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Complete intelligent safe Rexroth IndraDrive Rexroth IndraDrive Integrated Safety Technology.

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Presentation on theme: "Complete intelligent safe Rexroth IndraDrive Rexroth IndraDrive Integrated Safety Technology."— Presentation transcript:

1 complete intelligent safe Rexroth IndraDrive Rexroth IndraDrive Integrated Safety Technology

2 Reaction with enabling control handle when a linear axis starts up Linear axis with ball screw spindle, v=28m/min, M=1.4Nm, n=6000 rev/min (m/min) (ms) Overtravel: 110mm best reaction Overtravel: 200mm normal reaction Overtravel: 2mm with safety on board technology

3 Category B Risk Assessment According to DIN EN 954 Example: - Selection of cable cross-sections - Selection of the suitable power supply - Control without any safety precautions Safety-related parts must be designed so that they withstand the influences to be expected. Safety categories: System characteristics: A fault can lead to loss of safety.

4 Category 1 Risk Assessment According to DIN EN 954 Safety categories: Example: Proven components: Emergency stop switching device, fuse, cables to IEC, etc. Proven principles: Forced operation, over-dimensioning, limitation, etc. System characteristics: A fault can lead to loss of safety. (However, the probability of occurrence is lower than in category B) Requirements of cat. B must be met; in addition, proven components/principles must be used/applied.

5 Category 2 Risk Assessment According to DIN EN 954 Safety categories: System characteristics: A fault can lead to loss of safety between testing intervals. (But is recognized in the course of testing) Example: Structure of the control: Cyclical test Requirements of cat. B and 1 must be met; in addition, the safety function must be tested by the machine control at suitable intervals.

6 Category 3 Risk Assessment According to DIN EN 954 Safety categories: Example: Structure of the control: Redundancy System characteristics: If a single fault occurs, safety is maintained. Some - not all – faults are recognized. (Several faults can lead to loss of safety) Requirements of cat. B and 1 must be met. Safety-related parts must be designed so that: - a fault will not result in loss of safety. - a fault is recognized.

7 Category 4 Risk Assessment According to DIN EN 954 Safety categories: Requirements of cat. B and 1 must be met. Safety-related parts must be designed so that: - a fault will not result in loss of safety. - a fault is recognized upon or before the next request. Example: Structure of the control: Redundancy, short-circuit-proof System characteristics: If a single fault occurs, safety is maintained. All faults are recognized.

8 IndraDrive Integrated safety technology

9 Stop Categories Category 0 Uncontrolled shutdown Energy supply is imme- diately disconnected; if required application of mech. brakes Category 1 Controlled shutdown Energy supply is maintained until standstill is achieved Category 2 Controlled shutdown Energy supply is maintained also at standstill Stop functions for the shutdown of machines/axes/drives Control current circuits

10 Diversity Diversity is redundancy with different components, techniques and principles. e.g. different hardware manufacturers, different software structures by different programmers, etc. The integrated safety technology from Bosch Rexroth is consistently structured diversely

11  EU type test certificate for safety component “safety related starting lockout“ Safety category 3 (to EN 954-1) Stop category 0 (to EN ) IndraDrive Starting Lockout  The power supply to the drive is safely interrupted. The drive cannot generate torque/force and hence no dangerous movements. Display: "AS"  Forced dynamization for detecting dormant errors Time interval can be adjusted (e.g. open protective door every 8 hours). Note: For all applications of category 3 to EN it is not permitted to route both channels via a standard PLC! Starting Lockout

12 IndraDrive: Integrated safety technology  EU type test certificate for safety component  SI functions: - safety related standstill, - safety related operational stop, - safety related drive interlock, - safety related reduced speed, - safety related limited absolute position - safety related direction of motion  Execution in accordance with safety category 3 (to EN 954-1) Type test Integrated safety technology (safety on board) Safety technology only monitors! It does not control the safety related operation!

13 IndraDrive: Integrated safety technology Crosswise data comparison

14 IndraDrive: Integrated safety technology Operating principle The safety functions are monitored by the drive system during operation. To this end, three principles for detecting dormant errors are realized in the system:  Dual-channel data processing with diverse structure  Crosswise comparison of safety-relevant data  Dynamization of steady states These measures ensure that a single fault cannot result in the loss of safety functions (category 3 to EN 954-1).

