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SINAMICS Brake Test With Sinumerik 840D SL
SINAMICS Brake Test With Sinumerik 840D SL
https://support.industry.siemens.com/cs/ww/de/view/109477754
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1 Introduction
Axes and mechanical systems can drop due to gravity when the drives are
switched off. Dangerous motion can result for vertical axes or for rotary axes or
spindles with an asymmetrical weight distribution.
For this reason, a drive must also be safely held in position when switched off (no
current condition). This is usually implemented using a holding brake. The reliability
of this holding brake is an essential part of the protection function against falling
vertical axes.
The "Safe Brake Control" function (SBC) is used to control holding brakes that
function according to the closed-circuit principle (e.g. motor holding brake).
The brake is controlled via a two-channel output of the SINAMICS Motor Module.
SBC (if configured) is always triggered together with STO.
The brake test checks whether the expected holding torque is still available. The
drive moves against the closed brake and applies the test torque – there should be
no axis movement if the test is successful. However, if an axis movement is
detected, it must be assumed that the brake holding torque is no longer sufficient
to hold the axis in position. In this case, the relevant axis must be traversed to a
safe position and the brake checked and repaired, if required.
2 Task
This application example describes configuring the SINAMICS brake test for safety
axes (Safety Integrated with SPL), which are directly assigned a SINUMERIK NCU.
2.2 Preconditions
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Proceed as follows to configure the SIC/SCC telegram for an axis with SINUMERIK
Safety Integrated functionality:
Open the "DP slave properties" dialog.
There, select the "Configuration" tab.
Under "Option", select entry "SI motion monitoring + telegram 701" for the
required drive.
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Fig. 3-2: Logical basis address (in the example, for the 2nd drive)
Abbildung 4-2
The positioning response at the end of the SINAMICS brake test is set so that the
brake is subject to a minimum load. By pressing against the brake, the axis moves
away from the last programmable position. To conclude the brake test, the current
axis position is used for the next path motions. (MD36968
$MA_SAFE_BRAKETEST_CONTROL bit 2 = 0). This results in an approach
motion to the last programmed axis position on the path.
5 Drive parameterization
Preconditions
Note The parameters of this function can only be changed in the safety commissioning
mode p10=95
Enabling SIC/SCC
Note Axes with SINUMERIK Safety Integrated (SPL) only require this type of control.
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Brake type
= 0 inhibit:
This must be set if one of the brakes is either not available or is not to be
tested.
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The time, in which the test torque to be established and later also
decreased to zero, is specified in p10208.
Note When testing an external brake, whose mechanical design exhibits backlash
(e.g. if there is a gearbox located between the motor and external brake), it can
make sense to extend the ramp time (p10208) when ramping up and ramping
down the test torque.
You can parameterize 2 test sequences for each of the two brakes.
Using parameters p10210 and p10220, a factor is set for the individual test
sequences
which is multiplied by the value in p10209, to obtain the test torque for the
particular sequence. The permissible range of values extends from 0.3 up to 1.0.
Test torque = factor (p10210/p10220) * p10209
From software release 4.7 SP3 and higher, the brakes can be parameterized using
the following screen form:
NOTICE The brake test must be carried out before carrying out the test stop. If the
brake test was not successful (i.e. the brake cannot hold the axis), then it is
not permissible that the test stop is carried out.
The brake may only be tested when the axis is in an absolutely safe
position.
Preconditions
When testing the (motor) holding brake, that is controlled by SINAMICS,
SBC must also be configured and the brake configuration parameterized
just like the sequence control (p1215=1).
When selecting the SBT function the pulses must be enabled and the brake
opened.
Testing a motor holding brake
The timing of the brake test from the perspective of the PLC user program is shown
in the following diagram.
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PLC axis
AWP DB
Time
The timing of the brake test from the perspective of the PLC user program is shown
in the following diagram.
PLC axis
AWP DB
Close brake(DBx173.6)
Time
Note If bit axisDBX11.0 48 is set for a traversing axis, then NCK outputs alarm 27830
"Axis %1: control not ready for the drive integrated safe brake test" and status
signal axisDB.DBX71.0 is not set.
After the user selects the brake test, the static hanging/suspended load is
determined in the drive. This is the reason that all brakes must be open and the
pulses enabled when the brake test is selected. The brake, the test sequence and
the test direction are then selected by the user. Only when the brake test is active
after the user has started the brake test/brake test sequence is the holding brake
closed, or there is a prompt to close the external brake. A maximum time of 11
seconds is allowed to elapse until the feedback signal "Brake closed" is output,
otherwise alarm 201784 is output and the brake test canceled.
The test torque (test torque +/- load torque for a vertical axis) is specified during
the SBT. When n = 0 is entered, the controller builds up an appropriate test torque
against the closed brake. The test torque is built up along a ramp. The ramp is
defined by the time of p10208. At the end of the test sequence, the brake is
opened or there is a prompt to open the brake. After deselection of the test
sequence (test sequence is switched off), another test sequence can be started,
e.g. with a different brake in a different direction, assuming that the brake test is
still selected. When the test sequence is active, the brake that is not being tested
must remain open. After deselecting SBT, the original speed setpoint again
becomes effective.
