ROBA -topstop. The safest solution for. ROBA-stop. Machine tools Handling systems Assembly devices Multi-axis gantries

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1 The safest solution for Machine tools Handling systems Assembly devices Multi-axis gantries ROBA-stop The safest choice of brake ROBA -topstop Brake systems for gravity loaded axes Reliable protection in all operating modes Maximum safety due to redundancy and integrated functional monitoring Retrofitting to existing axes Patent applied for K.899.V01.GB your reliable partner 1

2 Perfect brakes for vertical axes Safe brake systems for gravity-loaded axes ROBA-stop brakes from mayr prevent an unintentional fall or crash of vertical axes! Reliable personal protection in all operating modes Maximum safety due to redundant brake concepts Controlled operational safety with an integrated monitoring brake function system Minimum braking distances due to quick reaction times and high to brake size performance Different brake concepts to suit individual axes designs Economic retrofitting to existing axes without problems 2 Additional measures are required to minimise the potential risk of a falling load in vertical axes, where personnel might be endangered. This measure is required by the 'Technical Committee for Mechanical Engingeering, Production Systems, Steel Construction ' * in their draft Information sheet "Gravity loaded axes". mayr Antriebstechnik, have addressed this requirement and developed various new braking systems, which guard against all critical dangerous situations, which can occur during operation of vertical axes. The operation of vertical axes represents a special problem. Any switching off of the drive energy due to an error in the machine control or failure can lead to a crash of the axis. Unpredictable mechanical wear as a result of the design, due to emergency OFF braking for example, also contamination of the friction linings through oil, drastically reduces the braking torque. Often, existing brakes integrated into the motor are equipped with insufficient reserves of braking torque and any failure of the brake cannot be excluded. With linear motors any braking in emergency OFF situations or in the event of a failure is not possible via a brake integrated into the motor. In order to avoid critical situations, there is the need to undertake further measures to minimise any risk. Safety systems working redundantly are to be provided according to DIN EN (category 3) for work stations, where persons are frequently in a danger area of the vertical axis. The safety brake product range ROBA -topstop, ROBA -alphastop, ROBA -pinionstop, ROBA -linearstop as also ROBA-stop -M all fulfil the requirements for a safe holding and braking system and minimise the endangerment of persons and machine. These brakes are used as safe single brake for protection according to the danger category 2, as component of a redundant safety system (category 3) or as independent redundant dual circuit brake systems.

3 ROBA -topstop ROBA -topstop Modular safety brake system for servo motor mounting on the A-bearing side Features and advantages Safe holding of the axis in any position, even with a disassembled servo motor, e.g. during machine maintenance Safe braking, also in the event of any emergency-off and failure Long service life, also with frequent emergency-off braking actions Sealed brake housing prevents penetration of cooling and lubrication media Indication of the operating condition (released/braked) by an integrated switch Integral wear monitoring indication optional Short, compact design Low dead weight Low head output even at 100 % switch-on duration ROBA -topstop with output shaft for direct mounting with a hollow shaft gear box. Brake system with integral plug-in shaft coupling. Separate flexible coupling and housing are not necessary. Compact, short design. Brakes - Designs: Single circuit brake with bearing supported output shaft, i.e. suitable for toothed belt drives Single circuit brake with integral, plug-in shaft coupling Single circuit brake with shaft coupling and complete with EAS -smartic safety clutch Redundant dual circuit brake with bearing supported output shaft Basic brake modules for special brake configurations Patent applied for Due to their flange dimensions ROBA -topstop safety brakes can be integrated into existing designs between servo motor and adapter flange. If necessary, any mounting situation can easily be realised by exchanging the standard flange. Three standard sizes for braking torques from 12 to 160 Nm are readily available within short delivery time. 3

