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CMAFH Drive For Technology 2010 Drive and Motor Safety

CMAFH Drive For Technology 2010

Drive and Motor Safety


Gary Thrall Senior Product Support Engineer Bosch Rexroth Corporation

Safety Safetyon onBoard Board Integrated, Integrated,certified certifiedand andconsistent consistent


Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

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CMAFH Drive For Technology 2010 Drive and Motor Safety

New European Standards IndraDrive safety functions according new standards


IndraDrive C/ M

Coming soon IndraDrive Cs L4 option


STO and SBC

Safety Safetyon onBoard Board Integrated, Integrated,certified certifiedand andconsistent consistent


Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

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CMAFH Drive For Technology 2010 Passport into European Community market (EEA)

European Machinery Directive Machine Builder

EC

Fulfilling harmonized standards the manufacturer can assume that the safety aspects of the machine directive are met

EN 13849-1 (EN 954-1) EN 62061 EN 61800-5-2


Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

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CMAFH Drive For Technology 2010 Change of Safety Standards


Today
European Machinery Directive 98/37/EG 2006/42/EG January 2010 Period 3 years Transition Extended 2 more years Transition Valid Standard November 2006 EN 62061 Valid Standard January 2006 Components EN 61800-5-2 Valid Standard IEC 61508 November 2007 Valid Standard December 2009

Machine Builder

EN 954-1 Valid Standard EN ISO 13849-1

Electric Drives and Controls

2009-02-26; BRC/SPD G. Kobs

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CMAFH Drive For Technology 2010

Performance Level of EN ISO 13849-1:2006


The Performance Level is defined by Category (architecture), identical to EN 954-1 and C-Standards MTTFd (Meantime to dangerous failure in one channel)
Denotation of MTTFd Low Medium High Range of MTTFd 3 years <= MTTFd < 10 years 10 years <= MTTFd < 30 years 30 years <= MTTFd < 100 years

DC (Diagnostic Coverage): Share of detected failures


Denotation of DC None Low Medium High Range of DC DC < 60% 60% <= DC < 90% 90% <= DC < 99% 99% <= DC

CCF (Common Cause Failures affecting both channels) Measures against systematic failures
Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

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CMAFH Drive For Technology 2010 Performance Level of EN

ISO 13849-1:2006

A Performance Level d could be achieved by: Cat. 3 DCavg = medium MTTFd = medium
Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

or

Cat. 2 DCavg . = medium MTTFd = high


6

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CMAFH Drive For Technology 2010 EN 62061 and EN 13849-1


Safety Integrity Level SIL IEC 61508 Probability of dangerous failure per hour (1/h) PFHd >= 10-5 to 10-4 >= 3 x 10-6 to 10-5 >= 10-6 to 3 x 10-6 >= 10-7 to 10-6 >= 10-8 to 10-7 < 10-8 Performance Level PL ISO 13849

IEC 62061

1 1 2 3 4

b c d e -

electrical, electronic and programmable calculation formula for subsystem architectures

All Technologies Simplified Estimation (worst case) regarding to: HW Structure (Category like EN 954) Diagnostic Coverage (DC) Reliability MTTFd Failure of Common Cause (CC)

PFHd Probability of a dangerous Failure per Hour


Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

ISO 13849

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CMAFH Drive For Technology 2010 Performance Level in total

Performance Level of the combination of SRP/CS

SRP/CS1 PL1

SRP/CS2 PL2

SRP/CS3 PL3

Cat 3

Cat 3

Cat 3

SRP/CS4 PL4 SRP/CS 5 PL5 SRP/CS 6 PL SRP/CS 6 7 PL7 SRP/CS 8 PL8 SRP/CS 9 PL9

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
Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

Cat 3

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CMAFH Drive For Technology 2010 SafeMotion - More than just Switching Off!

The evolution of safety technology


Safety reaction Switching off Safety condition SafeMotion

Electric Drives and Controls

2008-11-07; BRC/SPM; J. Ost

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CMAFH Drive For Technology 2010 Conventional versus Integrated

controller enable E

M external monitoring unit (standstill, speed, ...)

two-channel switching-off

additional feedback

Channel 1

Channel 2

Drive

Drive Drive-integrated safety technology

Conventional safety solution

Electric Drives and Controls

2008-11-07; BRC/SPM; J. Ost

10

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CMAFH Drive For Technology 2010 Safety 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.
3 principles are realized to detect latent failures

Dual channel data operation with diversity Cross data comparison of safety related functions Dynamization 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
Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

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.

