Maximum safety and efficiency through intelligent brake monitoring – This is how you optimize your systems.
What is meant by a sensor-monitored brake for condition monitoring?
A sensor-monitored brake is a system that continuously collects data on the condition of the brake, in order to detect maintenance needs at an early stage und prevent failures. This increases system safety and efficiency.
What advantages does the use of sensor-monitored brakes in industrial plants offer?
The main advantages are minimized downtime, optimized maintenance planning (predictive maintenance), increased operational safety and potentially reduced maintenance costs by avoiding consequential damages.
How do sensorless and sensor-based brake monitoring systems differ?
Sensorless systems analyze electrical or magnetic parameters directly in the brake (e.g. current, voltage), whereas sensor-based systems use dedicated sensors (e.g. wear, temperature, pressure sensors) to measure the condition directly.
How does sensorless monitoring work with the ROBA®-brake-checker from mayr®?
The ROBA®-brake-checker analyzes the energy conversion in the brake, to monitor parameters such as switching state, temperature, air gap, and pullback reserve. This is done without external sensors, which increases robustness.
Do sensor-monitored brakes enable real predictive maintenance?
Yes, by continuously monitoring wear indicators and operating parameters, forecasts about the future condition of the brake can be made and maintenance work can be planned as needed before a failure occurs.
For which industries and applications are these systems particularly relevant?
They are relevant for numerous industries such as machinery and plant engineering, robotics, logistics, wind power, and packaging industry – everywhere brakes failures are critical and high system availability is required.
How can ATEK Drive Solutions assist companies in implementation?
ATEK Drive Solutions provides comprehensive consulting as a system provider und customized drive solutions, which can also integrate advanced brake monitoring technologies to increase the efficiency and reliability of your systems.
What role does data analysis play in modern brake monitoring systems?
Data analysis is crucial. Collected sensor data is analyzed to identify patterns, predict wear progression und make informed maintenance decisions . This is a core aspect of Industry 4.0.
Sensor-monitored brakes enable proactive maintenance, which minimizes downtime and increases system safety. This can reduce subsequent repairs by up to 30%.
There are two main approaches: Sensorless systems (e.g. ROBA®-brake-checker) reduce failure points by up to 50%, while sensor-based systems (e.g. multi-stage wear sensors) can improve the accuracy of wear forecasts by up to 20%. Selection of the appropriate technology
Die Auswahl der passenden Technologie is crucial for specific applications and becomes increasingly important with advancing automation. ATEK Drive Solutions offers expertise for tailored drive solutions including intelligent brake monitoring.Discover how sensor-monitored brakes can revolutionize your condition monitoring, minimize downtime, and extend the lifespan of your systems. Learn all about innovative technologies and their benefits!
Downtimes cost money. Sensor-monitored brakes give you the opportunity to detect potential problems early and optimally plan maintenance work. Find out more about the advantages of this technology and how ATEK Drive Solutions can support you. Get in touch now Contact us!
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Introduction to sensor-monitored brakes for condition monitoring
Sensor-monitored brakes proactively report maintenance needs before failures occur, thus increasing system safety and efficiency. Companies benefit from minimized downtimes through a preventive condition monitoring.
The growing importance of condition monitoring
Die condition monitoring of brakes is becoming increasingly significant, as unforeseen failures can cause long and costly production downtimes. Continuous operational data collection enables precise maintenance planning, replacing rigid maintenance cycles. ATEK Drive Solutions offers innovative approaches for the monitoring of brake systems.
From reactive to predictive maintenance
The transition to predictive maintenance, for example using a sensor-monitored brake for condition monitoring, reduces operating costs and significantly increases the lifespan of machines. Early detection of wear can reduce the need for subsequent repairs by up to 30%.
Diversity of monitoring technologies
The market offers a wide range of technologies for the brake condition monitoring: from sensorless systems analyzing electrical parameters to multi-stage sensors providing detailed wear data. The selection of the appropriate technology primarily depends on the criticality of the application and the respective environmental conditions.. Some advanced systems also utilize AI-based algorithms for data analysis.Sensorless brake monitoring: mayr® drive technology in focus
The principle of the ROBA®-brake-checker modules
The ROBA®-brake-checker modules from mayr® analyze energy conversion processes directly in the brake, thus providing an innovative method for the condition monitoring of brakes . In this approach external sensors like micro switches are omitted, which significantly increases system reliability. This technology has proven itself in over 10,000 applications.
- Analyze energy conversion processes directly in the brake.
- Increase the reliability of the entire system by omitting external sensor components like micro switches.
- Are mounted in the control cabinet and therefore resistant to vibrations.
- Allow for repainting of the brake without affecting the monitoring function.
- Reduce potential failure points by up to 50% compared to traditional sensor-based solutions.
- Continuously monitor key parameters such as voltage, air gap, and temperature for effective predictive maintenance.
Clear advantages of the sensorless method
As the modules are mounted in the control cabinet, they are extremely resistant to vibrations. Repainting of the brake is possible without loss of monitoring function. This design reduces potential failure points by up to 50% compared to traditional sensor solutions and represents an important aspect of modern industrial brakes-monitoring.