4 ROBA -topstop Designs _ With bearing supported clamping hub shaft _ This brake type can directly be integrated or retrofitted in existing drives without appreciable additional technical expenditure. The brake flange and shaft connection dimensions on the output side correspond to the respective servo motor dimensions. A hole above the terminal box allows access to the tightening screw of the clamping hub design on the motor side. Radial forces can be absorbed via the bearing supported shafts, so that the mounting of belt pulleys and the application in belt driven drive system is possible without problems With integrated, plug-in shaft coupling (motor side: clamping hub) and The brake types _. are especially designed for the mounting at ball screws spindles. With a ROBA -ES backlash free shaft coupling, which compensates for axial, radial and angular shaft misalignments integrated into the brake housing, the application of this ROBA -topstop unit removes the necessity for separate coupling distance pieces and shaft couplings. The standard motor shaft mounted coupling hub is the ROBA -ES clamping hub type or shrink disc hub, whereas the coupling hub on the output side is safely connected with the spindle shaft via a shrink disc clamping connection. The short brake construction length does not require any additional space in comparison to the traditional coupling housing designs With integrated, plug-in shaft coupling (motor side: shrink disc hub) With integrated, plug-in shaft coupling and EAS -smartic torque limiter This ROBA -topstop brake is complete with an EAS -smartic torque limiting clutch in addition to the integral ROBA -ES shaft coupling. The EAS -smartic clutch disengages when the preset limiting torque is exceeded and the drive torque drops immediately. An integral inductive switch indicates the overload. The brake is engaged and the input supply is switched off. The gravity-loaded axis is safely held even with a disengaged clutch. Reliable torque overload protection and safely held axis offer maximum protection for persons and machine.

5 ROBA -topstop Designs Friction flange on machine side series Brake modules of the series have been designed for special customised mounting applications. Dependant on the corresponding mounting situations these brakes can be mounted directly to an already existing friction flange face or supplied with an adapter flange to suit the specific application. This brake module, equipped with the standard clamping hub shafts and ROBA -ES shaft couplings or with a special customised design, can optimally be adapted to existing mounting situations _ Brake module with clamping hub shaft Friction flange on machine side Design versions Brake module with plug-in shaft coupling SO Friction flange on machine side Brake module with plug-in shaft coupling (shrink disc hub) SO Redundant dual circuit brake with clamping hub shaft in bearing The dual circuit brake with clamping hub shaft in bearing is equipped with two brake circuits acting independently of each other. Each brake circuit is individually electrically controllable. Dependant on the single circuit brake system the operating condition of each brake circuit separately scanned and signalled. Consequently this redundant brake system fulfils all requirements of the dangerous category 3. 5

6 ROBA -topstop single circuit brake M16x1,5 L C D z z 1 C 2 l a Øm ØZ Ød l 1 Ød 1 ØZ 1 Øm 1 SW B B 1 b s 1 A Øs Fig _ With clamping hub shaft in bearing z a 1 z a 1 SW SW 1 Ød 2 l 2 l 3 Ød 3 Ød 2 l 2 l 3 Ød 4 SW 1 Fig With integrated, plug-in shaft coupling (motor side: clamping hub) Fig With integrated, plug-in shaft coupling (motor side: shrink disc hub) The missing dimensions in Figs. 2 and 3 are identical with the dimensions indicated in Fig. 1 ( _). 6

7 ROBA -topstop with torque limiting clutch L 1 The missing dimensions in Fig. 4 are identical with the dimensions indicated in Fig. 1 ( _). z a 2 Ød 2 l 2 l 4 Ød 5 SW 2 Fig With integrated plug-in shaft coupling and EAS -smartic safety clutch. Technical data 1) 2) Coil capacity with overexcitation Coil capacity with holding voltage 3) Braking torque tolerance +40 % / -20 % See page 10 for further technical details. Dimensions Braking torque 3) _1 [Nm] Braking torque 3) _2 [Nm] Input _1 [W] Input [W] _2 A a a 1 a 2 B B 1 b C C 2 D L L ,5 42, ,5 20 6,5 14,5 86, ,5 42, , ,5 42, A 1) 899. _. 899._ , B 2) Max. speed n max. [rpm] Shaft (Shaft) bore Ø Bores l 2 l 3 l 4 d k6 xl d F7 1 xl 1 1) from - to 1) from - to 1) from - to d H7 2 /d 4 F7 d 3 H7 d x x x x x50 32x58 24x64 32x , , x x x x * * 80 1) The transmittable torques in the bores d 1, d 2, d 3, d4 and d5 depend on the diameter, see Table 1 page 10 for it. * For shaft lengths above 60 mm max. bore 38 mm/up to shaft length 60 mm max. bore 45 mm permissible! m m 1 s s 1 SW SW 1 SW (115**) 9 4x M x M ,5 4x M ** Optionally available with pitch circle m 1 = 115. Z j6 H9 Z 1 z z ,

