Download - Drive and motor safety
1Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010Drive and Motor Safety
Safety on Board –Integrated, certified and consistentSafety on Board –Integrated, certified and consistent
CMAFHDrive For Technology 2010
Drive and Motor Safety
Gary Thrall Senior Product Support Engineer
Bosch Rexroth Corporation
2Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010Drive and Motor Safety
New European Standards
IndraDrive safety functions according new standardsIndraDrive C/ M
Coming soon – IndraDrive Cs L4 optionSTO and SBC
Safety on Board –Integrated, certified and consistentSafety on Board –Integrated, certified and consistent
3Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
EC
Machine Builder
EN 13849-1 (EN 954-1)EN 62061
EN 61800-5-2
CMAFH Drive For Technology 2010Passport into European Community market (EEA)
European Machinery Directive
Fulfilling harmonized standards the manufacturer can assume that the safety
aspects of the machine directive are met
4Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 Change of Safety Standards
EN ISO 13849-1
December 2009
EN 954-1
EN 61800-5-2
November 2006
November 2007
January 2006
IEC 61508
EN 62061
Valid Standard
Valid Standard Period 3 years
Valid Standard
Valid Standard
Valid Standard
Transition
Mac
hine
Bui
lder
Com
pone
nts
98/37/EG
January 2010
2006/42/EGEuropean Machinery Directive
Today
Extended 2 more years
Transition
5Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010Performance Level of EN ISO 13849-1:2006
The Performance Level is defined byCategory (architecture), identical to EN 954-1 and C-StandardsMTTFd (Meantime to dangerous failure in one channel)
DC (Diagnostic Coverage): Share of detected failures
CCF (Common Cause Failures affecting both channels)Measures against systematic failures
Denotation of MTTFd Range of MTTFd
Low
Medium
High
3 years <= MTTFd < 10 years
10 years <= MTTFd < 30 years
30 years <= MTTFd < 100 years
Denotation of DC Range of DC
None
Low
Medium
DC < 60%
60% <= DC < 90%
90% <= DC < 99%
High 99% <= DC
6Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 Performance Level of EN ISO 13849-1:2006
A Performance Level d could be achieved by:
Cat. 3 Cat. 2DCavg = medium or DCavg . = medium MTTFd = medium MTTFd = high
7Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 EN 62061 and EN 13849-1
-< 10-84
e>= 10-8 to 10-73
d>= 10-7 to 10-62
c>= 10-6 to 3 x 10-61
b>= 3 x 10-6 to 10-51
a>= 10-5 to 10-4-
Performance LevelPL
ISO 13849
Probability of dangerous failure per hour (1/h)
PFHd
Safety Integrity LevelSIL
IEC 61508IE
C 6
2061
ISO
138
49
PFHd – Probability of a dangerous Failure per Hour
All Technologies
Simplified Estimation (worst case)regarding to:
HW Structure (Category like EN 954)Diagnostic Coverage (DC)
Reliability MTTFdFailure of Common Cause (CC)
electrical, electronic and programmable
calculation formula for subsystem architectures
8Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 Performance Level in total
Performance Level of the combination of SRP/CS
PFHtotal = PFHSensor + PFHIO + PFHSafetyPLC + n x PFHDrive
PFHtotal = 2,29 10-7 + 4,29 10-8 + 2,47 10-8 + 6 x 4,29 10-8
PFHtotal = 5,54 10-7 < 10-6 -> PL d
EN ISO 13849-1:2006 Category 3 PL d
SRP/CS1PL1
SRP/CS2PL2
SRP/CS3PL3
SRP/CS4PL4SRP/CS5
PL5SRP/CS6PL6SRP/CS7
PL7SRP/CS8PL8SRP/CS9
PL9
Cat 3 Cat 3 Cat 3
Cat 3
9Electric Drives and Controls 2008-11-07; BRC/SPM; J. Ost© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 SafeMotion - More than just Switching Off!
