GB2585470A

GB2585470A - Braking system for electromagnetic motors

Info

Publication number: GB2585470A
Application number: GB2006779.9A
Authority: GB
Inventors: Arthur Cooke James; Emmanuelle Briodeau-Line Audrey; Edward Mead Graham; Kirby Andrew
Original assignee: Illinois Tool Works Inc
Current assignee: Illinois Tool Works Inc
Priority date: 2017-09-15
Filing date: 2017-09-15
Publication date: 2021-01-13
Anticipated expiration: 2037-09-15
Also published as: GB202006779D0; GB2585470B

Abstract

A mechanical brake for arresting movement of an output shaft 401 of a linear electric motor. The brake comprises a pivotally mounted plate 410 having a space, e.g. hole 411, for receiving the output shaft 401 and an electrically operated holding device, e.g. linear solenoid 423, contacting a free end of the plate. The solenoid 423 when activated, e.g. supplied with a voltage, holds the plate in a horizontal position against a biasing force of a spring 451 so that the shaft is free to move. When the voltage is turned off, the solenoid 423 is deactivated so that the plate is pivoted about a fulcrum by the spring 451 into a jamming position where the shaft 401 is jammed against a side of the hole 411, thereby preventing the shaft from moving. Also claimed is a test apparatus comprising the mechanical brake and a control system configured to identify an event from a velocity and/or an acceleration signal using a respective frequency spectrum, wherein the event corresponds to an uncontrolled movement of the output shaft and has a characteristic frequency spectrum.

Description

Braking System for Electromagnetic Motors The present invention relates to emergency braking systems and methods of use thereof, particularly those for electromagnetic motors for use in test apparatus.

Introduction:

Both common forms of motor used in test apparatus, servo-hydraulic and electromagnetic, comprise output shafts with large masses. Should a fault occur within the apparatus, the large mass can accelerate and cause damage to both the apparatus and any persons in the vicinity. Braking systems are therefore designed to prevent undesired movements of the output shaft.

Servo-hydraulic systems may comprise mechanical brakes whereby the movement of the output shaft is managed by gripping or releasing the output shaft and/or the movement of the output shaft can be managed by controlling the flow of oil in the hydraulic cylinder.

Electromagnetic motors are not operated by the same principles as a servo-hydraulic motor. Instead, an output shaft comprising magnetic material is positioned within a coil assembly, alternatively, moving coil electromagnetic motors mount the coil assembly to the output shaft and positioned within a housing comprising magnetic material. The coil assembly comprises a plurality of separate coil loops, an electric current signal applied through the coil assembly induces a magnetic field which interacts with the magnetic material's magnetic field and therefore a force on the output shaft is generated dependent on the magnitude and direction of the applied current. This force can be used to accelerate or decelerate a moving output shaft, additionally it can be used to counteract gravitational force acting on the output shaft when the test apparatus is in a vertical orientation or any orientation other than horizontal. In a non-horizontal orientation, it will be appreciated that in the absence of electrical power, the output shaft is free to move under the effect of gravity. Therefore, a mechanical brake must be actuated to prevent undesired movement of the output shaft such as when the motor is switched off. An additional means for braking a moving output shaft of an electromagnetic motor is through electromagnetic induction whereby motion of the output shaft within the coil assembly induces eddy currents in the output shaft so as to generate an electromagnetic braking force between the output shaft and the coils otherwise known as an e-brake.

While there is no current standard for compliance which dictates how quickly an output shaft with undesired motion must be arrested, it is desirable that motion be arrested prior to the output shaft travelling 2 mm or less and/or in the ease of rotary motors: 360 degrees. Due to the large combined mass of the output shaft, it is possible for the output shaft to travel the length of its travel within a few milliseconds when acting only under gravity. Thus, the response time of the braking system in engaging either the mechanical brake, or reversing the current applied to the coil assembly or applying an e-brake is required to be very short to prevent 2 mm or of travel.

Several known methods for controlling the actuation of the different braking methods involve monitoring the velocity of the output shaft. In an ideal situation, a perfect Safely Limited Speed (SLS) mechanism is used to pre-emptively prevent the output shaft from achieving speeds greater than a predetermined threshold -typically 10 mm/s or 30 deg/s for rotary movement. Unfortunately, current SLS mechanisms are unable to perform this desired function; they operate by monitoring the velocity and raising a fault condition when the threshold is exceeded. Therefore, the velocity of the output shaft has already exceeded the threshold once the fault condition has been raised -the SLS does not preemptively limit the speed to avoid exceeding the threshold, it reacts once the threshold is exceeded. This is equivalent to a Safe Speed Monitor (SSM) that monitors velocity and generates a safety and/or fault signal when the velocity is below or above a predetermined threshold, in conjunction with a Safe Torque Off (STO) mechanism that shorts the windings on the coil assembly producing a magnetic braking effect. Similarly, monitoring of the velocity can be extended to monitoring of the acceleration of the output shaft wherein the STO is engaged when a predetermined acceleration threshold is exceeded -typically 30 mm/s2 or 90 deg/s2 for rotary movement.