8 ROBA -topstop brake module L 3 C M16x1,5 D 1 Customer/machine side friction face/flange C 3 z 1 l a Øm 2 á 2(4x90 ) ØZ 2 ØR Ød l 1 Ød 1 ØZ 1 Øm 1 l 5 SW s 1 A1 z 2 b Øs 2 0,03 Friction surface bright Ra =1,6 m Fig _ Brake module with clamping hub shaft Customer/machine side friction face/flange a 1 Customer/machine side friction face/flange a 1 SW SW 1 SW 1 SW 1 Ød 2 l 6 l 3 Ød 3 Ød 2 l 6 l 3 Ød 4 l 7 l 7 z 2 Fig Brake module with plug-in shaft coupling (clamping hub) z 2 Fig Brake module with plug-in shaft coupling (shrink disc hub) The missing dimensiones in Figs. 6 and 7 are identical with dimensions indicated in Fig. 5 ( _). z z 1 C 3 L 2 C 1 M16x1,5 D 1 l a ØZ Ød l 1 Ød 1 ØZ 1 Øm 1 Øm SW B 2 b s 1 A1 Øs 8 Fig Redundant dual circuit brake with clamping hub shaft in bearing

9 ROBA -topstop dual circuit brake Technical data Input Braking torque 3) Braking torque 3) Braking torque 3) Input Input Max. speed [W] n max. [rpm] _ _ _ _ [Nm] [Nm] [Nm] [W] A 1) B 2) [W] 899. _. 899._ x12 31, x31, x x x x ) 2) Coil capacity with overexcitation Coil capacity with holding voltage 3) Braking torque tolerance +40 % / -20 % See page 10 for further technical details. Dimensions A 1 a a 1 B 2 b C C 1 C 3 D 1 L 2 L , , , , ,5 Shaft (Shaft) bore Ø Bores l 3 l 5 l 6 l 7 d k6 xl d F7 1 xl 1 from - to 1) 1) from - to d H7 2 /d 4 F7 d x40 24x50 19x55 24x x50 32x58 24x64 32x x x x x * 80* ,5 1) The transmittable bores in the bores d 1, d 2, d 3, d4 and d5 depend on the diameter, see Table 1 page 10 for it. * For shaft lengths above 60 mm max. bore 38 mm/ up to shaft length 60 mm max. bore 45 mm permissible! m m 1 m 2 R s s 1 s 2 SW SW (115**) x M8 5, x M10 6, ,5 4x M ** Optionally available with pitch circle m 1 = 115 Z j6 H9 Z 1 z z 1 z ,5 0, ,5 5 5,5 0, , Z 2 H7 Order example: To be included when ordering, please state: Order number: Voltage [VDC] Centering -Ø z/z 1 Output side Ød/d 2 Motor side Ød 1/d 3/d 4/d 5 Input 120; 150; 200 Single circuit brake.. 0 Single circuit - brake module. 1 Dual circuit brake. 2 Output side Shaft design Output side Hollow shaft clamping hub... 1 Motor side Shaft bore with clamping... 0 Motor side ROBA -ES clamping hub... 1 Motor side ROBA -ES shrink disc hub... 2 Motor side EAS -smartic... 3 Without elastromeric element... 0 Elastromeric hardness 64 Sh D (green)... 1 Elastromeric hardness 98 Sh A (red)... 2 Elastromeric hardness 92 Sh A (yellow)... 3 According to dimension sheet According to dimension sheet According to dimension sheet Via terminal box Mounting examples: Terminal, release monitoring, wear monitoring, plug etc. 24; 104; 180; 207 V coil Voltage tolerance +/- 10 % acc. to DIN IEC Nominal torque 2... Maximum torque (only possible with overexcitation in case of AC voltage) In this case please contact the factory. Example: ROBA -topstop shaft design - nominal torque Order number 120/ / 24 V / ØZ=110/Ø Z 1 =110/Ød=24/Ød 1 = 20 / configuration terminal box 9

