Machine drives using closed-loop speed control are state of the art. As on drives without closed-loop speed control, the movement of a machine part at varying speeds frequently gives rise to a hazard against which the machine operators must be protected. The simplest means of preventing movements during manual intervention in danger zones is the (safe) disconnection of the energy driving the relevant motors. This is however often not possible, for example when intervention is required whilst the machine is running for the purpose of clearing faults, setup, during test operation, etc. Scenarios such as these require the machine to be operated with protective equipment disabled. In order for the operators‘ safety to be assured nonetheless, Annex I, Section 1.2.5 of the Machinery Directive sets out the required measures. Safety sub-functions for drive controls have been defined for implementation of the machine functions required for this purpose. Examples are STO (safe torque off), SLS (safely limited speed) and SS1 (safe stop 1). This report addresses the use of drive control equipment that implements safety sub-functions at a certain Performance Level according to ISO 13849-1 in consideration of the application and risks. The basic safety sub-functions of drive controls and the requirements relating to their use are presented. The principles of operation of frequency inverters and DC converters are described, and implementation of the safety sub-functions are explained. Examples are provided of application circuits by which the various machine safety functions can be implemented. The corresponding SISTEMA files for quantification of these safety functions are available for download free of charge. The examples include both standard frequency inverters and frequency inverters with integrated safety functions.
The EN ISO 13849-1 standard, “Safety of machinery – Safety-related parts of control systems”, contains provisions governing the design of such parts. This report is an update of BGIA Report 2/2008e of the same name. It describes the essential subject-matter of the standard in its third, revised 2015 edition, and explains its application with reference to numerous examples from the fields of electromechanics, fluidics, electronics and programmable electronics, including control systems employing mixed technologies. The standard is placed in its context of the essential safety requirements of the Machinery Directive, and possible methods for risk assessment are presented. Based upon this information, the report can be used to select the required Performance Level PLr for safety functions in control systems. The Performance Level PL which is actually attained is explained in detail. The requirements for attainment of the relevant Performance Level and its associated Categories, component reliability, levels of diagnostic coverage, software safety and measures for the prevention of systematic and common-cause failures are all discussed comprehensively. Background information is also provided on implementation of the requirements in real-case control systems. Numerous example circuits show, down to component level, how Performance Levels a to e can be engineered in the selected technologies with Categories B to 4. The examples provide information on the safety principles employed and on components with well-tried safety functionality. Numerous literature references permit closer study of the examples provided. The report shows how the requirements of EN ISO 13849-1 can be implemented in engineering practice, and thus makes a contribution to consistent application and interpretation of the standard at national and international level.
FUNCTIONAL SAFETY OF MACHINERY Enables readers to understand ISO 13849-1 and IEC 62061 standards and provides a practical approach to functional safety in machinery design Functional Safety of Machinery: How to Apply ISO 13849-1 and IEC 62061 introduces functional safety of machinery as a single unified approach, despite the existence of two standards. Aligning with the latest updates of ISO 13849-1 and IEC 62061, the book explains the intent behind the standards and the mathematical basis on which they are written, details the differences between the two standards, and prescribes ways to put them into practice. To aid in seamless reader comprehension, detailed examples are included throughout the book which walk readers through concepts like Random and Systematic Failures, High and Low demand mode of operation, Diagnostic Coverage, and Safe Failure Fraction. Other sample topics covered within the book include: Basics of reliability engineering and functional safety Roles of the standards in the design and evaluation of safety functions Description of the Main Parameters used in the two standards How to deal with Low Demand Safety Systems The Categories of ISO 13849-1 and the Basic Subsystem Architectures of IEC 62061 How Categories and Architectures can be validated Machinery design engineers, machinery manufacturers, and professionals in system and industrial safety fields can use this book as a one-stop resource to understand the specifics and applications of ISO 13849-1 and IEC 62061.
From the point of view of a user this book covers all aspects of modern electrical drives. It is aimed at both users, who wish to understand, design, use, and maintain electrical drives, as well as specialists, technicians, engineers, and students, who wish to gain a comprehensive overview of electrical drives. Jens Weidauer and Richard Messer describe the principles of electrical drives, their design, and application, through to complex automation solutions. In the process, they introduce the entire spectrum of drive solutions available and their main applications. A special aspect is the combination of multiple drives to form a drive system, as well as the integration of drives into automation solutions. In simple and clear language, and supported with many diagrams, complex relationships are described and presented in an easy-to-understand way. The authors deliberately avoid a comprehensive mathematical treatment of their subject and instead focus on a coherent description of the active principles and relationships. As a result, the reader will be in a position to understand electrical drives as a whole and to solve drive-related problems in everyday professional life.
International Conference on Electrical, Control and Automation （ICECA 2014）will be held from February 22nd to 23rd, 2014 in Shanghai, China. CECA 2014 will bring together top researchers from Asian Pacific areas, North America, Europe and around the world to exchange research results and address open issues in all aspects of Electrical, Control and Automation. The ICECA 2014 welcomes the submission of original full research papers, short papers, posters, workshop proposals, tutorials, and industrial professional reports.
