Encoder - Mostre Convegno

HEIDENHAIN ITALIANA S.r.l.
Encoder induttivi assoluti EQI
1331 EnDat22 full digital
per applicazioni Safety SIL 3
Arienti Oscar
sales manager automation division
[email protected]
cell. 348/4108857
Arienti Oscar
March 2013
Agenda
ƒ HEIDENHAIN Corporate Group – trend tecnologici
ƒ Fondamenti Normativa Macchine / Fault Exclusion
ƒ Panoramica encoder assoluti induttivi ECI 1xx, ExI 1130, ExI 1331
ƒ Encoder assoluti induttivi EnDat 22 Safety SIL 3 categoria 4 PLe
ƒ Encoder assoluti ottici EQN 1337, EQN 1135 EnDat 22 FS
ƒ Road Map Prodotti FS
Arienti Oscar
March 2013
Agenda
ƒ HEIDENHAIN Corporate Group – trend tecnologici
ƒ Fondamenti Normativa Macchine / Fault Exclusion
ƒ Panoramica encoder assoluti induttivi ECI 1xx, ExI 1130, ExI 1331
ƒ Encoder assoluti induttivi EnDat 22 Safety SIL 3 categoria 4 PLe
ƒ Encoder assoluti ottici EQN 1337, EQN 1135 EnDat 22 FS
ƒ Road Map Prodotti FS
Arienti Oscar
March 2013
Basket product of HEIDENHAIN Group
SUMTAK
HEIDENHAIN
RSF
Arienti Oscar
March 2013
RENCO
LTN
HEIDENHAIN Corporate group
Numerik Jena
LEINE+LINDE
Feedback for application segments
Materials
handling
ERN/ECN
Printing
and paper
ERN/ECN
Robotics
EQI
Packaging
industry
Textile
industry
ROD
ROC
ROQ
EQN
Arienti Oscar
March 2013
Drives
and motion
ERN
ECN
EQN
ROD
ROC
ROQ
ERM
EQN
ROD/ROC
ROQ
LIDA 400
ECI/EQI
LIC 4000
LS
New
EBI 1135
LS/LC/LIDA/LIC
HEIDENHAIN ITALIANA S.r.l.
Arienti Oscar
March 2013
ƒ EnDat 2.2 wide basket product (types and performance levels)
ƒ Feedback with High Technology suitable for entry level segments too
ƒ Safety Functionality without hardware redundancy and benefit of
EnDat22 full digital protocol
Agenda
ƒ HEIDENHAIN Corporate Group – trend tecnologici
ƒ Fondamenti Normativa Macchine / Fault Exclusion
ƒ Panoramica encoder assoluti induttivi ECI 1xx, ExI 1130, ExI 1331
ƒ Encoder assoluti induttivi EnDat 22 Safety SIL 3 categoria 4 PLe
ƒ Encoder assoluti ottici EQN 1337, EQN 1135 EnDat 22 FS
ƒ Road Map Prodotti FS
Arienti Oscar
March 2013
Why Safety Technology?
When a machine tool is in setup mode of operation,
there may be a person within the machine's work
envelope. To avoid damage to persons, it must be
ensured – for example - that:
Stationary axes do not start moving
uncontrolledly
Æ Safe operating stop
Driven axes move at low speed
Æ Safely limited speed
„
„
„
In Europe safety requirements are regulated by law
(Machinery directive - 2006/42/EG)
Standards describe "how to reach safety"
New standards with improved requirements are established
(IEC 61508, EN 13849 - successor of EN 954-1)
Arienti Oscar
March 2013
Comparison of PL and SIL
Performance Level
(PL - EN ISO 13849)
PFHd
Arienti Oscar
March 2013
Probability of a dangerous
failure per hour [1/h]
Safety Integrity Level
(SIL - EN 61508)
a
10-5 to 10-4
No specific requirements
b
3x10-6 to 10-5
1
c
10-6 to 3x10-6
1
d
10-7 to 10-6
2
e
10-8 to 10-7
3
SIL2 / PL “d” = usual requirement on a machine tool (corresponds to category 3 as per EN 954-1)
A direct correlation of “old” categories as per EN 954-1 and the Performance Levels
as per EN 13849 are possible only if the structure of the system (e.g. single-fault
tolerance), the diagnostic coverage and the probability of failure are known.