10 ROBA -topstop Technical data _ _ Mass moment of inertia J [kgm 2 ] , , ,001 0, , , , , , ,0020 0,0025 0, , , , , , ,0069 0,01 0, , , , ,00776 Mass m [kg] _ _ , ,4 4,2 5,6 4,5 6, , , ,5 11, , , , _1_.1_ 92 ShA 2 Torque flexible coupling (ROBA -ES ) 899._1_.2_ 98 ShA 2) See ROBA -ES catalogue K _as to furthur information for the flexible coupling as for example angle misalignments, spring rigidities, temperature resistance. [Nm] 899._1_.3_ 64 ShD M nonn M max M nonn M max M nonn M max of the flexible coupling 2) (ROBA -ES ) Torque limiting clutch (EAS -smartic 3 Setting Setting Setting Setting Setting Setting of the torque range I range II range III range IV range V range VI limiting clutch from - to from - to from - to from - to from - to from - to (EAS -smartic 3) ) 120 2, ) See EAS -smartic catalogue P as to further information for the torque limiting clutch as for example torque range and setting. ) [Nm] Assignment of the bore diameters d1, d2, d3, d4 and d5 in dependence on the corresponding transmittable torques (without key) Preferred bores Ø d 1 (clamping hub) Ø d 2/Ø d 4(shrink disc hub) Ø d 3/Ø d 5(clamping hub) and associated transmittable torques [Nm] of the frictional locking Ø15 Ø16 Ø19 Ø20 Ø22 d 1 d 2 /d 4 d 3 d 5 d 1 d 2 /d 4 d 3 d 5 d 1 d 2 /d 4 d 3 d 5 d 1 d 2 /d 4 d 3 d 5 d 1 d 2 /d 4 d 3 d Ø24 Ø25 Ø28 Ø30 Ø32 d 1 d 2 /d 4 d 3 d 5 d 1 d 2 /d 4 d 3 d 5 d 1 d 2 /d 4 d 3 d 5 d 1 d 2/d 4 d 3 d 5 d 1 d 2 /d 4 d 3 d Ø35 Ø38 Ø40 Ø42 Ø45 d 1 d 2 /d 4 d 3 d 5 d 1 d 2 /d 4 d 3 d 5 d 1 d 2 /d 4 d 3 d 5 d 1 d 2/d 4 d 3 d 5 d 1 d 2 /d 4 d 3 d Table 1 We reserve the right to make dimensional and design alterations.

11 ROBA -topstop Switching times: 899. _._ _._ Table 2 Engaging time t 1 (DC Switching) [ms] Engaging time t 1 (AC Switching) [ms] Disconnection Engaging time t 1 time t 2 (Switching DC) [ms] [ms] Engaging time t1 Disconnection (Switching AC) time t2 [ms] [ms] 76, The mentioned values are mean values, related to the nominal air gap and nominal torque (100 %) with a warm brake. Torque-time-diagram M M 2 M 1 M 6 P ON OFF M 4 t 11 t 21 t 1 t 2 t 4 0,1 M 2 t t It means: M 1 = switching torque M 2 = nominal torque (characteristic torque) M 4 = transmittable torque M 6 = load torque t 1 = engaging time t 11 = delay in re-action during engagement t 2 = disconnection time t 21 = react delay during switching off t = slip time + t 4 11 Permissible motor mounting/max. permissible tilting torque (Fig. 9 and Table 3) The permissible components of the motor bolted at the brake module include the static and dynamic loads "F" from motor weight, mass acceleration and vibration, multiplied with the center of gravity distance "I s" of the motor. M k =FxIS Mk perm Perm. tilting torque M k perm. [Nm] Table 3 Friction diagram Friction diagram 899. _._ 1 (Nominal torque) n = 3000 rpm Fig. 9 l s F Friction diagram 899. _._ 2 (Maximal torque) n=3000rpm Permissible switched energy [J] Permissible switched energy [J] Switching frequency [1/h] Switching frequency [1/h] 11

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