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As much as necessary, as little as possible
Perfect voltage adaptation optimizes safety brakes
Electromagnetic spring applied safety brakes are fail-safe. This decisive advantage arises from a minor disadvantage. In malfunction-free operation, the brakes must constantly remain energised so that they stay open. Adapting the voltage to the respective operational condition saves up to 75 % on energy, reduces the operating temperature and optimizes the switching behaviour of the brake.
- The yearly energy cost savings when using the ROBA-switch. The calculations are based on 16 operating hours per day for 7 days a week, at an energy cost of 0.20 € per kWh.
Safety brakes must be capable of bringing machines and systems to a halt as quickly as possible, in order to protect people and machines from injury and damage. Only fail-safe brakes fulfil this demand. Fail-safe means that the brakes must take effect even in unfavourable conditions, operating malfunctions, emergency off and power failure. ROBA-stop brakes are closed when in de-energised condition. They therefore accord with the safety aspects demanded of them. Even if the brake is damaged, e.g. due to cable breakage or to magnetic coil failure, the braking torque is maintained. Fail safe brakes are suitable for application areas with the most stringent safety demands. They are, for example, integrated in vertical axes on machine tools, handling devices and installation equipment, and ensure that the axis is always held safely in a de-energised condition.
ROBA-stop safety brakes are spring applied, and are generally released electromagnetically. During normal, malfunction-free operation, the brakes are permanently energised; being first switched off again at the end of operation. Often, this means that an unnecessarily large amount of energy is used in order to hold the brake open. The optimum electrical control as used on the new ROBA-switch 24 V, for example, can minimise energy consumption.
Even during the development of their electromagnetic safety brakes, mayr power transmission has optimised the magnetic flow via constructive design and selection of materials so that the magnetic tensile force can be achieved with the lowest possible coil power. Optimum dimensioning of the magnetic coil and suitable magnetic flow construction are important aspects of energy-saving. A further, far larger potential for energy-saving, however, can be found during operation. When the voltage is applied to the brake coil, a magnetic field is built up, which pulls an armature disk against the spring force to release the brake. In general, the brakes are dimensioned so that they can be released with coil nominal voltage even with maximum permitted wear on the friction linings. After release, a far lower voltage is perfectly sufficient to keep the brake open reliably. This physical effect is used consistently on ROBA-stop brakes via control with a ROBA-switch 24 V. Due to the coil nominal capacity reduction of 50%, the electrical power, and therefore the energy requirement sinks by 25 %. The savings are enormous.