The evolution of safety technology
Safety reaction
Switching off SafeMotion
Safety condition
10Electric Drives and Controls 2008-11-07; BRC/SPM; J. Ost© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010Conventional versus Integrated
M
E
G
externalmonitoring
unit(standstill, speed, ...)
controllerenable additional
feedback
Conventional safety solution
Drive
Channel 1
Channel 2
M
E
E two-
chan
nel s
witc
hing
-off
Drive-integratedsafety technology
Drive
11Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
3 principles are realized to detect latent failures
Dual channel data operation with diversityCross data comparison of safety related functionsDynamization of static modes
Due to this method one single failure may not deactivate the safety function --> Category 3 (recommended Safety level in most guidelines)A risk analysis by the machine builder and end user is required in accordance to Annex I of the European Community Directive for machines 98/37/EG
CMAFH Drive For Technology 2010Safety On Board with IndraDrive
Note: - only Safe Torque Off
in BASIC
Encoders with only TTL interface or only serial interface are not allowed for integrated safety technology functions.
All encoders with 1 Vpp signals (e. g. EnDat, HIPERFACE,...) and all resolvers supported by the encoder interface can be used for integrated safety technology. It is always the feedback at X4 connector that is evaluated.
12Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
SafeMotion – Functional Safety in Automation Technology
CMAFH Drive For Technology 2010Selection of safety functions
Channel 1
Communication
M
E
Channel 2E
Control
Option S224V / 24V
Auto Set-up
Two.
-cha
nnel
inte
rruptChannel 1
Communication
M
E
Channel 2E
Control
Option S224V / 24V
Auto Set-upAuto Set-up
Two.
-cha
nnel
inte
rrupt
Drive
Channel 1
Safe Communication(Profisafe, SERCOS III Safety)
M
Channel 2
E
SafeControl
Option S2Safe communication
Auto Set-upAuto Set-up
Two-
chan
neli
nter
rupt
Drive
13Electric Drives and Controls 2008-11-07; BRC/SPM; J. Ost© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 Safety on Board - Functional Safety
channel 2
channel 1
X41
X41
channel 2
channel 1
transducer
X41
SERCOScommon
parts
STO using 24V / 24V or 24V / 0V
SLS using SERCOS / 24VOne L2 PFH value independent from control (opener / closer, opener / opener)
One S2 PFH value independent from the control and the safety technology feature.Separate PFH value for the feedback
power section
channel 2
channel 1
transducer
X41
X31/X32common
parts
SLS using 24 V/ 24V
Safe Torque Off Safe Motion
Preliminary information
Safe Torque Off:PFH = 2 * 10 -9 1/h
Safe Motion:PFH drive and feedback = 5 * 10 -8 1/h
14Electric Drives and Controls 2008-11-07; BRC/SPM; J. Ost© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 Functional Safety According to ISO 13849-1
safety switches safety I/O safety PLC safety drives
Certified components
Standard components
SRP/CS1PL1
SRP/CS2PL2
SRP/CS3PL3
SRP/CS4PL4
SRP/CS5PL5
SRP/CS6PL6
SRP/CS7PL7
SRP/CS8PL8
SRP/CS9PL9
S
S
input PPCDP SIIDP
safety switches I/O PLC
IndraDrive
K1
IEC 61508 IEC 61508IEC 61508
IEC 61800-5-2
ISO 13849
ISO 13849Drive
safety switches safety I/O safety PLC safety drives
Certified components
Standard components
SRP/CS1PL1
SRP/CS2PL2
SRP/CS3PL3
SRP/CS4PL4
SRP/CS5PL5
SRP/CS6PL6
SRP/CS7PL7
SRP/CS8PL8
SRP/CS9PL9
S
S
input PPCDP SIIDP
safety switches I/O PLC
IndraDrive
K1
IEC 61508 IEC 61508IEC 61508
IEC 61800-5-2
ISO 13849
ISO 13849Drive
safety switches safety I/O safety PLC safety drives
Certified components
Standard components
SRP/CS1PL1