Several problems exist in relation to the above braking system that uses an SSM in conjunction with an STO to prevent undesired movement. There are scenarios that exist in which the threshold for either velocity or acceleration can be exceeded but a fault has not occurred. These are termed false-triggering events or nuisance tripping. In these scenarios, the braking system engages and the apparatus is made safe until an inspection can be carried out. The frequency at which these false-triggering events occur results in a sizable proportion of operators for test apparatus switching off the emergency braking system; a practice which can lead not only to apparatus damage but also injury to operators.

Examples of scenarios where the threshold for either velocity or acceleration is exceeded but a fault has not occurred include (but are not limited to): 1. Each time the mechanical brake is released an impulse is experienced by the output shaft resulting in large acceleration and velocity.

2. Working in the environment with the test apparatus, the apparatus can be knocked accidentally, resulting in large acceleration and velocity.

3. Adjusting the load string with tools can result in impulses that produce large acceleration and velocity.

4. Operating the specimen holding grips can result in impulses that produce large acceleration and velocity.

5. When operating in a set-up mode, in which the current applied to the motor is strictly limited, 'motor cogging' can result in the velocity and acceleration thresholds being 20 exceeded.

There is therefore a need to develop an emergency system that has a high accuracy in differentiating false-triggering events from actually undesired output shaft motion.

Conventional means for arresting the motion of an uncontrolled output shaft is the use of an electrical brake: by connecting each of the plurality of the separate coil loops of the coil assembly to each other. To do this, a mechanical device is used; a delay between the instruction to apply the e-brake and the mechanical device enacting the brake results in the time between identifying a failure event and the output shaft being arrested being of the order 10 milliseconds. A delay of this duration is not sufficient to bring the output shaft to rest within 2 mm of travel and as such a new device is required to decrease the distance of travel by reducing the delay time.

Test apparatus must abide by certain safety standards, one such standard involves the lifetime of the mechanical brake pads used in each mechanical brake. It is therefore desired to produce a means for monitoring the lifetime of brake pads fitted to a mechanical brake.

Summary of Invention:

A first aspect of the present invention relates to a method for controlling the braking system of a electromagnetic motor, the electromagnetic motor having a moveable output shaft comprising the steps of receiving a velocity signal and/or an acceleration signal to based on movement of the output shaft, said velocity signal and/or acceleration signal having a respective frequency spectrum; identifying an event from the velocity and/or the acceleration signal using the respective frequency spectrum, wherein said event corresponds to an uncontrolled movement of the output shaft and has a characteristic frequency spectrum.

Identifying the event comprises filtering the velocity and/or acceleration signal to attenuate one or more frequency components of the frequency spectrum; the one or more frequency components attenuated by the filter can represent a part or a whole of a frequency profile of the uncontrolled movement of the output shaft that does not pose a risk to an operator. As such, the applicant gives a way of distinguishing between previously indistinguishable events.

To reduce the delay between triggering actuation of the electric brake and the actual actuation, the second aspect of the present invention proposes a device comprising: a coil assembly circuit comprising a plurality of separate coil loops configured to cause movement of an output shaft of the motor while electrical power is applied; a switching device configured to form an electrical connection between the plurality of separate coil loops of the coil assembly circuit such that movement of the output shaft is arrested; and an opto-isolator for actuating the switching device. Said device also has the benefit of electrically isolating high voltage circuits from low voltage circuits therefore providing a means for protecting components from damage.

To mitigate the movement of the output shaft when the mechanical brake is released from engagement with the output shaft, the third aspect of the present invention suggests a method comprising the steps of: determining the position of the output shaft; determining a current based on the position of the output shaft that when applied in the coil assembly induces a force on the output shaft to prevent motion of the output shaft when the mechanical brake is released and, applying the current to the coil assembly. Said method can also comprise using a look-up table to determine the current applied to the coil assembly based on the position of the output shaft. To generate said look up table, the applicant also proposes the method of determining a first current needed to to hold the output shaft in a first position; determining, a second current needed to hold the output shaft in a second position; storing the first and second positions together with the first current and second current in the look-up table.

