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Industry 4.0

Brake Technology 4.0

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Safety brakes by mayr® power transmission – fit for the future

Monitoring modules of the latest generation, a technologically leading friction system and consistently-observed safety principles – safety brakes by mayr® power transmission are equipped for the challenges of the Industry 4.0. The perfectly-coordinated complete system guarantees the utmost level of operational and functional safety, and increases the productivity of machines and systems through preventative fault detection and maintenance. mayr® power transmission presents its brake technology 4.0 at the Hanover Trade Fair 2017.

With Industry 4.0, the Internet of Things and Services enters companies. That’s why mayr® power transmission as the leading manufacturer is already offering reliable safety brakes, which are equipped for the challenges for the forth industrial revolution. Brake technology 4.0 by mayr® power transmission stands for monitoring modules of the latest generation: The modules such as the ROBA®-brake-checker or the ROBA®-torqcontrol allow permanent brake monitoring. The ROBA®-brake-checker module, for example, monitors the switching condition as well as the tension path or tension force reserve without sensors and detects safety-critical changes in voltage, air gap and temperature. As a result, significantly more processes are depicted during the safety brake monitoring than was previously the case. On reaching the tension path reserve, the ROBA®-brake-checker therefore sends a warning signal indicating that the brake can continue to be operated for a certain amount of time at an early stage. During this time, the machine owner can undertake targeted maintenance – in coordination with their work process. In addition, the module also simultaneously assumes the control of the brake and therefore replaces a rectifier. Switching condition monitoring und brake controls are thus combined in one device.

Braking movements gently and in a controlled manner
For applications, which require braking torque control in addition to status monitoring, mayr® power transmissions provides the braking torque control module ROBA®-torqcontrol. It shares the features of the 

ROBA®-brake-checker and can also change the level of the braking torque in operation through purposeful influencing of current and voltage. As a result, devices and machines can be evenly and gently decelerated. The ROBA®-torqcontrol module permits the development of control loops and brakes movements intelligently – the ideal basis for its use in smart, interconnected machines.

mayr® friction lining technology – always a step ahead

The developers at mayr® power transmission have successfully created a new friction lining technology through which the brakes achieve even further-improved torque consistency and a higher performance density. Using the new linings, higher braking torques as well as higher area-specific friction work values can be achieved, which means the brakes are of a more compact design, but with the same features. Under certain circumstances, a smaller, lighter brake construction size can be selected for higher braking torques and for brakes, on which higher demands are placed. This takes into account the general trend for machines and their components, for example engines, to be increasingly more compact in construction and with greater performance density.

Brake technology 4.0

Brake technology 4.0 by mayr® power transmission is therefore a comprehensive overall concept, meaning a technologically leading friction system which, together with consistently considered safety principles, stands for reliable, safe brakes with extremely high performance density. Innovative monitoring solutions are firmly integrated into this system, and as a result mayr® brakes and the corresponding monitoring modules are able to master all challenges when safety regulations and standards meet Industry 4.0 and the demand for the depiction of all processes involved. They ensure the utmost operational reliability and enable preventative, purposeful maintenance in the increasingly compact, higher performance density machines and systems.

Brake technology 4.0 by mayr® power transmission stands for monitoring modules of the latest generation: The modules such as the ROBA®-brake-checker or the ROBA®-torqcontrol allow permanent brake monitoring and make the safety brakes fit for the challenges of the Industry 4.0.

Furthermore, firmly connected with brake technology 4.0 are a technologically leading friction system and consistently considered safety principles. All of this forms the basis for reliable, safe brakes with extremely high performance density.

The developers at mayr® power transmission have managed to create a new friction lining technology using which the brakes can achieve a further-improved torque constancy and higher performance density. With the new linings, higher braking torques and higher area-specific friction work values can be achieved, which means that brakes can be reduced in size whilst retaining the identical properties. Under certain circumstances, a smaller, lighter brake construction size can be selected for higher braking torques and for brakes, on which higher demands are placed.

I manage the editorial affairs for MONETA Tanıtım, which produces specific publishing, specially for the sphere, Turkey industry. We work for content development through digital and print media, with a new generation, dynamic publishing intellection.