SRP/CS2PL2
SRP/CS3PL3
SRP/CS4PL4
SRP/CS5PL5
SRP/CS6PL6
SRP/CS7PL7
SRP/CS8PL8
SRP/CS9PL9
S
S
input PPCDP SIIDP
safety switches I/O PLC
IndraDrive
K1
IEC 61508 IEC 61508IEC 61508
IEC 61800-5-2
ISO 13849
ISO 13849Drive
safety switches safety I/O safety PLC safety drives
Certified components
Standard components
SRP/CS1PL1
SRP/CS2PL2
SRP/CS3PL3
SRP/CS4PL4
SRP/CS5PL5
SRP/CS6PL6
SRP/CS7PL7
SRP/CS8PL8
SRP/CS9PL9
S
S
input PPCDP SIIDP
safety switches I/O PLC
IndraDrive
K1
IEC 61508 IEC 61508IEC 61508
IEC 61800-5-2
ISO 13849
ISO 13849Drive
Verification with SISTEMALibrary for certified and standard components
15Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 Certification according to new Standards
Safe Motion EN
954
-1IE
C 6
1508
IndraDriveSince 2004 more than 100,000
installed drivesCategory 3
Development project “New Standards”
Hardware Modification of Control UnitsCSH….-L1-…. -> CSH….-L2-…. CSH….-S1-…. -> CSH….-S2-….CSB….-L1-…. -> CSB….-L2-…. CDB….-L1-…. -> CDB….-L2-…. CDB….-S1-…. -> CDB….-S2-….
New Firmware Version MPX07VRS
Deliverable since July 2009
16Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 SafeMotion – Preliminary Data
Safe Torque Off (L2):
EN ISO 13849-1:2006 Category 3 PL = e
IEC 61508EN 62061:2005EN 61800-5-2:2007 SIL3
PFHd = 2 * 10 -9 1/h
MTTFd = 100 years (limitation by standard)
Mission Time = 20 years
The PFH values are based on a 100% duty cycle (24h/ 365 days)
17Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 SafeMotion – Preliminary Data
Safe Motion (S2):
EN ISO 13849-1:2006 Category 3 PL = d
IEC 61508EN 62061:2005EN 61800-5-2:2007 SIL2
PFHd Drive = 3 * 10 -8 1/hPFHd Feedback = 2 * 10 -8 1/h (Stegmann/ Heidenhain motor feedback)
MTTFd = 100 years (limitation by standard)
Mission Time = 20 years
To calculate the MTTFd value for a drive and feedback combination: Add the PFH values and convert then into a MTTFd value. Do not add the MTTFd values since they are limited to 100 years.
The PFH values are based on a 100% duty cycle (24h/ 365 days)
18Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 SafeMotion – Preliminary Data
Preliminary Data for IndraDrive, Safety on Board
Safe Torque Off: PFHd = 2 * 10 -9 1/h = 2 % of max. SIL3 value
Safe Motion: PFHd Drive and feedback = 5 * 10 -8 1/h = 5 % of max. SIL2 value
-< 10-84
e>= 10-8 to 10-73
d>= 10-7 to 10-62
c>= 10-6 to 3 x 10-61
b>= 3 x 10-6 to 10-51
a>= 10-5 to 10-4-
Performance LevelPL
ISO 13849
Probability of dangerous failure per hour (1/h)
PFHd
Safety Integrity LevelSIL
IEC 61508
IEC
620
61
ISO
138
49
19Electric Drives and Controls 2008-11-07; BRC/SPM; J. Ost© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 IEC 61800-5-2 – New Terminology (not all available)
SCASafe Cam
SMTSafe Motor Temperature
STRSafe Torque Range
SLTSafely-limited Torque
SBS 1)Safe Braking and Holding System
SBCSafe Brake Control
SMP 1)Safely-monitored Position
SLPSafely-limited Position
SDISafe Direction
SLISafely-limited Increment
SMS 1)Safe Maximum Speed
SSMSafe Speed Monitor
SSRSafe Speed Range
SLSSafely-limited Speed
SARSafe Acceleration Range
SLASafely-limited Acceleration
SMD 1)Safely-monitored Deceleration
SOSSafe Operating Stop
SS2Safe Stop 2
SS1Safe Stop 1
STOSafe Torque Off
1) N
ot d
efin
ed in
IEC
618
00-5
-2
EN 61800-5-2: 2007 Functional safety for speed variable drives
20Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 Terms of EN 61800-5-2 – New Terminology (available)
EN 61800-5-2: 2007 Functional safety for speed variable drives (C-standard)New terms and definitions
EN 954-1 Rexroth Safety functionsSafety option IEC 61800-5-2 Terms Abk.