The present invention provides, in its fourth aspect, a mechanical brake design that increases the speed of engagement of the brake with the output shaft. Said brake comprises a pivotally mounted plate having a space for receiving the output shaft of the motor; an electrically operated holding device contacting a free end of the plate and arranged to hold the plate in a condition to permit movement of the output shaft and to permit the plate to pivot to a jamming position; wherein the electrically operated holding device comprises a solenoid to control the movement of the plate. The solenoid can be a linear solenoid to provide an advanced actuation mechanism over that known in the prior art. Furthermore, the mechanical brake can comprise a resilient member arranged to bias the plate towards the jamming position.

The present invention provides, in its fifth aspect, a method for monitoring the performance of a mechanical brake for a linear electromagnetic motor, the linear motor having a linearly moveable output shaft, comprising monitoring travel of the output shaft over the duration of actuation of the mechanical brake and comparing said travel with a predetermined travel threshold. Said method provides a means to monitor reliability, ensure proper functioning and increase safety of the linear motor. A user can be alerted to the degree of travel so that they can take appropriate actions.

Each aspect of the present invention can be combined with any other aspect, as can each option within each aspect; unless they are specifically taught as alternatives. The different aspects of the invention individually or in any combination provide an improved test apparatus.

Brief Description of Drawings:

Further preferred features and aspects of the present invention will be apparent from the claims and die following illustrative description made with reference to the accompanying drawings in which: Figure 1 is a flow chart representation of an electromagnetic motor control system known in the prior art.

Figure 2 is a flow chart representation of an electromagnetic motor control system according to a first aspect of the present invention.

Figure 3a is plot of the frequency response of the FIR filter on the first channel according to an option of the first aspect of the present invention.

Figure 3b is plot of the frequency response of the FIR filter on the second channel according to an option of the first aspect of the present invention.

Figure 4 is a flow chart representation of analysis of motion of the output shaft according to an option of the first aspect of the present invention.

Figures 5a and 5b are illustrative graphic plots of the raw velocity signal and filtered velocity signal against time respectively according to an option of the first aspect of the present invention.

Figures 5c and 5d are illustrative graphic plots of the raw acceleration signal and filtered acceleration signal against time respectively according to an option of the first aspect of the present invention.

Figure 6a is a circuit diagram of a mechanical relay switch known in the prior art.

Figures 6b and 6c are circuit diagrams of Solid-State-Relay circuit switches according to a second aspect of the present invention.

Figure 7 is a illustrative graphic plot of the current required to hold the output shaft stationary against the action of gravity vs the position of the output shaft according to a third aspect of the present invention.

Figure 8 is a flow chart representation of an option of the present invention for determining the look up table according to the third aspect of the present invention.

Figures 9a and 9b are diagrammatic representations of a mechanical braking system according to a fourth aspect of the present invention, showing the mechanical brake in an off configuration and an on configuration respectively.

Figure 10 is a flow chart representation of a method of brake performance monitoring according to an option of a fifth aspect of the present invention.

Detailed Description of the Invention:

The present invention has, as an object, the provision of a construction of a braking system for an actuator comprising an electromagnetic motor as well as methods for the actuation thereof by a control system. Whilst the below description is given in reference to a vertically orientated test apparatus, the present invention is not so limited and may be incorporated to another system requiring the effects offered thereby.

The control system and braking system may be incorporated into a conventional test apparatus comprising an actuator comprising an electromagnetic motor comprising an output shaft moveably positioned within a coil assembly. Alternatively, the electromagnetic motor may comprise a coil assembly mounted to an output shaft, the output shaft positioned within a housing comprising magnetic material (known as a moving coil motor). The coil assembly comprising a coil assembly circuit arranged such that the motor is a multi-phase motor. In the option of the present invention described herein, the motor is a three-phase motor configured to produce linear and/or rotary movement of the output shaft. The actuator comprising the motor comprises one or more displacement sensors for determining a displacement of the output shaft within the coil assembly and an encoder for calculating the displacement of the output shaft as a function of time. Examples of displacement sensors include but are not limited to LVDT (linear variable differential transformer); strain gauges and rotary potentiometers. The encoder having a sampling frequency, the sampling frequency may be fixed or controllable such that the sampling frequency is between 1 kHz and 20 kHz. Alternatively, displacement of the output shaft may be determined through measurement of the velocity and/or acceleration of the output shaft and subsequent integration to find displacement. An example of a device for measuring the velocity is a velocity transducer. An example of a device for measuring acceleration is an accelerometer. These devices can be included in the actuator using any known method e.g. incorporation into the output shaft. Further alternatively, displacement of the output shaft may be determined through differentiation of a measurement of the absement of the output shaft and subsequent differentiations to find velocity and/or acceleration.