11

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CMAFH Drive For Technology 2010 Selection of safety functions SafeMotion Functional Safety in Automation Technology
Communication Control Safe Control Safe Communication (Profisafe, SERCOS III Safety)

Auto Set-up

Auto Set-up

T w o .-c h a n n e l in te rru p t

T w o -c h a n n e l in te rru p t

Channel 1

Channel 1

Channel 2

Channel 2

Drive
Option S2 24V / 24V
Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

Drive
Option S2 Safe communication
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CMAFH Drive For Technology 2010 Safety on Board - Functional Safety Safe Torque Off Safe Motion

STO using 24V / 24V or 24V / 0V


X41 channel 1
power section

SLS using 24 V/ 24V


X31/X32 channel 1
common parts

transducer

X41

channel 2

X41

channel 2

One L2 PFH value independent from control (opener / closer, opener / opener)

SLS using SERCOS / 24V


SERCOS channel 1
common parts

Preliminary information Safe Torque Off: PFH Safe Motion: PFH drive and feedback
Electric Drives and Controls

transducer

X41

channel 2

= 2 * 10 -9 1/h
One S2 PFH value independent from the control and the safety technology feature. Separate PFH value for the feedback

= 5 * 10 -8 1/h

2008-11-07; BRC/SPM; J. Ost

13

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CMAFH Drive For Technology 2010 Functional Safety According to ISO 13849-1

Verification with SISTEMA


Library for certified and standard components
IEC 61508 SRP/CS1 PL1 SRP/CS2 PL2 IEC 61508 SRP/CS3 PL3 IEC 61508 IEC 61800-5-2 SRP/CS 4 SRP/CS 5 SRP/CS 6 PL SRP/CS 4 7 PL SRP/CS 5 8 SRP/CS PL 9 6 PL 7 PL 8 PL 9

safety switches

safety I/O

safety PLC

safety drives
ISO 13849

Certified components

input DP

DP PPC SII

IndraDrive

S safety switches I/O Standard components


Electric Drives and Controls 2008-11-07; BRC/SPM; J. Ost

K1 PLC Drive
ISO 13849
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CMAFH Drive For Technology 2010 Certification according to new Standards


Safe Motion EN 954-1 IndraDrive Since 2004 more than 100,000 installed drives Category 3

Development project New Standards Hardware Modification of Control Units CSH.-L1-. -> CSH.-L2-. CSH.-S1-. -> CSH.-S2-. CSB.-L1-. -> CSB.-L2-. CDB.-L1-. -> CDB.-L2-. CDB.-S1-. -> CDB.-S2-. New Firmware Version MPX07VRS
Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

IEC 61508

Deliverable since July 2009

15

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CMAFH Drive For Technology 2010 SafeMotion Preliminary Data


Safe Torque Off (L2):

EN ISO 13849-1:2006 Category 3 PL = e IEC 61508


EN 62061:2005 EN 61800-5-2:2007 SIL3 2 * 10 -9 1/h 100 years (limitation by standard) 20 years

PFHd = MTTFd = Mission Time =

The PFH values are based on a 100% duty cycle (24h/ 365 days)
Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

16

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CMAFH Drive For Technology 2010 SafeMotion Preliminary Data


Safe Motion (S2):

EN ISO 13849-1:2006 Category 3 PL = d IEC 61508


EN 62061:2005 EN 61800-5-2:2007 SIL2 3 * 10 -8 1/h 2 * 10 -8 1/h

PFHd Drive =
PFHd Feedback =

(Stegmann/ Heidenhain motor feedback)

MTTFd = Mission Time =

100 years (limitation by standard) 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)
Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

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CMAFH Drive For Technology 2010 SafeMotion Preliminary Data

Safety Integrity Level SIL IEC 61508 -

Probability of dangerous failure per hour (1/h) PFHd >= 10-5 to 10-4 >= 3 x 10-6 to 10-5 >= 10-6 to 3 x 10-6 >= 10-7 to 10-6 >= 10-8 to 10-7 < 10-8

Performance Level PL ISO 13849

IEC 62061

1 1 2 3 4

b c d e -

Preliminary Data for IndraDrive, Safety on Board Safe Torque Off: PFHd Safe Motion: = 2 * 10 -9 1/h = 2 % of max. SIL3 value

PFHd Drive and feedback = 5 * 10 -8 1/h = 5 % of max. SIL2 value

Electric Drives and Controls

2009-02-26; BRC/SPD G. Kobs

ISO 13849

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CMAFH Drive For Technology 2010 IEC 61800-5-2 New Terminology (not all available)
Safe Torque Off Safe Stop 1 Safe Stop 2 Safe Operating Stop STO SS1 SS2 SOS SMD 1) SLA SAR SLS SSR SSM SMS 1)