Safety related starting lookout L2 Safe Torque off STOSafety related standstill S2 Safe Stop 1 SS1Safety related operational stop S2 Safe Stop 2 SS2Safety related operational stop S2 Safe Operating Stop SOSSafety related drive interlock S2 Safe Stop 1 (Emergency Stop) SS1 ESSafety related monitored stopping process S2 Safely-Monitored Deceleration *1 SMDSafety related reduced speed S2 Safely-Limited Speed SLSSafety related limited increment S2 Safely-Limited Increment SLISafety related direction of motion S2 Safe Direction SDISafety related absolute position S2 Safely-Monitored Position SMPSafety related absolute end position S2 Safely-Limited Position SLPSafety related control of a door locking device S2 Safe Door Locking *1 SDLCommunication via PROFIsafe S2 Safe Communication *1 SCOSafety related in-/outputs via PROFIsafe S2 Safe I/O *1 SIOSafety related braking and holding system S2 Safe Braking and Holding System 1 SBS
*1 Not defined in EN 61800-5-2
21Electric Drives and Controls 2008-11-07; BRC/SPM; J. Ost© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010Drive-Integrated Safety Features
Safe Torque Off (STO)Safe Stop 1 (SS1)Safe Stop 1 - Emergency Stop (SS1-ES)Safe Stop 2 (SS2, SOS)Safely Monitored Deceleration (SMD)Safely Limited Speed (SLS)Safe Maximum Speed (SMS)Safely Limited Increment (SLI)Safe Direction (SDI)Safely Monitored Position (SMP)Safely Limited Position (SLP)Safe Door Locking (SDL)Safe I/O interface for Safety-PLC (SIO)Safe Braking and Holding System (SBS)new
22Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
Safe Torque off (Stop Category 0*)
Drive is torque-lessPower is cut safely (pulse inhibit)
v
tt0
Safe Torque Off (STO)
CMAFH Drive For Technology 2010 Drive Based Safety Functions
* according to EN 60204-1
23Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 Drive Based Safety Functions
Safe Stop 1 (SS1) / Safe Stop 2 (SS2)
Controlled Stopping according to stop category 1* (SS1)
monitored stopping, control or drive controlled with safe decelerationTorque-less standstill of the drivesPower is cut safely (STO)
Controlled Stopping according to stop category 2* (SS2)
monitored stopping, control or drive controlledcontrolled standstill after stopping, no power off (SOS)
* according to EN 60204-1
v, s tt0 t1
v
tt0 t1
24Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 Drive Based Safety Functions
Safely Limited Speed (SLS) / Safely Limited Increment (SLI)
Within the Safe Mode a safely limited speed and / or a safely limited increment can be enabled (enabling device)
In case the speed/increment monitoring window will be triggered the drive will be safely stopped automatically in accordance with the stop category 1.
v, s
v
t
v, s
t
t0 t1 30
25Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 Drive Based Safety Functions
Safe Direction (SDI)
In addition a safe direction (right, left) can be defined.