The object of the first aspect of the present invention is to produce a control system capable of differentiating between different movements of the output shaft such that the control system arrests the movement of the output shaft when a failure event occurs, a failure event being an uncontrolled (unauthorised, uninstructed etc.) movement of the output shaft caused by a failure of a component of the linear motor.

As discussed in the introduction, there exist several events which result in a conventional control system arresting the movement of the output shaft. A conventional control system is configured to determine when a velocity of the output shaft (calculated by a motion detector 11) exceeds a predetermined threshold using the displacement measured by a displacement sensor as a function of time. To achieve this, a conventional SSM 10 as shown in Fig. 1 comprises at least one comparator 20 adapted to compare the velocity of the output shaft with a predetermined velocity threshold, for instance 10 mm/s for linear movement and/or 30 deg/s for rotary movement. The velocity signal may be determined through differentiation of a displacement signal, integration of an acceleration signal, or by measurement using a velocity detector. When said predetermined velocity threshold is exceeded, an output of the comparator triggers a Safe Torque Off (STO) device 40 which activates a braking device. Additionally, the conventional SSM may also comprise another at least one comparator adapted to compare the acceleration of the output shaft with a predetermined acceleration threshold (for instance 30 mm/s for linear movement and/or 90 deg/s for rotary movement) and trigger the STO device, in addition to or as an alternative to the velocity comparator.

The predetermined velocity and/or acceleration thresholds may be exceeded by several events. These events include but are not limited to those discussed in the introduction and repeated below: 1. An impulse is experienced by the output shaft resulting in a momentary large acceleration and velocity when the mechanical brake is disengaged.

3. Adjusting the load string with tools can result in impulses that produce large acceleration and velocity 4. Operating the specimen holding grips can result in impulses that produce large acceleration and velocity.

5. When operating in a set-up mode, in which the current applied to the motor is strictly limited, 'motor cogging' can result in the velocity and acceleration thresholds being exceeded.

6. The uncontrolled movement of the output shaft as a result of a fa lure of a component of the test apparatus or any other event which poses a risk to an operator said risks include but are not limited to: entanglement, friction or abrasion, cutting, shearing, stabbing or puncture, impacting, crushing, or drawing-in. Wherein an uncontrolled movement beyond a predetermined movement threshold corresponds to a risk to the operator. The predetermined movement threshold for linear movement is optionally in the range 0 mm to 200 mm, or 0 mm to 60 mm. in an option of the present invention, the threshold is 2 mm. For rotary movement the predetermined movement threshold is optionally in the range 0 degrees to 30 degrees.

Events 1-5 are known as false-failure events, not caused by component failure and/or without presenting a risk to operators, as opposed to event 6 which is a true failure event.

The applicant identified that there is a need to differentiate between the different events when the test apparatus is operating such that the frequency of occurrences when the STO device is triggered is reduced i.e. only triggered by a (true) failure event and not by a false-failure event. Therefore, leading to a lower probability of an operator switching off the control system when dissatisfied by the high frequency of occurrences (false-failures).

In the present invention, the applicant noted that if a signal representing the velocity or acceleration of the output shaft is broken down into discrete periods of time, analysing the frequency spectrum of each period can be used to identify and differentiate between the events which cannot be differentiated by using conventional comparator methods involving examining only the velocity and/or acceleration in time signal. Fourier transform is one example in the present invention to provide a frequency domain representation of the signal representing either the velocity or acceleration of the output shaft.

As such, according to a first aspect of the present invention, a control system for controlling a braking system is provided. The control system and braking system may be incorporated into test apparatus comprising actuator comprising an electromagnetic motor comprising an output shaft moveably positioned within a coil assembly. A moving coil motor is not excluded from the scope of the invention. The braking system comprises a means for generating a signal based on the movement of the output shaft. For the purpose of explanation of the present invention, such a means is generally known as a linear and/or rotary motion detector 111. In an option of the present invention, the motion detector comprises one or more displacement sensors for determining the displacement of the output shaft within the coil assembly and an encoder for producing the displacement of the output shaft as a function of time. The encoder having a sampling frequency, the sampling frequency may be fixed or controllable such that the sampling frequency is between 1 kHz and 20 kHz. In an option of the first aspect of the present invention the encoder has a sampling frequency of 10 kHz. In an option of the present invention, the velocity of the output shaft can be determined using a velocity transducer.

In another option of the present invention, the motion detector comprises an acceleration detector, such as an accelerometer. In another option of the present invention, the linear and/or rotary motion detector comprises at least one of a displacement detector, a velocity detector or an acceleration detector.