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For a brake test, the motor should apply a force to the brake that is applied in
addition to the force due to weight. The direction in which the drive should establish
its force is specified from the PLC using bit axis-DB.DBX143.3 (1 negative/0
positive). The sign of the load torque before the brake test can be determined
using bit axis DB.DBX173.7 (1 negative/0 positive).
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7 Diagnostics options
The actual states and test progress can be monitored using a status words r10234
and r10242 and diagnostics parameter r10240.
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Englisch
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8 PLC programming
This application example is provided in a block in STL.
DBSI_SBT_X_axis
EN EN0
Close external
Selection brake Brake_1_2 CloseBrk
brake
Selectoion
Torque_1_2
toruqe Step Step counter
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Start
BT_Start
brake test
Extenal brake
Brake_closed
closed
Quit Quittierung
Pulses
DB3x.DBB93.7 Select brake
released DB3x.DBX143.0
test
Brake test DB3x.DBB71.0
active DB3x.DBX143.1 Start brake
System test
interface Brake test
DB3x.DBB173.0
selected
DB3x.DBX143.2 Brake 1/2
Bake 1/2 DB3x.DBB173.2
Traversing
DB3x.DBX143.3
DB3x.DBB173.4 direction
Brake test ok
Close Brake
DB3x.DBB173.6 DB3x.DBX143.5
brake closed
// Test axis 2
// Test motor brake
// Test sequence 1
// Start brake test
Input parameters:
Axis_NR: number of the axis to be tested
Brake_NR: brake to be tested (motor brake = 0/external brake = 1)
Direction_AUTO: specifies the direction for the brake test
= 0 specifies the direction
= 1 and direction = 0 = direction = DBax.DBX173.7
= 1 and direction = 1 = direction = DBax.DBX173.7 negated
Direction: direction specification manual brake test
Torque_1_2: torque selection (test sequence 1 = 0 / test sequence 2 = 1)
Start_BT: start of the brake test
Brake_closed: feedback signal external brake closed
Time1: time for brake test
Quit: acknowledgment error
Output parameters:
Error: error
Done: brake test OK
DiagnoseStep: actual step
DiagnoseError: error number
Close_Brake: request to close external brake
Diagnostics
DiagnoseError:
DiagnoseStep
Selection brake 1
Close Brake 1
BT active
Brake 1
Start BT
of the position offset < tolerance
Presetting torque
Monitoring n<10% Nn
Presetting direction of rotation
1,5xP10208
act. test torque
Diagnostics test torque
The requested test torque is applied
Test period
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End
Finished torque build-up
Brake
Open Brake 1
Brake 1
BT ok
BT inactive
BT finished
Selection torque
Selection brake 2
BT active
Brake 2
Brake closed
Start BT
of the position offset < tolerance
Monitoring n<10% Nn
Presetting direction of rotation
1,5xP10208
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End BT
Finished torque build-up
Brake open
Brake 2
BT ok
BT inactive
BT finished
The SIC is the feedback signal channel for the brake test
9 Alarms
9.1 Setting of the SINAMICS alarm screen form
The bits for alarms (CU and Motor Module) must be set for the brake test in
general machine data MD 13150.
27830 axis %1: Control not ready for the "safe brake test" integrated in
the drive
Parameter %1: Axis name, spindle number
Explanation The request for the drive-integrated "safe brake test" via the
VDI interface has been rejected by the motion control system.
Response alarm is displayed
Remedy The alarm disappears if the conditions in the motion control
system for carrying out the drive-integrated "safe brake test" are
fulfilled, or the request for the drive-integrated "safe brake test"
is withdrawn.
Program Alarm display disappears when the cause of the alarm is
resolved.
continued No additional conditions required
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Missing conditions:
If, when the dbBT is selected via VDI, the interpolator or the axis is not
stopped, i.e. the axis is still moving or the exact stop is no (longer) applicable.
If a new dbBT was requested and the previous dbBT was not exited in the
control system.
If another axis in the channel is moving
9 Alarms
Entry ID 109477754
01/2018
32
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9 Alarms
Entry ID 109477754
01/2018
33
10 Supplementary conditions
10 Supplementary conditions
Master-slave:
When using a master-slave configuration, a distinction must be made as to whether
it involves a temporary or a permanent coupling.
Before testing the brake mechanical system, a temporary coupling can be opened
so that the brakes can be individually tested.
For a permanent coupling, it must be decided on a case-for-case basis whether a
defective brake could result in mechanical damage.
The brake test should not be performed if mechanical damage could occur.
Gantry group:
For a gantry group, it must be decided on a case-for-case basis whether a
defective brake could result in mechanical damage.
The brake test should not be performed if mechanical damage could occur.
The "Safe Brake Test" (SBT) function is not available for SINAMICS HLA.
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