMs, an important aspect of Industry 4.0 integration. For example, usage terms define data use. Data sovereignty promotes trust and collaboration.
Use cases in practice
Manufacturing-X addresses concrete industry problems that can be tackled by the integration of technologies such as digitally controlled brakes in Industry 4.0-structures. For example, efficient parts traceability enables scrap reduction by up to 8% through rapid fault analysis. Other use cases: ESG reporting, decarbonization through CO2 balances, product passport management, capacity management.Future developments and optimization potentials
Expansion of data collection
Future developments in digitally controlled brakes target additional data points to deepen their integration in Industry 4.0-systems further and fully exploit the benefits of digital networking. For example, temperature, operating hours, and precise switching cycles can be integrated. Extended data enables cost/quality optimization, e.g., extending lifespan by 10-15%.
integration of Industry 5.0 concepts
Industry 5.0 concepts like human-machine collaboration (HMC) set new requirements for the digitally controlled brake and their integration into the production environment. A cobot manufacturer uses brakes with dynamic adjustment, an example of advanced Industry 4.0 integration and the transition to Industry 5.0. For example, cobots require adaptable parameters, supported by brakes with encoder feedback.. Adaptive systems increase safety and efficiency.
Standardization and interoperability
Established standards for protocols/data formats are crucial for successful integration of digitally controlled brakes in Industry 4.0-landscapes; missing standards increase implementation costs by up to 40%. This significantly impacts system integration. For example, OPC UA/MQTT ensure interoperability (e.g., administration shell). Standardization is key to integration and scalability.
Digitally controlled brakes are thus not only pure actuators, but intelligent data providers and process optimizers, whose importance for the Industry 4.0 integration is continuously growing. Using the brake coil as an internal sensor without additional hardware offers efficiency. Equip your drives for Industry 4.0 and benefit from the advantages of the digitally controlled brake. Contact us for advice on the optimal integration of this advanced technology.