The control system, according to the first aspect of the present invention, comprises a safe speed monitor (SSM) 110 configured to identify an uncontrolled movement of the output shaft using the frequency spectrum of the velocity and/or acceleration signal. The SSM is configured to receive an input signal from the motion detector 111 chosen from at least one of the displacement detector, the velocity detector or the acceleration detector whose signals correspond to the motion of the output shaft. The SSM may additionally be configured to determine a velocity signal and/or an acceleration signal corresponding to the velocity and/or acceleration of the output shaft based on the input signal being any one of: the displacement, the velocity or the acceleration of the output shaft.

Fig. 2 represents an option of the present invention wherein the motion detector comprises a displacement detector, the SSM is configured to determine the velocity signal and/or acceleration signal corresponding to the motion of the output shaft based on the displacement by differentiating the signal with respect to time (d/dt).

The control system as shown in Fig. 2 comprises a first channel 120 comprising a first filter 121 for attenuating one or more frequency components of the velocity signal. In an option of the first aspect of the present invention, the first filter is a finite impulse response (FIR) filter. Whilst the present invention does not wish to exclude the provision of the first filter being a software filter, a delay in the processing of the signal between receiving the output of the displacement detector and applying the first filter as a software filter using components available at prices suitable for inclusion in a commercially saleable product is not short enough to satisfactorily limit the movement of the output shaft. As discussed above, a software filter would make use of a mathematical operation whereby a frequency domain representation of the velocity signal is calculated, e.g. Fourier transform, specific frequencies would then be attenuated. The present invention therefore acknowledges that some software filters may be suitable for the present purpose but are not practicable in relation to commercial requirements. Furthermore, within software filters there are more opportunities for errors or faults to be present leading to a reduction in safety and an increase in production and maintenance costs. Therefore, in an option of the present invention, the first filter is implemented in hardware as an analogue or a digital filter.

As shown in Fig. 2, an option of the first aspect of the present invention can include a second channel 130 comprising a second filter 131 for modifying the acceleration signal by attenuating one or more frequency components of the acceleration signal in the frequency domain. In a further option, the second filter may be a finite impulse response (FIR) filter. As with the first filter, the second filter may be implemented in software or in hardware. The reader should be aware that the first aspect of the present invention, whilst described with both the first and second channels, could be implemented with only one of the first or second channels i.e. only the velocity signal or the acceleration signal is modified by a filter.

The following description of the first or second filters uses a FIR filter as an example, however any other form of filter that produces the desired signal attenuation may be implemented. A typical FIR filter comprises a delay line having N stages, each stage having a predetermined coefficient. The selection of the number of stages and their respective coefficients is dependent on the desired functional requirement of the filter.

The choice of coefficients for each stage will affect the function or 'shape' of the filter, i.e. whether it is a low-pass filter, a band-filter or high-pass filter. Increasing the number of stages will increase the delay between receiving the output of the encoder and outputting a signal from the filter; however, it will increase the precision of discrimination of the filter.

In analysing the frequency spectrum of each occurrence that causes a failure event or false-failure event, it can be noted that the frequency spectrum of failure events is substantially lower than that of the false-failure event which occur momentarily. By designing an ideal low-pass filter, equating to the characteristic frequency spectrum of a failure event, it is therefore possible to filter out the false-failure events such that these events do not result in the triggering of the STO device. To determine the parameters of the ideal low-pass filter, an average characteristic frequency spectrum of several failure events can be determined computationally or by hand-calculation. Once determined, the ideal low-pass-filter is chosen such that the filter will remove all false-failure events -by attenuating frequency components in the velocity and/or acceleration signals present in the frequency spectrum due to false-failure events -but still capable of detecting outlier failure events. An outlier failure event being one with frequency spectrum that is statistically unlikely. An example of the frequency response of an ideal filter for the first filter is shown in Fig. 3a and an example of the frequency response of an ideal filter for the second filter is shown in Fig. 3b.

A compromise must be made between the precision of the discrimination of the filter and the delay introduced as the number of stages of the filter increases. In an option of the present invention, the second low-pass filter is chosen to have 20 stages and therefore 21 coefficients, In a further option, the first low-pass filter is chosen to have 60 stages and therefore 61 coefficients. The number of stages within the second filter is chosen to be less than the number of stages of the first filter to reduce the reaction time of the control system. The sooner a failure event is detected the less momentum is built up and the less risk presented to the operator. In an alternative option of the first aspect of the present invention, each filter may have any number of stages and coefficients or alternatively the second filter may have more stages than the first filter.