Note: The PFHd-value is only related to the failure of the safety function of a system not its general function.
Safe Axes
„
Arienti Oscar
March 2013
No interaction between operator and machine
Safety is realized via safety systems such as guard-door switches or light curtains that cut off current to the
axis when a person enters the danger zone.
Æ In these cases, the position encoder is not included in the safety chain and is therefore not
needed for a safety-relation evaluation of the machine
„
Interaction between operator and machine
It must be ensured that the machine does not make any uncontrolled movements. In this case, position
information on the axis or axes is needed in order to realize a safety function. The evaluating safety module
(control, external shaft speed monitor, etc.—referred to as "control" in the following) has the task of
recognizing faulty position information and responding to it accordingly.
Æ Various safety strategies can be pursued depending on the topology of the axis and the evaluation
capabilities of the control. In any event, both components (control and
encoder) must be adjusted to each other!
Position value encoder 1
Control/
subsequent electronic
Position value encoder 2
Encoder Configurations for Safety-Oriented Drives
Arienti Oscar
March 2013
Reliable position value acquisition requires redundant position information
„ Dual-channel redundancy can be ensured by installing two encoders per axis.
Advantage: High safety
Disadvantage: Additional costs
safe control
„ To reduce costs, the use of solutions with one position encoder is intended.
Analog sin/cos
Absolute position is not reliable.
Disadvantages of analog signals
Pure serial data transfer
Reliable absolute position
Advantages of serial data transmission
(first encoders in Nov. 11 2006)
Sine
Cosine
Pos1 + Pos2
(EnDat 2.2)
safe control
safe control
Fault Table in EN 61800-5-2, D16
Arienti Oscar
March 2013
„
The faults that are to be examined in encoders are listed in the standard for electrical motors EN 61800-5-2,
Table D16 . The table lists both electrical and mechanical faults for various encoder types with differing
interfaces.
„
It is the responsibility of the encoder manufacturer to describe the failure behavior of the encoder for the listed
fault. With this description, the control manufacturer can check whether a detection measure for the
described fault is possible on the control.
„
According to EN 13894, two essential aspects are to be considered in this regard
• The probabilistic examination of a safety function requires from the encoders information on failure
rates, and from the control it requires information on probabilities of detecting an encoder error.
• Most target applications require a “single-fault tolerance.” The occurrence of even a single fault must not
lead to a dangerous failure. Therefore, for every assumable fault there must be a detection capability.
Æ Some fault events, however, practically cannot be detected by the control. One such fault is a loosening of
the mechanical connection between the encoder and the motor. In a single-encoder system this fault
cannot be detected in every situation (e.g. during standstill). In order to nevertheless ensure a single-fault
tolerance, a fault exclusion for this fault is required
Fault Exclusion – Mechanical connection of the encoder
„
Arienti Oscar
March 2013
The EN 61800-5-2, Table D16 lists the mechanical fault:
Loss or loosening of attachment during motion:
- sensor housing from motor chassis
- sensor shaft from motor shaft
„
Fault exclusion - depending on the characteristic of the attachment different verifications have to be done:
ƒ
Form Fit (e.g. bolt):
no loosening of the bolt
no slipping of the fixed parts
no breakage of the bolt
ƒ
Friction Fit:
safety factor (e.g. 20x)
The proof of these specifications includes both calculation of the values and real testing
(temperature/vibration). Also a quality system has to be installed to ensure a good workmanship.
Æ
All our fault exclusions of “loss or loosening of attachment“ are proofed by TÜV Süd.
HEIDENHAIN gets a test report by TÜV Süd.
Explanation of terms MTTF, MTTFD, FIT, DC and PFHD
PFHd/PFH:
Probability of a dangerous failure per hour [1/h]
PFH is often used instead of PFHd. Both terms usually mean the same.
FIT:
Failure in time [10-9/h]
Used in EN ISO 61508
The FIT value is the reciprocal of the MTTF value
MTTF/MTBF: Mean time to(between) failure [h]
Used in EN ISO 13849
MTTFd:
Mean time to dangerous failure
The MTTFd value does not itself contain any diagnosis of the values.
Estimation from the MTTF value (according to EN ISO 13849): MTTFd = 2 x MTTF
DC:
Diagnostic coverage
The DC indicates the probability with which certain faults can be detected. The
percentage of non-detected faults leads to the PFHd value.