15 Selection of channel 1 via I/Os IndraDrive control section M IndraDrive power section SI active I/ O Processor A with SI function Processor B with SI function SI active Channel 2 Channel 1 I/ O IndraDrive: Integrated safety technology

16 SERCOSSERCOS Control SERCOSSERCOS Channel 1 M I/O SI active I/ O Processor A with SI function Processor B with SI function SI active Channel 2 Channel 1 Selection of channel 1 via command communication IndraDrive: Integrated safety technology IndraDrive control section IndraDrive power section

17 IndraDrive: Integrated safety technology Internal dynamization Dynamization signal 24V 0V Slave Master

18 IndraDrive: Integrated safety technology External dynamization Dynamization signal 24V 0V Slave

19 IndraDrive: Integrated safety technology  Standstill: State, in which the mechanical component is at a standstill, with the drive being no longer supplied with energy. Safety related standstill Caution: Vertical axes must be held in position by the motor brake / external brake / weight compensation after the power stage was locked!  Safety related standstill Stop category 1 (to EN ) - The time for shutdown (transition to a safety related status) can be adjusted. - The safety related standstill is interrupted by the actuation of an enabling control! Display: “SH“

20 IndraDrive: Integrated safety technology  The safety function corresponds to “safety related standstill halt“ (stop category 1 to EN ) The only exception: The drive interlock cannot be interrupted by the actuation of an enabling control! Display: „ASP“ Safety related drive interlock Caution: Vertical axes must be held in position by the motor brake / external brake / weight compensation after the power stage was locked! Note: The motor holding brake alone is not permitted for the protection of persons!

21 IndraDrive: Integrated safety technology  The drive is at a standstill, all control loops are active, dual-channel standstill monitoring equipment is active. Stop category 2 (to EN ) - Standstill window can be adjusted. - The time for shutdown (transition to a safety related status) can be adjusted. - The safety related operational stop is interrupted by the actuation of an enabling control! Display: “SBH” Safety related operational stop Note: The axes must be held in position by an external brake or mechanical lock, if external forces acting on the axis must be expected during safety related operational stop!

22 IndraDrive: Integrated safety technology  The drive rotates at reduced speed. Speed monitoring is activated in two channels. - The time for activating the enabling control is monitored. - The time for deceleration (transition to a safety related status) can be adjusted. - Combination with “safety related limited absolute position“ is possible. - Combination with “safety related direction of motion“ is possible. - Combination with “safety related limited increment“ is possible. - Up to 4 safe speeds are possible. Display: “SBB” Safety related reduced speed

23 IndraDrive: Integrated safety technology  The compliance with a maximum safety related limited increment is monitored via two channels. Exceeding the safety related limited increment results in the shutdown according to stop category 1. - In addition, safety related reduced speed is active. - The time for activating the enabling control is monitored. - Combination with “safety related limited absolute position“ is possible. - Combination with “safety related direction of motion“ is possible. Display: “SBB” Safety related limited increment

24 IndraDrive: Integrated safety technology  The compliance with the given, absolute position limit values is monitored via two channels. Exceeding of a limit value results in a shutdown according to stop category 1. The same is valid for an actuating of this feature outside the limit values. - In addition, safety related reduced speed is active. - The time for activating the enabling control is monitored. - “Safety related homing” is a precondition for this. - Combination with “safety related direction of motion“ is possible. - Combination with “safety related limited increment“ is possible. Display: “SBB” Safety related limited absolute position

25 IndraDrive: Integrated safety technology  It is monitored via two channels, that the movement is carried out in only one given direction. A movement in the non-released direction results in a shutdown according to stop category 1. - In addition, safety related reduced speed is active. - The time for activating the enabling control is monitored. - Combination with “safety related limited absolute position“ is possible. - Combination with “safety related limited increment“ is possible. Display: “SBB” Safety related direction of motion

26 IndraDrive: Integrated safety technology Safety related maximum velocity  With the safety function “safety related maximum velocity“, two channels monitor the drive for exceeding the given speed limit value. Exceeding results in the shutdown according to stop category 1. Display:“---“ Note: This monitoring feature is active in any operating mode. It cannot be directly activated or deactivated.

27 IndraDrive: Integrated safety technology Safely monitored stopping  The function controls the transition: - from the normal operating mode to the safety related operating mode of safe standstill, - from one safety related operating mode of safe movement to safety related standstill.  The transition (type of deceleration) to safety related standstill or safety related drive interlock can optionally be controlled by the drive or the master control. The transition to safety related operational stop must be controlled by the master control.  A tolerance time must be determined for the transition to standstill. Exceeding results in the shutdown according to stop category 1.