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Industry 4.0

A digital transformation in the cold chain

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John Rodes

Emerson Commercial & Residential Solutions

Digital technologies, data mining and analytics tools are dominating the modern economy, transforming nearly every aspect of how we operate. Businesses are beginning to realize the power of data and how it can be used to improve the customer experience, grow market share and improve operational performance — all culminating in what’s commonly being referred to as the digital transformation. This transformation has the potential to bring significant benefits to several areas of the industry, including food safety, energy conservation and refrigerant management, to name a few. 

Today, retailers have access to more data than ever before, allowing for new opportunities to innovate and implement more comprehensive management in the cold chain. Rather than narrowing focus onto one section of the business, operators can now think across entire enterprises and supply chains for broader insights and deeper intelligence into how their stores are operating and learn where they can improve and innovate. 

One factor that makes this transformation so interesting is the amount of commitment industry leaders are putting into developing deeper, stronger relationships with their customers, rather than using the newfound data to exploit sales opportunities. Customers have rewarded this dedication and innovation with increasing loyalty — which translates into better sales. 

A recent example of the potential data has to help solve problems in the cold chain was the concern surrounding an outbreak of foodborne illness from romaine lettuce purchased at grocery outlets. After customers got sick and the story hit the 24/7 news cycle, many demanded to know where the contamination had occurred. In this case, technology and data were essential in tracking the instance of contamination to a specific farm. But this example is just the tip of the iceberg. 

A similar, data-driven approach can allow retail stores to reduce their energy costs during peak demand periods. By connecting building management systems (BMS) to the local energy provider, companies can limit or avoid “peak time surcharges” that are assessed when the greatest amounts of energy are required. The BMS receives notices from the utility when demand reduction opportunities arise and, through a demand response program, retailers can automatically shut down non-essential equipment and optimize energy use. 

The amplitude of data available from this digital transformation is ushering in an intriguing period in cold chain history. At Emerson, we see this happening not in grandiose, intangible, all-consuming approaches, but in the expansion of existing, proven technologies coupled with the use of emerging digital assets to create new insights. 

As the iterative development of connected, adjacent systems accelerates and becomes more powerful, there will be opportunities to revolutionize how companies operate. We at Emerson are here to help you make this critical cold chain transition a reality for your business.

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Industry 4.0

Self-driving systems for internal flows of materials

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No name would have been more desirable. With the Packman 200, Opteq Robotics has developed a self-driving solution for material flows which makes its way quickly and directly through the aisles to reach its destination, just like the popular arcade game from the 1980s. While making the wrong turn soon means game over in the classic Japanese arcade game when the main yellow character becomes the victim of voracious ghosts, detours also signify a loss for the Dutch company´s new solution, i.e. through lost time in rapid material flows. The Packman 200 features KOLLMORGEN AKM synchronous servo motors as drives, based on a new version with specially tuned winding for 48 volts.

The mobile robot systems are connected via WiFi with a fleet management system which in turn communicates with a higher-level ERP system and receives the travel jobs from there so that the Packman 200 does not lose its bearings. The network is so finely interconnected based on the Industry 4.0 concept that the ANT (Autonomous Navigation Tool) always passes the job onto the correct Packman. The correct one depends for instance on the distance to the job destination, the capacity of the relevant battery, as well as on the relevant model is capable in the first place of transporting the freight weight required. »Our self-driving systems have a modular structure, because of which there will be different categories of weight», says Henk Kiela, Managing Director at Probotics. The current model is able to transport loads of up to 150 kilograms with an own operating weight of 40 kilos, and with availability of more than six hours. The mobile assistant then needs to return to the charging station.

Flexibly linking production islands

The Dutch firm from the small town of Haps, just south of Nijmegen, believes that the machines will be used much more in production companies as well as in clinics rather than in large logistics centers. The aim of the Packman 200 is to automate the transport routes here which were previously covered by employees in a time-consuming process. Henk Kiela mentions the different configuration options for linking production islands with no fixed routes as examples here. “The special feature with our solution is that we do not need magnetic sections for the routes. On the contrary, we are able to take flexible routes as a result of the level of freedom in the programming. This makes integration into modifiable production facilities so easy and so attractive based on cost aspects”, highlights the firm´s owner, who also still works as Professor of Mechatronics and Robotics at the Fontys University of Applied Sciences, Eindhoven.