Arienti Oscar
March 2013
Dependency between MTTF, MTTFD, FIT, DC and PFHD
Arienti Oscar
March 2013
„ Basic principle of calculation of a safe axis and the incorporation of the encoder:
PFHd_axis = PFHd_encoder + PFHd_control + PFHd_actor
The PFHd value of the encoder depends both on the failure behavior of the encoder as on the diagnostic
capabilities in the control
„ PFHd for certified EnDat 2.2 Encoders:
The PFHd can be entered directly. Here the catalog of measures describes in detail how to evaluate the
encoder data for the safe control (see D533095). This reveals the diagnostic coverage (DC) of the control,
and the PFHd value can be provided immediately to the customers.
„ PFHD for non certified Encoders:
HEIDENHAIN cannot provide a PFHd value for the encoder because the diagnostic possibilities of the
control (DC) must be known. In this case, HEIDENHAIN provides the customer with a failure rate (MTTF
value) for the encoder. The MTTF value includes both nonhazardous and hazardous failures of the
encoder. According to EN ISO 13849, it is standard practice to assume that 50% of the faults are
dangerous.
MTTFd_encoder
= 2 x MTTFencoder
PFHd_encoder
=
(as per EN ISO 13849)
HEIDENHAIN -Safety Related Position Encoder System
Arienti Oscar
March 2013
EnDat-Master:
•
•
•
Position values and error
bits
via two interfaces
Monitoring functions
Efficiency test
Note:
The EnDat-Master and the
catalog of measures are
independent to the used
encoder type (linear, angle)
Encoder:
„
Two independent position
values
„
Internal monitoring
„
Protocol formation
Serial data transfer
(EnDat 2.2 + HEIDENHAIN cable)
Catalog of measures
for safe control
Agenda
ƒ HEIDENHAIN Corporate Group – trend tecnologici
ƒ Fondamenti Normativa Macchine / Fault Exclusion
ƒ Panoramica encoder assoluti induttivi ECI 1xx, ExI 1130, ExI 1331
ƒ Encoder assoluti induttivi EnDat 22 Safety SIL 3 categoria 4 PLe
ƒ Encoder assoluti ottici EQN 1337, EQN 1135 EnDat 22 FS
ƒ Road Map Prodotti FS
Arienti Oscar
March 2013
Advantages of inductive rotary encoders
Arienti Oscar
March 2013
„ Higher resolution than in standard systems (e.g. typical resolver: 14 bits)
Singleturn and multiturn:
19 bits/16bits
19 bits / 12 bits
18 bits / 12 bits
18 bits / 16 bits
ECI / EQI 100
ECI / EQI 1300
ECI / EQI 1100
EBI 1100
Advantages of inductive rotary encoders
Arienti Oscar
March 2013
„ The overall length of the motor can be shorter compared with optical rotary encoders
Typical overall lengths:
18 mm
39 mm
22 mm
ECI 119
ECI / EQI 1300
ECI / EQI 1100
13 mm
50.5 mm
EBI 1100
ExN 13xx
Advantages of inductive rotary encoders
„ Low probability of failure due to the smaller number of individual components
„ Longer service life of inductive systems without bearings because bearing wear is excluded
„ Starting torque of inductive systems without bearings is independent of the temperature
„ No motor shaft currents because of galvanic isolation of housing and shaft
„ Improved noise immunity through purely digital data transmission
„ Possibility of diagnostics with EnDat22
„ Safety with EnDat22
„ Measurement of scanning gap with ATS (allowed during mounting at room temperature)
New ExI 13xx EnDat22 SIL3
Arienti Oscar
March 2013
ExI 13xx Gen. 3 with
Mounting PWM 20 ATS s.w.
Arienti Oscar
March 2013
Advantages of Inductive Rotary Encoders
Arienti Oscar
March 2013
„ Vibration (shock) resistant absolute scanning
for servo motors and torque motors
40 g
5g
5g
30 g
Radial forces on the motor shaft can lead to excessive
values in optical systems with bearings as the encoder
is connected to the vibrating motor shaft.
5g
In inductive systems without bearings there are no
excessive values as there is no connection between
the encoder housing and the vibrating motor shaft!