EN 61800-5-2: 2007 Functional safety for speed variable drives

Safely-monitored Deceleration Safely-limited Acceleration Safe Acceleration Range Safely-limited Speed Safe Speed Range Safe Speed Monitor Safe Maximum Speed Safely-limited Increment Safe Direction Safely-limited Position Safely-monitored Position Safe Brake Control Safe Braking and Holding System Safely-limited Torque Safe Torque Range Safe Motor Temperature

SDI SLP SMP 1) SBC SBS 1) SLT STR SMT SCA

Electric Drives and Controls

2008-11-07; BRC/SPM; J. Ost

Safe Cam

1) Not defined in IEC 61800-5-2

SLI

19

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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
Safety option L2 S2 S2 S2 S2 S2 S2 S2 S2 S2 S2 S2 S2 S2 S2 IEC 61800-5-2 Terms Safe Torque off Safe Stop 1 Safe Stop 2 Safe Operating Stop Safe Stop 1 (Emergency Stop) Safely-Monitored Deceleration * 1 Safely-Limited Speed Safely-Limited Increment Safe Direction Safely-Monitored Position Safely-Limited Position Safe Door Locking * 1 Safe Communication * 1 Safe I/O *1 Safe Braking and Holding System
*1 Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

EN 954-1 Rexroth Safety functions Safety related starting lookout Safety related standstill Safety related operational stop Safety related operational stop Safety related drive interlock Safety related monitored stopping process Safety related reduced speed Safety related limited increment Safety related direction of motion Safety related absolute position Safety related absolute end position Safety related control of a door locking device Communication via PROFIsafe Safety related in-/outputs via PROFIsafe Safety related braking and holding system

Abk. STO SS1 SS2 SOS SS1 ES SMD SLS SLI SDI SMP SLP SDL SCO SIO SBS

Not defined in EN 61800-5-2 20

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CMAFH Drive For Technology 2010 Drive-Integrated Safety Features

new

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)

Electric Drives and Controls

2008-11-07; BRC/SPM; J. Ost

21

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CMAFH Drive For Technology 2010 Drive Based Safety Functions

Safe Torque Off (STO)

Safe Torque off (Stop Category 0*)


v

t0

Drive is torque-less Power is cut safely (pulse inhibit)

* according to EN 60204-1
Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

22

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CMAFH Drive For Technology 2010 Drive Based Safety Functions

Safe Stop 1 (SS1) / Safe Stop 2 (SS2) Controlled Stopping according to stop
v

t0

t1

category 1* (SS1) monitored stopping, control or drive controlled with safe deceleration Torque-less standstill of the drives Power is cut safely (STO)

Controlled Stopping according to stop


category 2* (SS2) monitored stopping, control or drive controlled controlled standstill after stopping, no power off (SOS) * according to EN 60204-1
23

v, s t0 t1

Electric Drives and Controls

2009-02-26; BRC/SPD G. Kobs

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CMAFH Drive For Technology 2010 Drive Based Safety Functions

Safely Limited Speed (SLS) / Safely Limited Increment (SLI)


v

Within the Safe Mode a safely limited


speed and / or a safely limited increment can be enabled (enabling device)
t0 t1 t

30
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, s

Electric Drives and Controls

2009-02-26; BRC/SPD G. Kobs

24

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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.

Electric Drives and Controls

2009-02-26; BRC/SPD G. Kobs

25

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CMAFH Drive For Technology 2010 Drive Based Safety Functions

Safe Maximum Speed (SMS1) The monitoring of a safely limited maximum


vMax

speed is active always, regardless the operation mode of the drive (Automatic/Manual Mode)

120
t

In case the parameterized maximum speed


will be exceeded the drive will be safely stopped automatically in accordance with the stop category 1.

Electric Drives and Controls

2009-02-26; BRC/SPD G. Kobs

1) Not defined in IEC 61800-5-2

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CMAFH Drive For Technology 2010 Drive Based Safety Functions

Safely Monitored Position (SMP1)

In the safe operation mode


Working Area a working area (absolute position) can be defined

In case the parameterized


Position 1 Position 2 working area will be left, the drive will be safely stopped automatically in accordance with the stop category 1.