28 IndraDrive: Integrated safety technology Safety related homing  To be able to realize diverse, i.e. dual-channel-separated position monitoring, the individual channels and their actual position value systems must be diversely referenced. - Dual-channel activation of the homing command. - Dual-channel evaluation of both homing switches.  With absolute measuring systems the homing procedure must also be diverse. Instead of a home cam, a manually operated switch may be used for acknowledging the correct absolute position.

29 IndraDrive: Integrated safety technology Safety related outputs  Safety related diagnostic outputs “Safely acquired states" are passed on to other system components. Controlling of:- Safety relays, - Safety PLC, etc.  Safety related control of a door locking device For several axes within a hazardous zone, a diagnostic master is activated in one of the drive control units, which acquires the safety related status of these axes and controls the door locking device. Note: Position monitoring of the locked, separating protective equipment is additionally required.

30 IndraDrive: Integrated safety technology Normal operation Operating mode switch 4 dual-channel inputs: - Operating mode switch - Enabling control device - Safety switch 1 - Safety switch 2 Operating mode switch + enabling control Enabling control Safely reduced speed 1 Safe standstill

31 4 dual-channel inputs: - Operating mode switch - Enabling control device - Safety switch 1 - Safety switch 2 IndraDrive: Integrated safety technology Normal operation Operating mode switch Enabling control Operating mode switch + enabling control (+ safety switch 1) Enabling control + safety switch 1 Safely reduced speed 2 4 dual-channel inputs: - Operating mode switch - Enabling control device - Safety switch 1 - Safety switch 2 Safely reduced speed 1 Safe standstill

32 Safe standstill IndraDrive: Integrated safety technology Normal operation Operating mode switch Enabling control Enabling control + safety switch 1 Enabling control + safety switch 2 Enabling control + safety switch 1 + safety switch 2 Safely reduced speed 4 Safely reduced speed 3 Safely reduced speed 2 Safely reduced speed 1 Operating mode switch + enabling control (+ safety switch 1 + 2) 4 dual-channel inputs: - Operating mode switch - Enabling control device - Safety switch 1 - Safety switch 2

33 4 dual-channel inputs: - Operating mode switch - Enabling control device - Safety switch 1 - Drive interlock IndraDrive: Integrated safety technology Normal operation Operating mode switch Enabling control Enabling control + safety switch 1 Safely reduced speed 2 Safely reduced speed 1 Drive interlock Drive interlock (ASP) Drive interlock 4 dual-channel inputs: - Operating mode switch - Enabling control device - Safety switch 1 - Drive interlock Safe standstill

34 IndraDrive: Integrated safety technology Dynamization Starting Lockout  Manual (actuation of starting interlock)  Required after power-on and within an adjustable time interval Safety technology I/O:  Dynamization takes place automatically, without being noticed by the user: - Internally by SI master - Externally by PLC / safety PLC Safety technology I/O:  Dynamization takes place automatically, without being noticed by the user: - Internally by SI master - Externally by PLC / safety PLC  Adjustable time intervals Safety technology I/O:  Dynamization takes place automatically, without being noticed by the user: - Internally by SI master - Externally by PLC / safety PLC  Adjustable time intervals  Due to NC/NO combination, one channel is always lead through Integrated Safety Technology (I/O):  Dynamization takes place automatically, without being noticed by the user: - Internally by SI master - Externally by PLC / safety PLC  Adjustable time intervals  Due to NC/NO combination, one channel is always lead through  Synchronization of dynamization in the slaves

35 SI master IndraDrive: Integrated safety technology SI master Different hazardous zones

36 IndraDrive: Integrated safety technology In the case of a control and drive system with integrated safety technology, the following components of conventional safety technology are no longer required:  Motor standstill guard for monitoring the safe standstill  Rotary speed guard for monitoring safely reduced speeds  Power contactors between control devices and motors  Limit switches or position cams for recognizing ranges Note: The integrated safety technology is not intended to substitute conventional safety technology such as emergency stop equipment and protective door guards.

37 IndraDrive: Integrated safety technology Examples: Monitoring of safe motion External:  Delayed reaction times  Particularly fatal with drives with high acceleration rates  Additional measuring and evaluation technology required Internal:  Direct responding reduces reaction time (  2 ms)  Often more cost-efficient  Free selection of control technology  Simple interlinking of safety functions possible (e.g. safely reduced speed + safe direction of movement) Source: BIA report 5/2003 Advantages over conventional solutions Monitoring Drive Controller M v External monitoring Drive Controller with safety integrated M v Internal monitoring


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