5g
5g
30 g
Advantages of inductive rotary encoders
„ Vibration 55 to 2 000 Hz (EN 60 068-2-6)
Vibration
measurement point
M2: Vibration measurement point see D741714
Arienti Oscar
March 2013
„ ECI / EQI 1100:
„ EBI 1135:
30 g
30 g
„ ECI / EQI 1300 :
Generation 2.5
20 g
„ ECI / EQI 1300 :
Generation 3
60 g stator
40 g rotor
„ ECI 119:
„ EQI 135
30 g
30 g
ExI 13xx Gen. 2.5
Technology
Arienti Oscar
March 2013
„ Modular inductive absolute encoder
„ Resolution:
12 bit multiturn
19 bit singleturn
„ Interface:
EnDat01 with 1 Vpp
EnDat21 w/o 1 Vpp (pure serial)
„ Supply voltage range: 4.75 V … 10 V
„ System accuracy: ± 150″ (at 20 °C)
„ New multiturn gear box
„ Mounting compatible version to Functional
Safety – ExI 13xx Gen. 3 in preparation
„Vibration 55 Hz to 2000 Hz: ≤ 200 m/s2
„ Operating temperature: -40 °C … 115 °C
old
Æ
new
Agenda
ƒ HEIDENHAIN Corporate Group – trend tecnologici
ƒ Fondamenti Normativa Macchine / Fault Exclusion
ƒ Panoramica encoder assoluti induttivi ECI 1xx, ExI 1130, ExI 1331
ƒ Encoder assoluti induttivi EnDat 22 Safety SIL 3 categoria 4 PLe
ƒ Encoder assoluti ottici EQN 1337, EQN 1135 EnDat 22 FS
ƒ Road Map Prodotti FS
Arienti Oscar
March 2013
ExI 13xx Gen. 3 with
Technology
Arienti Oscar
March 2013
„ Modular inductive absolute encoder
„ Resolution, absolute:
„ 12-bit multiturn (gearbox only, no battery-buffering)
„ 19-bit singleturn
„ 10-bit safe position (position value 2)
„ Interface: EnDat22 w/o 1 Vpp (pure serial)
„ Supply voltage range: 3.6 V … 14 V
„ System accuracy: < ± 65’’ (at 20 °C)
„ No mechanical adjustments during mounting
(no special adjustment tools necessary)
„ Integrated / external temperature sensor via EnDat
„ Safe Position ± 3.75°
„ SIL 3 PLe-application PFHD 15 x 10-9
„ Check of the scanning gap via evaluation
numbers (mounting verification)
„ Extended scanning gap tolerance: ± 0,5 mm
„ Vibration 55 Hz to 2000 Hz: ≤ 300 m/s2
„ Operating temperature: -40 °C … 115 °C
ExI 13xx Gen. 3 with
ExN/ExI 13xx
Arienti Oscar
March 2013
„ Common Mounting
ExI 1300
Gen. 3
ExN 1300
Mating Dimensions
ExI 1100 Gen. 3 with FS
Technology
Arienti Oscar
March 2013
„ Modular inductive absolute encoder
„ Mounting compatible to ExI 1100 Gen 2 and
ExN 1100 FS Gen 2
„ Resolution, absolute:
„ 12-bit multiturn (gearbox only, no battery-buffering)
„ 19-bit singleturn
„ 10-bit safe position (position value 2)
„ Interface: EnDat22 (pure serial)
„ Supply voltage range: 3.6 V … 14 V
„ System accuracy: ± 120’’ (typical value at 20 °C)
„ SIL 2 Pl d (prepared for SIL 3 Pl e application)
„ Operating temperature: –40 °C … 110 °C
„ Max. vibration: 30 g / max. shock: 100 g
„ Integrated / external temperature sensor via EnDat
„ No mechanical adjustments during mounting
(no special adjustment tools necessary)
„ Check of the scanning gap via diagnosis evaluation
numbers (mounting verification)
„ Axial scanning gap tolerance: ± 0.3 mm
ExI 1100 Gen. 3 with FS
Preliminary Drawing
Arienti Oscar
March 2013
ExI 1100 Gen. 3 with FS
Common Mounting Concept
„ Common Mounting
ExI 11xx
Gen. 3
EBI 11xx
Gen. 2
Mating Dimensions
ExN 11xx
Gen. 2
ExI 1100 Gen. 3 with FS
Common Mounting Concept
Arienti Oscar
March 2013
Agenda
ƒ HEIDENHAIN Corporate Group – trend tecnologici
ƒ Fondamenti Normativa Macchine / Fault Exclusion
ƒ Panoramica encoder assoluti induttivi ECI 1xx, ExI 1130, ExI 1331
ƒ Encoder assoluti induttivi EnDat 22 Safety SIL 3 categoria 4 PLe
ƒ Encoder assoluti ottici EQN 1337, EQN 1135 EnDat 22 FS
ƒ Road Map Prodotti FS
Arienti Oscar
March 2013
ECN 1325 / EQN 1337 in Safety Applications
The “nose“ prevents the coupling and so the
encoder from turning = form fit!