In case the direction changes the drive will be safely stopped automatically in accordance with the stop category 1.
v
t0
26Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 Drive Based Safety Functions
Safe Maximum Speed (SMS1)
The monitoring of a safely limited maximum speed is active always, regardless the operation mode of the drive (Automatic/Manual Mode)
In case the parameterized maximum speed will be exceeded the drive will be safely stopped automatically in accordance with the stop category 1.
vMax
t
120
1) Not defined in IEC 61800-5-2
27Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
In the safe operation mode a working area (absolute position) can be defined
In case the parameterized working area will be left, the drive will be safely stopped automatically in accordance with the stop category 1.
Position 1 Position 2
Working Area
CMAFH Drive For Technology 2010Drive Based Safety Functions
Safely Monitored Position (SMP1)
1) Not defined in IEC 61800-5-2
28Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010 Drive Based Safety Functions
s
v v max
Max. deceleration
Positive Limit Switch
Negative Limit Switch
Max. deceleration
Safely Limited Position (SLP)active in normal and safe operation mode
- The drive is not able to cross the limited switches- The drive is stopped automatically when the available
deceleration torque would not be sufficient to stop the load before the parameterized position area will be left
Offers cost saving by replacing hardware position limit switch
29Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
Safely Monitored Deceleration – safety in the stopping process
CMAFH Drive For Technology 2010 Drive Based Safety Functions
n
t1
SMDNC-controlled stopping process with safely
monitored deceleration (SMD)
Braking of coupled drives: It may occur that individual axes must still accelerate, in order to stop the total movement
Safe stop in a defined time due to predictive behavior of the drive
The drive checks each cycle whether it is possible to stop within the time t1. If this is not possible such as by wrong set point of the control, the drive takes over the braking.
30Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
Safe braking and holding system – a new milestone
CMAFH Drive For Technology 2010Safety on Board - Safe Braking and Holding System
Safe Braking and Holding System (SBS)
Fall protection for axes with gravity loads
Operator protection in special operating mode
World’s only on board solution which complies with EN ISO 13849-1, Cat. 3 PL d and EN 62061 SIL 2
Two independent brakes separately controlled and monitored by redundant, diverse channels in the drive
Escalation strategy to protect the mechanical subsystems
Active as well after energy cutting by emergency stop
31Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010Safety on Board - Safe Braking and Holding System
During special operation modepersons may be present in the machine when following special safety precautions- Configuration- Measuring- Troubleshooting
During automatic operation the machines and equipment are running at full speed without operators
Vertical or inclined axes can even present a danger when they are switched off and inadvertently coming down
32Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010Safety on Board - Safe Braking and Holding System
• Safe
• Braking and
• Holding system
Effective even after energy cut-off through emergency stop
Fall protection of gravity-loaded axes
Personal protection of operators during special operation mode
33Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
The safe braking and holding system is based on two independent brakes which are separately controlled and monitored by the redundant diversified channels in the drive.
two-channel control of the brakes
two-channel selection of the safety feature e.g. safely-monitored deceleration
Safe energy cutting Universal integration of different brake types, e.g.