The fact that the mobile units are linked beyond the classic automation pyramid and thereby increase efficiency in material flows makes them a powerful representative for Industry 4.0. Another particularly attractive feature of autonomous intelligent vehicles (AIVs) is their simple structure with few components. A look at the interior essentially reveals a laser sensor for ascertaining distances, the battery pack, a powerful controller featuring Motion Control along with two low voltage DC servo motors from KOLLMORGEN´s AKM series in frame size 3 as wheel drives.

48 volt drives with reserves

The AKM-31´s regular nominal power rating is 1.3 kW with its 400 V winding. With the adjustment to 48 volts the compact units provide 300 watt of power with planetary gears installed directly. As supplier of fully-integrated automation systems, SigmaControl has used the S-Dias range from Sigmatek together with the KOLLMORGEN motors. “This way we have matched the perfect couple, implementing the control movements with different speeds on the wheels and also taking responsibility for the process and motion control”, says Frank ten Velde, Account Manager for SigmaControl, exclusive distributor of SIGMATEK Netherlands. The DC 061 axis module provides virtually 300W of nominal power and is designed to control a synchronous servo motor with up to 6A of continuous current at 48V DC. The breakaway torques required when starting up the mobile transport robots can be easily controlled since the module is able to provide a peak current of up to 15A at short notice. “This allows us to avoid constantly oversizing the drive technology, thereby saving space and helping us to extend coverage, since the batteries don´t need to supply as much electrical power”, explains Frank ten Velde further. Together with Dynamic Drives the company has already been working for more than 20 years as a certified partner in Belgium and the Netherlands to KOLLMORGEN.

A very generous design also provides more space for further versions of the Packman. »We are reducing the variety of versions available. Our customers benefit from this through lower purchase costs as well as with subsequent provisioning», explains ten Velde. The power reserve provides purely benefits for the system integrator in this case. “There´s barely any difference in price whether we provide a controller for four or six amps. Yet the solution space becomes significantly larger.” This aspect makes it possible for instance to implement applications with the 48 volt AKM servomotors in combination with the SIGMATEK-Motion-Control system which require highly dynamic positioning. These types of applications can regularly be found in packaging technology, e.g. for labeling.

The drive and control technology can be adapted easily

Aside from the pure functionality and power of the drive technology, spiritual father of the Packman 200 Henk Kiela also appreciates the ease related to configuration and programming of the drive and control solution from KOLLMORGEN and SIGMATEK. “This gives us the option, for instance, of easily adapting the Packman 200 to different ground conditions. If I have a rough surface for example, then I can optimize the drive technology in such a way that it suits pneumatic tires perfectly.”

Since the Dutch innovation center´s core knowledge and expertise can be found in system development and integration, the professor of mechatronics and his development team rely on partners for implementation »who provide technology that also works in reality in the way that we imagine at the start of a project».  The success of the collaboration between KOLLMORGEN and SigmaControl is clearly illustrated in the brief implementation phase for the prototype for the Packman 200 of just three months. “I know how to put drives together myself, but it takes a lot of time. I can save that time by purchasing a fully-connected solution with ready-made standard functions, and then focusing instead on the object-based programming for our own robot system.”

More room for the really essential tasks

The professor of mechatronics and robotics is convinced that the systems such as the Packman 200 enable much more efficient configurations for in-house flows of goods. “We expect savings of at least 15 percent.” Given this potential he says that he expects the mobile robots to be implemented on a broad basis within the next ten years. He claims that the aim of this is not to save headcount, but rather to provide relief to staff from unproductive in-house transportation tasks. For him this also includes tasks in clinics as well as any potential usage in the production industry. The central issue with this is why nurses should waste the little time they already have moving hospital waste, bed clothes and beverages? The efficiency savings thereby create more room for spending time with patients.

Sandra Becker,

Marketing Communications Manager EMEA & India, KOLLMORGEN, Ratingen

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