A 2 times safety has to be proved and is by the
TÜV against overload breakage and 1.5 times
against fatigue breakage!
The motorshaft is expected to be made out of steel and the housing of aluminum!
Arienti Oscar
March 2013
Taper Shaft 65B or HUB shaft67M in FS Applications
Î Taper shaft 65B in combination with materially bonding anti-rotation lock
Î Bottomed hollow shaft 67M1) in combination w adhesive screw lock safe acc. to TUV Süd!
1) Limitation of the max. allowed acceleration and the minimum temperature to -30°C
Arienti Oscar
March 2013
Mounting Test: Shaft Connection
Arienti Oscar
March 2013
Taper shaft
The usage of a screw with materially bonding anti-rotation lock is required
for fastening the shaft!
A screw is no longer delivered
with the encoder!
New!
With this test tool 680644-01, which has to be attached to the M10,
the customer has to proof the tight fit of the shaft by a torque of 5 Nm
Max. torque at shaft connection = 0.5 Nm
20x security = 10 Nm (certified by TÜV Süd)
10x security = 5 Nm ( 100% test by the customer)
Note: The screw with Tuflock is still delivered with ″Non-FS“ encoders!
Cured!
Product Information
Control category / standards
The encoder can be used in applications up to …
PFH-value encoder + cable
catalog of measures is taken into account
(EnDat-Master is not included in PFH-value)
Angular error for the safe position
gives the maximum angular error of the
safe position
Arienti Oscar
March 2013
Agenda
ƒ HEIDENHAIN Corporate Group – trend tecnologici
ƒ Fondamenti Normativa Macchine / Fault Exclusion
ƒ EQN 1337 EnDat 22 FS ( Functional Safety)
ƒ EQN 1135 EnDat 22 FS
ƒ Road Map Prodotti FS
Arienti Oscar
March 2013
ECN 1123 / EQN 1135 in Safety Applications
Arienti Oscar
March 2013
ECN 1123 / EQN 1135 in Safety Applications
Arienti Oscar
March 2013
Fixing of encoder/motor shaft
M3 central screw
max. tightening
torque of 1.2 Nm
Friction lock fixing of
shaft front surface
Motor shaft w/ M3
thread
Fixing of stator coupling
Encoder:
Blind hollow shaft ‫ ׎‬6 mm
with positive fit element
Motor:
Shaft with negative
fit element
ECN 1123 / EQN 1135 in Safety Applications
Screws from HEIDENHAIN have to be used!
Arienti Oscar
March 2013
Agenda
ƒ HEIDENHAIN Corporate Group – trend tecnologici
ƒ Fondamenti Normativa Macchine / Fault Exclusion
ƒ Panoramica encoder assoluti induttivi ECI 1xx, ExI 1130, ExI 1331
ƒ Encoder assoluti induttivi EnDat 22 Safety SIL 3 categoria 4 PLe
ƒ Encoder assoluti ottici EQN 1337, EQN 1135 EnDat 22 FS
ƒ Road Map Prodotti FS
Arienti Oscar
March 2013
Schedule for Safety-Related Position Measuring Systems
Encoders with EnDat 2.2 (EnDat22) for
safety related applications
Status
ExN 4xx / 13xx c
Series production
3
ExN 10xx / 11xx c
Series production
3
LC 100/400
Series production
3
LC 200
Series production
RCN 2000/5000/8000
Concept verified
Series planed : 2. Q./2013
ECI, EQI 13xx
Series production
c safe in the single turn range
3
3
Arienti Oscar
March 2013
Arienti Oscar
March 2013
Siete i benvenuti al nostro stand
per ulteriori approfondimenti.
Grazie!