With continuous restrictions on emission standards and demands for higher driving comfort, the calibration of shift quality is linked deeply and widely to automated transmission control algorithms. This calibration process is typically implemented with real vehicles on the road under poorly reproducible conditions, where the calibration engineer has no other choice but to try different control parameters till the subjective assessment on the shift quality meets certain requirements, such as shifting comfort or sportiness. Compared with today’s multiplying number of variants in vehicle-engine-transmission combinations and exponential growth of control parameters, this traditional method is backward and costly. An efficient way to rise to the challenge is the model-based automatic calibration. In contrast to the conventional shift quality calibration, this novel method uses a closed loop approach based on a dynamic model instead of human know-how. A shift quality correlated position trajectory is proposed. Compared to the traditional control parameter adjustment method, the guided trajectory has a higher tolerance to the system’s hardware components and a better compatibility with TCUs from diverse suppliers. Since shift quality is not restricted to a general summarized grade, e.g., comfort and sportiness are always two conflicting influence factors in the terms of shift quality calibrations, a multi-objective evolutionary algorithm is applied to search the set of Pareto-optimal front, which includes all the optimal compromised control parameters of the gear shifting trajectory for possible choice. In this work a hydro-mechanical AMT synchronization system is used as an example to explain the proposed optimization process. A Modelica® based non-linear hydro-mechanical AMT system is modeled, which describes the transient behavior during gear shifting in detail. An effective fuzzy sliding-mode position controller is designed for the referenced position tracking during synchronization; in contrast to the conventional trial-and-error tuning method, a genetic algorithm is applied to automatically identify and optimize the sliding-mode controller parameters. A novel multi-objective evolutionary algorithm, MLIA, is developed to find out the optimal control set for the synchronization trajectories. Verification at a transmission test bench shows that this model-based multi-objective optimization method has a guiding capability in automated transmission calibration. Mit deutlich strengeren gesetzlichen Anforderungen hinsichtlich der Abgasemissionen und einer zunehmend anspruchsvolleren Nachfrage bezüglich des Fahrkomforts, rückt die Frage nach der Schaltqualität stärker in den Fokus der Getriebeentwicklung. Die Kalibrierung (umgangssprachlich die Applikation) ist deshalb ein Schwerpunkt bei der Entwicklung von Algorithmen für die Schaltqualität von automatisierten Getriebesteuerungen. Der Kalibrierungsprozess wird in der Regel im Fahrzeugversuch auf der Straße durchgeführt. Der Applikationsingenieur versucht unter diesen nicht reproduzierbaren Bedingungen verschiedene Steuerparameter zu adaptieren. Dies wird für eine Schaltung solange durchgeführt bis die subjektive Beurteilung der Schaltqualität und die zugehörigen Eigenschaften, wie zum Beispiel Schaltkomfort und Sportlichkeit, erfüllt ist. Dieser beschriebene Prozess ist zeit- und personalaufwendig, was mit dem aktuellen Angebot an Motor-Getriebe-Fahrzeugvarianten kaum bewältigt werden kann. Als weitere Herausforderung steigt die Anzahl der kalibrierbaren Parameter der Regler- und Steuerungsmethoden stetig um die Kundenbedürfnisse zu befriedigen, weshalb auch aus Kostensicht ein besserer Prozess gefunden werden muss. Eine effiziente Möglichkeit zur Lösung der skizzierten Problemstellungen ist die modellbasierte automatische Kalibrierung. Im Gegensatz zu der herkömmlich auf Fahrversuche basierende Kalibrierung der Schaltqualität verwendet dieses neue Verfahren ein dynamisches Modell in einer geschlossenen Schleife. Anstelle des Applikationsingenieurs für die Fahrvorgaben wird in der Schleife ein Fahrerregler und ein Optimierungsalgorithmus verwendet, um so eine hohe Reproduzierbarkeit des Schaltereignisses sicherzustellen. Es wird vorgeschlagen, die Bewegung der Schaltstellung zu optimieren, da diese mit der Schaltqualität korreliert. Diametral steht dem die allgemein übliche Regleranpassung verschiedener Parameter für die Synchronisation gegenüber. Die vorgeschlagene Methode der geführten Schaltbewegung weist eine deutlich höhere Toleranz gegenüber der Varianz an Hardwarekomponenten und damit eine bessere Kompatibilität zu den Getriebesteuergeräten (TCUs) verschiedener Lieferanten auf. Die Schaltqualität lässt sich nicht auf ein subjektives Kriterium zusammenfassen, es werden immer unterschiedliche Faktoren wie z.B. Komfort und Sportlichkeit den Schaltvorgang bestimmen. Deshalb wird für die Optimierung des Schaltvorgangs eine mehrkriterieller evolutionärer Algorithmus angewandt, um die Paretofront zu identifizieren, was alle Kompromisse der Schaltbewegungsregelung einschließt. Es wird ein Modell eines hydromechanischen Synchronisationssystems für ein automatisiertes Getriebe als Beispielanwendung benutzt, um den vorgeschlagenen Optimierungsprozess zu demonstrieren. Das nichtlineare hydromechanische Synchronisationssystem wird mit der objektorientierten Sprache Modelica® modelliert. Mit dem Modell werden Schaltvorgänge detailliert beschrieben. Ein Fuzzy-Sliding-Mode-Regler wird für die jeweilige Bewegung der Schaltung während der Synchronisation benutzt. Im Gegensatz zur herkömmlichen empirischen Anpassung der Reglerparameter wird ein genetischer Algorithmus angewendet, um die automatische Erkennung und Bewertung der Parameter vom Fuzzy-Sliding-Mode-Regler zu optimieren. Ein neuartiger evolutionärer mehrkriterieller Algorithmus (MLIA) wurde angewandt, um eine optimale Bewegung der Schaltstellung während der Synchronisierung zu finden. Die Validierung am Getriebeprüfstand zeigt, dass diese modellbasierte Methode der mehrkriteriellen Optimierung in der automatisierten Getriebekalibrierung eine deutliche Verbesserung darstellt.
Contains 97 papers which provide a valuable overview of the latest technical innovations in this rapidly expanding field. Areas of development which receive particular attention include the emergence of power switching transistors, the application of microprocessors to regulation and control of static converters and electrical drives, the use of more sophisticated control strategies and the utilization of power electronics in new application fields.