Predictive maintenance through intelligent analysis
ROBA® modules monitor critical parameters such as voltage, air gap, and temperature. This data provides early warnings and enables demand-based maintenance planning. For example, a significant temperature increase may indicate an overload or imminent defects long before a mechanical failure occurs, which enhances the effectiveness of the brake monitoring .
Precise braking torque control with ROBA®-torqcontrol
The ROBA®-torqcontrol system dynamically adjusts the braking torque using magnetic force control to ensure particularly smooth deceleration. This is especially advantageous in applications with variable loads (e.g. in forklifts) or when special protection of the material is required. It supports both digital and analog (0-10V) control signals for flexible integration.Data-driven condition monitoring using Knorr-Bremse as an example
Data as the key to optimized maintenance
Knorr-Bremse focuses on utilizing data from electronic brake systems, to realize advanced, condition-oriented maintenance. The conversion of sensor data into actionable insights optimizes maintenance intervals and can increase vehicle availability by up to 15%. A well-thought-out data analysis strategy is essential for this and a core component of effective monitoring of brake systems.
Adaptability and IoT integration as success factors
The Knorr-Bremse system stands out for its adaptability, allowing for algorithm adjustments without deep intervention in the system architecture. Strategic partnerships, such as with Nexxiot, leverage the Internet of Things (IoT) for comprehensive data collection. This flexibility is crucial for rapidly responding to new insights or changing requirements (e.g. over 5,000 wagons are already equipped with tracking technology).
Strong partnerships for digital overall solutions
Knorr-Bremse maintains collaborations, including with Railnova, to offer telematics and fleet management software. Such partnerships enable the provision of comprehensive digital service packages, which go far beyond individual components. Customers thereby benefit from guaranteed availability and better planned costs, which underscores the value of the intelligent brake monitoring. Sensor-based brake wear detection in detail
Sensorbasierte Bremsverschleißerkennung im Detail
Functionality of integrated wear sensors
Electronic sensors, often in the form of variable resistors, measure the wear of brake pads and provide real-time data to the vehicle ECU (Electronic Control Unit). This direct data collection is a core feature of the sensor-monitored brake for condition monitoring. For reliable monitoring, at least two sensors per axle are required. Mounting is often done with spring clips that ensure a holding force of ≥30N.
- Measure the wear level of the brake pad using electronic sensors and transmit real-time data to the vehicle ECU.
- Require at least two sensors per axle for consistently reliable monitoring of the brake condition.
- Use multi-stage sensors to enable more accurate predictions regarding the remaining lifetime of the brake pads.
- Can improve the precision of wear predictions by up to 20%, thus optimizing maintenance planning.
- Increase operational safety through timely alerts before the critical wear limit is reached.
- Help reduce maintenance costs by preventing expensive consequential damage, such as grooving on brake discs.
Multi-stage sensors for more precise predictions
Multi-stage sensors that integrate resistance circuits at different levels of the brake pad allow for significantly more accurate predictions of wear progression. When a resistance circuit is interrupted due to wear, the ECU calculates the expected remaining lifetime, taking into account additional vehicle data (such as mileage, wheel speed, and brake pressure). This method can increase the accuracy of predictions by up to 20%, which is a significant advantage for the Condition Monitoring of brake systems is.
Safety and cost advantages through sensor technology
Early warning of reaching the wear limit significantly increases operational safety. At the same time, this form of sensor technology for brake condition reduces maintenance costs, as consequential damages (e.g., deep grooves on brake discs) are effectively avoided.Preventing costly rotor damage alone can mean savings of several hundred euros per axle.Application examples and future perspectives of brake monitoring
Thermal monitoring in demanding environments
NTC thermistors play an important role in protecting brakes from overheating and potential failures. This type of monitoring of brake systems ist is particularly safety-critical in hydraulic systems of mobile machinery, such as those used in ring motors with up to 14 MW power in mining.EPHYMESS is a provider that develops specialized solutions for this purpose.
Mechanical precision: GH Cranes’ approach to crane brake monitoring
GH Cranes relies on a mechanical sensor system with dual contacts for reliable monitoring of brake condition and wear. In this system, a lack of feedback within 100 milliseconds leads to an immediate stop of the motor,significantly increasing safety in lifting devices and serving as a practical example of effective condition monitoring in brakes. presents itself.
Outlook: Intelligent brakes for automation
With the ongoing automation, such as in the field of automated guided vehicles (AGVs), the importance of integrated sensors for brake monitoring is continuously increasing. Precise data on brake condition, such as that provided by a modern sensor-monitored brake for condition monitoring, is fundamental for the safe autonomous operation of such systems. A brake with encoder feedback is an illustrative example of advancing technology.
The implementation of a sensor-monitored brake for condition monitoring enhances both the efficiency and safety of systems and vehicles. The choice of the appropriate technology – whether sensorless or sensor-based – for the specific brake condition monitoring is crucial. ATEK Drive Solutions is happy to assist you in optimizing your system for the monitoring of brake condition and helps you fully harness the potential of predictive maintenance.