The result of the application of the first and/or second filter, to the filtered velocity or acceleration signal respectively, is that only true failure events can result in the arresting of the output shaft by triggering a STO device 140. The filtered velocity signal, having been either passed without attenuation or with attenuation by the filter, is transmitted to a first comparator 122 on the first channel configured compare the filtered velocity signal with a predetermined velocity threshold. This is implemented similarly by a second comparator 132 on the second channel with the filtered acceleration signal and a predetermined acceleration threshold. An option of the first aspect of the present invention has the predetermined velocity threshold at about 10 mm/s for linear movement and at about 30 deg/s (for example 29.8 deg/s) for rotary movement and the predetermined acceleration threshold at about 30 mm/s2 for linear movement and at about 90 deg/s2 (for example 89.4 deg/s2) for rotary movement. Any other values may be chosen and are not outside the scope of the present description, other values are chosen in order to change the sensitivity of the SMM; for instance the predetermined velocity threshold is optionally in the range 0 mm/s to 100 mm/s for linear movement and/or 0 deg/s to 360 deg/s for rotary movement; and/or the predetermined acceleration threshold is optionally in the range 0 mm/s2 to 500 mm/s2 for linear movement and/or 0 deg/s2 to 1000 deg/s2 for rotary movement.

The result of the identification by the first and/or second comparators of the filtered signals is that the STO device is only triggered if a failure event occurs.

Expressed alternatively with reference to the flow diagram of Fig. 4 and the graphs of Fig. 5a & 5b: a raw velocity signal 125 corresponding to the velocity of the output shaft is input to a filter, the filter is configured to attenuate frequency components of the velocity signal that arc due to false-failure events. Therefore, the filter is tailored such that frequency components within a characteristic frequency spectrum, corresponding to failure events, are not attenuated and those not within the spectrum are attenuated; this profile is known as a predetermined frequency profile. The filtered signal 126 is then input into a comparator, comparing the amplitude of the velocity signal with a predetermined velocity threshold 127. If the predetermined velocity threshold is exceeded, the STO device is triggered and the output shaft is arrested. The same method can be applied equally to an acceleration signal corresponding to the acceleration of the output shaft as shown in Fig. 5c & 5d, wherein references 135, 136 and 137 correspond to the raw acceleration signal, filtered acceleration signal and the predetermined acceleration threshold respectively. As can be seen from Fig. 5a and 5c the raw velocity and acceleration signals -in particular peaks 128 and 138 -would result in the trigger of the STO device for a traditional SSM, however, following filtering to remove false-failure events from the raw signals, the STO is not triggered when the comparison with the requisite thresholds is performed using the filtered signals i.e. the peaks in acceleration and velocity no longer exceed the predetermined thresholds.

The first and/or second channel may each comprise a decimator. Fig. 2 shows an option of the first aspect of the present invention in which the first channel comprises a decimator 123, converting the frequency of the input velocity signal from the sampling frequency of 10 kHz to about 200 Hz. It should be understood that the decimator may reduce the input signal frequency to any chosen frequency. Decimation is performed in order that a filter is sufficiently discriminatory; to ensure this the sample frequency of the input velocity or acceleration signals should be close to a corner frequency of the filter.

In a further option of the first aspect of the present invention, signals from the SSM are fed into a watchdog timer 150. The watchdog timer can be configured to determine component failure within the SSM. During normal operation, the watchdog timer monitors the signals within the SSM, should the watchdog detect a fault, e.g. if the signal fails to propagate through the SSM to the watchdog timer, the watchdog timer generates a timeout signal which triggers actuation of the STO. The watchdog timer can be configured to receive inputs corresponding to the input or outputs of the components within the SSM and/or from the motion detectors. In a chosen option of the present invention shown in Fig. 2, the watchdog timer is configured to receive an input from the SSM, after the velocity and/or acceleration signals have been filtered as they enter the comparator such that performance of the filters can be monitored. In an option of the present invention, the input to the watchdog timer is the filter velocity and/or acceleration signal, if the watchdog does not receive the input within a predetermined time-period since the last input was received, the STO is triggered.

In an option of the first aspect of the present invention, a second SSM 170, identical to the first SSM, shares and is communicatively coupled to the STO device and the displacement detector to provide redundancy, via a cross check, in case of component failure in either the first or second SSM and/or to ensure accurate actuation of the STO device. The first and second SSM independently determine if the input signal comprises a failure event.

In an option of the present invention, if the outputs of the first and second SSM do not equate, within the cross check, that a failure event has occurred, the STO will not trigger the braking systems. Alternatively, the STO will trigger the braking systems regardless of whether the SSM' outputs equate, an error is then flagged so that the operator can be made aware of a possible fault in one of the SSMs.