1) Not defined in IEC 61800-5-2


Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

27

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CMAFH Drive For Technology 2010 Drive Based Safety Functions

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

v
Max. deceleration Positive Limit Switch

v max Max. deceleration Negative Limit Switch

Electric Drives and Controls

2009-02-26; BRC/SPD G. Kobs

28

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CMAFH Drive For Technology 2010 Drive Based Safety Functions

Safely Monitored Deceleration safety in the stopping process


NC-controlled stopping process with safely monitored deceleration (SMD)

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.

t1

Electric Drives and Controls

2009-02-26; BRC/SPD G. Kobs

29

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CMAFH Drive For Technology 2010 Safety on Board - Safe Braking and Holding System

Safe braking and holding system a new milestone


Safe Braking and Holding System (SBS)

Fall protection for axes with gravity loads Operator protection in special operating mode Worlds 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

Electric Drives and Controls

2009-02-26; BRC/SPD G. Kobs

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CMAFH Drive For Technology 2010 Safety on Board - Safe Braking and Holding System

During automatic operation the


machines and equipment are running at full speed without operators

During special operation mode


persons may be present in the machine when following special safety precautions - Configuration - Measuring - Troubleshooting

Vertical or inclined axes can even


present a danger when they are switched off and inadvertently coming down
Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

31

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CMAFH Drive For Technology 2010 Safety on Board - Safe Braking and Holding System

Fall protection of gravity-loaded axes Personal protection of operators during special operation mode

Safe Braking and Holding system

Effective even after energy


cut-off through emergency stop
Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

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CMAFH Drive For Technology 2010 Safety on Board - Safe Braking and Holding System 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. Safe energy cutting Universal integration of different brake types, e.g.

two-channel selection of the safety feature e.g. safely-monitored deceleration

two-channel control of the brakes

IndraDrive

HAT

Electric Drives and Controls

2009-02-26; BRC/SPD G. Kobs

Safe feedback

33

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CMAFH Drive For Technology 2010 SafeMotion functional safety in automation technology

IndraDrive with safety functions a convincing 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
Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

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CMAFH Drive For Technology 2010 Coming 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 TV 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.
Electric Drives and Controls 2009-02-26; BRC/SPD G. Kobs

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CMAFH Drive For Technology 2010 Coming Soon Safe Torque Off for IndraDrive Cs SS1 functionality [single axis wired] with ktion einer Achse in Verbindung mit einem Sicherh eitsschaltg ert anSS1-Fun external safety device:
+ 2 4V R es et 24 V Dy nam is ierte A us gn ge 24 V m it < 1 ms Tes tim puls

Single channel STO application over a Einkanalige STO-Anwahl ber ein einpoliges Schaltgert single pole switch device
24 V Dynamisierte Ausgnge 24 V mit < 1 ms Testimpuls

No t Ha lt

E x ternes S ic he rh eit ss c haltgert K ate gorie 4, P L e , SI L 3

Z e i t v e r z g e r t

IndraDrive Cs STO-Option Kategorie 4, PL e SIL3

Einpoliges Schaltgert der Kategorie 3, PL d, SIL 2 mit Zwangsffner gem EN 60947-5-1

IndraDrive Cs STO-Option Kategorie 4, PL e SIL3

R c km eldung

24 V STO -Anw ahl Ch1 24 V S TO -A nwa hl Ch2

24 V STO -Anwahl Ch1 24 V STO -Anwahl Ch2 0 V G round fr Ch1 und Ch2

E.Stopp oder NC-S top p

0 V G roun d f r Ch1 u nd C h2 A nwahl b er 2 ffn erk onta kte

SS1 function multiaxis with an external safety device and wiring SS1-Funktion mehrerer Achsen mit external Sicherheitsschaltgert und externer Verdrahtung
24 V 24 V 24 V 24V 24 V 24 V

Anwahl ber 1 ffnerkontakt

SBC-Funktion

SBC Function
24 V

SBC-Anwahl Ch 1 Nicht sichere Ansteuerung der Bremse aus der Standard-FW Bremse 24 V
ODER

STO-Option 1. Antrieb

STO-Option 2. Antrieb

Bremse 0 V
Anwahl Ch1 Anwahl Ch2 0V Anwahl Ch1

SBC-Anwahl Ch 2
Anwahl Ch2 0V

0V

Electric Drives and Controls

2009-02-26; BRC/SPD G. Kobs

36

Alle Rechte bei Bosch Rexroth AG, auch fr den Fall von Schutzrechtsanmeldungen. Jede Verfgungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

CMAFH Drive For Technology 2010 Safety 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)

Electric Drives and Controls

2009-02-26; BRC/SPD G. Kobs

37

Alle Rechte bei Bosch Rexroth AG, auch fr den Fall von Schutzrechtsanmeldungen. Jede Verfgungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

CMAFH Drive For Technology 2010 Functional Safety with Safety on Board

Unexpected movements
Risk for human and machine.

Safety on Board

Always on the safe side

Electric Drives and Controls

2009-02-26; BRC/SPD G. Kobs

38

Alle Rechte bei Bosch Rexroth AG, auch fr den Fall von Schutzrechtsanmeldungen. Jede Verfgungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.