IndraDrive
Safe feedback
HAT
CMAFH Drive For Technology 2010Safety on Board - Safe Braking and Holding System
34Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
IndraDrive with safety functions – a convincing technology
CMAFH Drive For Technology 2010SafeMotion – functional safety in automation technology
Safety Technology made by the experts having more than 10 years field experience
Scalable Safety Functions minimize the potential of tampering and therefore reduce the hazard for injury caused by passing the safety measures
Increased productivity by reducing downtime
Online Testing (Failure Detection) during runtime
Cost savings by reduction of external components and wiring
Minimal Movement in case of emergency by detecting failures within 2 ms
High reliability due to an encapsulated, certified solution
Stand-alone – whether wired, or with or without a safety PLC
35Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010Coming Soon – Safe Torque Off for IndraDrive Cs
Safe Torque Off (L4): (A new type code to distinguish different features)IndraDrive Cs with L4 option is currently expected to go from EW to PT (available for sale) by end of May 2010
Certification by TÜV Rheinland is expected to be done by then• L4 option will include STO (Safe Torque Off) and SBC (Safe Brake
Control)• SBC is 2-channel control of the standard holding brake so that if there is a
short in either wire or a failure in one channel, the brake will still be applied. • L4 STO circuit is completely redesigned from L1/L2
• has safe mode within a test period. The test pulse is < 1ms. • with on-line dynamization, no need for an acknowledgement contact to meet
Cat. 4, PL e, SIL 3 -- the lifetime issue of the relay contact in the L1/L2 is gone. • L4 connector for is no longer a D-sub
• 6-pin cage clamp connector with separate clamp for incoming and outgoing wire at each pin
• daisy-chain up to 25 axes. Just daisy chain 4 terminals with discrete wires from one drive to the next. This eliminates the cable management issues of the ribbon cable in previous design. Easier and less expensive.
36Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
Einpoliges Schaltgerät der Kategorie 3, PL d, SIL 2 mit Zwangsöffnergemäß EN 60947-5-1
IndraDrive CsSTO-Option
Kategorie 4, PL eSIL3
24 V24 V
24 V STO-Anwahl Ch1
24 V STO-Anwahl Ch2
Dynamisierte Ausgänge mit < 1 ms Testimpuls
Einkanalige STO-Anwahl über ein einpoliges Schaltgerät
Anwahl über 1 Öffnerkontakt
0 V Ground für Ch1 und Ch2
CMAFH Drive For Technology 2010Coming Soon – Safe Torque Off for IndraDrive Cs
R eset
R ückm eldung
No tHa lt
Zei t verzögert
IndraDrive CsSTO-Option
Kategorie 4, PL eSIL3
24 V24 V
24 V STO-Anw ahl Ch1
24 V S TO-A nwa hl Ch2
+ 2 4V
E.Stopp
E xternes S iche rh eit s-schaltgerätK ate gorie 4, P L e , SIL 3
Dynam is ierte A usgän ge m it < 1 ms Testim puls
SS1-Funktion einer Achse in Verbindung mit einem Sicherheitsschaltgerät
A nwahl üb er 2 Öffn erkonta kte
oderNC-Stopp
0 V Groun d fü r Ch1 u nd C h2
Single channel STO application over a single pole switch device
SS1 functionality [single axis wired] with an external safety device:
STO-Option
Anwahl Ch1
STO-Option1. Antrieb 2. Antrieb
SS1-Funktion mehrerer Achsen mit Sicherheitsschaltgerät und externer Verdrahtung
Anwahl Ch2
Anwahl Ch1
Anwahl Ch2
24 V24 V
24 V24V
24 V24 V
0 V0 V
SS1 function multiaxis with an external safety device and external wiring
SBC-Funktion
24 V
0 V
ODER
Bremse 24 V
Bremse 0 V
SBC-Anwahl Ch 2
SBC-Anwahl Ch 1
Nicht sichere Ansteuerung der Bremse aus der Standard-FW
SBC Function
37Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010Safety on Board and Safe Motion - Additional Resources
www.BoschRexroth.com/safety
http://www.dguv.de/ifa/en/pra/softwa/sistema/index.jsp or just Google “IFA SISTEMA” for BGIA software to calculate PFHd and Performance Level to IEC 13849
www.BoschRexroth.com/MediaDirectory for downloadable manuals including Safety on Board Application Manual
Bosch Rexroth Safety on Board hands-on workshop – next scheduled for April 21st and 22nd in Hoffman Estates (more to follow)
38Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
CMAFH Drive For Technology 2010Functional Safety with Safety on Board
Safety on Board
Always on the safe side
Unexpected movements
Risk for human and machine.