In another option of the first aspect of the present invention, the SSM comprises an error manager 160, the error manager configured to optionally receive inputs from at least one of the first channel, the second channel and the motion detector(s). The error manager generates a signal for delivery to a user, identifying which component or signal of the control system is responsible for triggering the STO device. For instance, if the filtered acceleration signal exceeds the acceleration threshold, the error manager will generate a signal representing that the acceleration threshold has been exceeded. In the instance where one or more components of the control system trigger the STO device, the error manager can generate a signal representing such an event. In an option of the present invention comprising the cross check and the first and second SSM, the SSMs may share an error manager, or each may comprise a separate error manager.

While the object of the first aspect of the present invention is to produce a control system that increases the accuracy with which failure events are identified, the second aspect of the present invention has the object of increasing the speed with which, once an event is identified as a failure event, the output shaft is arrested.

As discussed in the introduction and shown in Fig. 6a, conventionally an STO device comprising a mechanical relay 210 is used to connect each of a plurality separate coil loops of the coil assembly to each other such that the current induced in the shaft generates a Lorentz force sufficient to arrest the shaft. The mechanical relay comprises an electromagnetic coil, controlled by the SSM, used to open and close an electrical circuit 211 for which the coil assembly is connected to. Use of the mechanical relay is chosen for its extended lifetime and reliability in function throughout. However, current mechanical devices are unable to connect the separate coil loops of the coil assembly in sufficient time to comply with stopping the output shaft before the maximum distance that the shaft can travel, e.g 200 mm for linear movement and 360 degrees for rotary movement.

The voltage used to drive the electric motor are necessarily high in order that the magnetic field generated in the coils produces a sufficient Lorentz force on the output shaft. A mechanical switch is traditionally used to remove the isolation between the separate coil loops such that this high voltage is not able to damage low voltage components of the STO and SSM.

To reduce the delay between decision to arrest and the output shaft coming to rest, the second aspect of the present invention comprises an STO device having a solid-state relay (SSR) circuit switch 220.

The solid-state relay circuit switch optionally comprises a back-to-back MOSFET 224 design as shown in Fig. 6b; Fig. 6B represents an STO device for a coil assembly comprising two separate coil loops. Under normal operation, i.e. when the STO device is not triggered, each of the plurality of separate coil loops is isolated. An SSR circuit is positioned between the each of the plurality of separate coil loops, such that when the STO device receives an instruction input from the SSM to arrest motion of the output shaft, the SSR circuit is switched from an 'off configuration to anon' configuration, and current can flow through the right-hand side of the SSR circuit therefore removing the isolation between the loops.

In an option of the second aspect of the present invention, the problem of high voltages within the coil assembly is overcome through the inclusion of an opto-isolator 221. The opto-isolator enables the SSR circuit to be switched without exposing the low voltage circuit to high voltages from the coil assembly by isolating the circuits. The opto-isolator comprises a light emitting diode LED 222 and a photovoltaic cell 223. On instruction to arrest the output shaft, a supply current activates the LED, emitted light is detected by the photocell, and within the back to back MOSFET circuit the SSR circuit is completed as current can flow, therefore connecting the separate coil loops and providing a braking effect. The supply voltage, the LED, photovoltaic cell and parameters of the MOSFET transistors are chosen such that the switching time of the SSR circuit is minimised.

In an effort to further minimise the risk of component damage due to exposure to high voltage, the SSR circuit is connected to the coil assembly via a protection means 225. These protection means can comprise fuses, or in an option of the present invention, a Transient Voltage Suppressor (TVS) Diode such that in the case of high voltage (beyond those expected in normal operation) the MOSFET transistors are protected.

For a three-phase motor, two solid state relay circuits are utilised, as depicted in Fig. 6c. A first SSR circuit 226 is used to connect a first and a second coil loops; a second SSR circuit 227 is then used to connect the second coil loop to a third coil loop. To provide redundancy, in an option of the present invention, the STO device comprises a set of redundant SSR circuits configured for connecting the coil loops of the coil assembly. The redundant SSR circuits are triggered by identical means to the primary SSR circuits. For instance, in an option of the present invention wherein the motor is a three-phase linear motor, inclusive of the redundancy circuits, there are four SSR circuits within the STO device.

Although the present invention according to the first aspect enables the control system to sufficiently differentiate between failure events and false-failure events, it is preferable to reduce or eliminate the causes thereof.

The object of the third aspect of the present invention relates to the impulse experienced by the output shaft when the mechanical brake is released from or applied to the output shaft.

