In a project developed for MOVIN (www.movin.it), an Italian company active in industrial automation, Sytrama (www.sytrama.com), a manufacturer of Cartesian manipulators, has chosen safety brakes from Mayr (mayr.com/it) to ensure maximum protection during the operational phases of its robots. This is a significant application which confirms the importance of reliable components when humans and machines share the same space
Robotics continues to grow in Italy, driven by the need for advanced automation, by exports and by the increasingly widespread integration of collaborative technologies. Cartesian robots, in particular, are used in many assembly lines due to their flexibility and precision. In this context, safety is an essential priority: careful design of interactions, supported by mechanisms capable of coping with unexpected situations, is necessary to ensure the safety of machinery, products and, above all, people.
When humans work alongside robots
In many production lines, direct interaction between operators and robots is an integral part of the process. This requires solutions to ensure human safety in the event of malfunctions or sudden stops.
Among the most important components from this standpoint are, of course, safety brakes, which are essential to ensure that robot movements do not result in collisions with potentially serious consequences, not only during standard operation but also in situations where the relative position of operators and machines deviates from the expected.
Redundancy in braking systems
In a production environment where the presence of people in the vicinity of robots requires high safety standards, redundancy is a key principle in the design of fail-safe systems capable of ensuring safety even in the event of component failure.
In the field of safety brakes, Mayr offers two complementary approaches to redundancy:
• Redundancy with two separate brakes, mounted on different parts of the drive system (for instance, one on the motor and one on the shaft), ensures that the holding function is maintained even in the event of mechanical failure of one component;
• Redundancy with a single dual-circuit brake, which integrates two independent drive circuits within the same brake housing. If one of the two circuits fails, the other is able to maintain the position in complete safety.
The choice between the two configurations depends on the characteristics of the system and the design objectives: in both cases, the designers can choose from reliable, certified solutions offering the necessary redundancy without compromising system efficiency.
Reliable and safe
The Mayr brake range is extensive and includes models suitable for all types of industrial applications. In robotics, the most commonly used Mayr brakes are ROBA-servostop brakes, spring-safe electromechanical brakes designed specifically for mounting on servo motors.
Thanks to their compact design and low moment of inertia, they are ideal for integration in confined spaces and for highly dynamic applications such as robotics. They offer reliable braking action even in the event of a power failure and are available in different versions to suit different motor systems. The wide range of customisation options and high repeatability make them particularly suitable for ensuring safety in complex systems with fast and precise cycles.
For collaborative applications, Mayr has developed the ROBA-servostop Cobot range; these brakes are designed to stop and hold axes in position even in the event of a power failure thanks to the action of the springs. Compact and quiet, they integrate sensors for monitoring operating conditions and are certified for use in environments shared with human operators.
Sytrama: experience and specialisation
An interesting example of the use of brakes in an environment where robots and operators coexist is provided by a recent application developed by Sytrama, a company which develops and markets Cartesian robots designed for industrial automation and servo applications.
With extensive experience in the sector, the company is part of the Negri Bossi – Nissei Plastic Industrial group and is a reference point for those seeking reliability, customisation and technical support.
Sytrama created this solution for MOVIN, an Italian company specialising in automated assembly systems and lines, which expressed the need to guarantee safety even in the close presence of operators. To meet this requirement, Sytrama designed a configuration with redundant brakes on the axes of its Cartesian robots.
Innovative components and reliable partners
Sytrama turned to Mayr for the brakes: ‘We used Mayr brakes on the working axes of Cartesian robots installed on assembly lines where operators are present,’ Paolo Bonin, design engineer at Sytrama, explained. ‘Mayr was already our supplier of transmission couplings. We had never used their safety brakes before,’ Bonin continued. ‘The Mayr sales engineer presented their range of brakes to us and together we identified the most suitable type for the application”.
The brakes were selected for installation on rack and pinion transmissions, alongside the brakes already fitted on the electric motors. The aim was to achieve functional redundancy in maintaining the position of the axes, preventing unwanted movements in the static phase.
Valuable technical support
The joint work between Sytrama and Mayr’s technical team made it possible to identify and correctly size the brakes, also selecting the most suitable electronic control devices. Mayr confirmed its full willingness to work alongside the customer, positioning itself as a partner rather than a simple supplier, a characteristic always appreciated by companies choosing its products.
‘The sales engineer was courteous and helpful. The technical office staff dimensioned the brakes according to our specifications,’ Mr. Bonin confirmed.
Collaborative safety: The importance of redundancy
In this application, Sytrama chose a braking system which guarantees redundancy in order to eliminate any risk to operators, even in the close proximity to robots required by the production process.
Once again, Mayr’s engineers provided valuable support in selecting the most suitable braking system to guarantee redundancy in this particular installation and ensure its perfect integration into the plant.
Future prospects
Satisfied with the result achieved, Sytrama is looking forward to new opportunities for collaboration with Mayr on other future projects. Human-machine safety remains a priority for those who, like Sytrama, design solutions for advanced industrial automation.
Since 1897, Mayr, the reliable partner for drive technology and power transmission, has been offering innovative solutions to leading companies in a wide range of mechanical engineering industries.
With its comprehensive range of torque limiters, transmission couplings and safety brakes, the company is able to respond quickly to most requests, thanks in part to its efficient and forward-thinking logistics management, refined over decades of experience in the Italian market. Mayr’s warehouse in Italy, covering over 400 square metres, enables it to deliver the most popular products promptly.
Mayr’s technical experts are available to provide no-obligation advice on the right product to choose or, if necessary, to customise a product to meet specific production requirements. For further information on Mayr solutions, please contact the company by telephone on +39 049 8791020 or by email (info@mayr-italia.it), or visit the website mayr.com/it.