According to an option of the third aspect, the present invention provides a means to reduce movement of the output shaft caused by the motion of the output shaft when the output shaft is released by the mechanical brake and held by the force induced by the coil assembly. The current required to maintain the position of the output shaft within the coil assembly varies with the position of magnets within the output shaft in relation to the three-phases of the coil assembly. Thus, it is possible to determine for the test apparatus a current vs. position look up table, as shown graphically in Fig. 7 where the position of the output shaft along the length of motion is plotted against necessary current.

According to the third aspect of the present invention, the movement control system for a motor comprises a mechanical brake and a controller configured to receive a position of the output shaft within the coil assembly and to correlate the position with a current required to apply to the coil assembly such that motion of the output shaft is resisted when a mechanical brake is released. The controller can correlate the position with current by calculation or by referencing a look up table of current vs position. The look up table can be calibrated during manufacture or alternatively may be calibrated each time a specimen is loaded for testing as the mass of the specimen and a chosen load cell will change the values of current at each position.

Calibrating the look-up table can be performed using the following method, also shown in Fig. 8: Step Al -determining a first current needed to hold the output shaft in a first position without engaging the mechanical brake.

Step A2 -determining a second current needed to hold the output shaft in a second position without engaging the mechanical brake.

Step AS -optionally -determining a third current needed to hold the output shaft in the second position without engaging the mechanical brake.

Step A4 -optionally -repeating step AS for successive positions of the output shaft.

Step A5 -storing the first position and first current, and others in the look-up table.

In an option of the present invention, the look-up table is calibrated for every position along the entire length of travel of the output shaft.

The above calibration process can be performed automatically, e.g. during start-up of the testing machine, whereby each time the mechanical brake is released at a given position along the coil assembly a feed-back loop is used to vary the current in the coil assembly until the output shaft is held at that position. Movement of the output shaft can be detected by a motion sensor. This is repeated at different positions of the output shaft along the coil assembly. The current values to hold the output shaft at the different position within the coil assembly are stored in a look-up table.

Through the implementation of the look-up table, there is minimal or no motion of the output shaft each time the mechanical brake is disengaged, in an option of the present invention motion is reduced to less than 2 mm.

Industry standards require shoes of the mechanical brake to be rated such that they reliably engage throughout their life. Conventional test apparatus monitor the number of times that the mechanical brake has been actuated for each brake shoe and recommend to a user that the shoe be replaced once a predetermined actuation threshold has been exceeded.

The purpose of the mechanical brake is to prevent the output shaft dropping under gravity when the linear motor is turned off. Without a mechanical brake, a risk hazard to an operator's hand or fingers is present when accessing the test workspace. The source of the crushing force is derived from the falling mass of the actuator shaft.

The object of the fourth aspect of the present invention is to provide a mechanical brake that enables improved engagement reaction timing over that achieved from conventional linear motor brakes.

A brake 400, mounted on the frame of a test apparatus incorporating the output shaft 401 of a linear motor as shown in Fig. 9a, 9b, comprises an elongate plate 410 provided with a space, wherein the space in the elongate plate according the present invention may include, but is not limited to, a hole, an opening, a cut-out, an aperture or a slot (made by any suitable means). For the purposes of description, in the following options the space in the elongate plate is a hole 411. The elongate plate 410 plane may be positioned such that it is perpendicular to the axis 403 or direction of movement of die output shaft 401 when the brake 400 is not engaged. The shape and size of the hole is just larger than the cross-sectional shape and size of the output shaft so as to frictionally engage with the output shaft and/or the brake shaft when the elongate plate is tilted. Alternatively, the shape and size of the hole may correspond to the output shaft such that the edges of the hole are proximate to but not in contact with the output shaft and/or the brake shaft when the brake is not engaged. To help the elongate plate frictionally engage with the output shaft, more particularly the hole of the elongate plate, the output shaft comprises a brake shaft 402 to which the brake engages. In an option of the present invention, the brake shaft and the output shaft can be integrally formed as a single body; alternatively brake shaft 402 is formed as a sleeve around the output shaft or is an extension of the output shaft. The brake shaft can be fastened to the output shaft by any suitable means, e.g. adhesive or mechanical fasteners. The elongate plate is pivotally, or hingedly, mounted or coupled at one end 412 and is contacted at its other end 413 by a brake inhibitor 420 which is arranged to hold the plate in a position such that there is sufficient clearance between the edge of the hole and the brake shaft and/or the output shaft to allow the brake shaft and/or the output shaft to pass freely through the hole without contacting the edge of the hole. Preferably, this is when the plate is at right angles to the axis or direction of movement of the brake shaft and/or the output shaft.

The brake inhibitor is an electrically actuated device 420 such as a solenoid 423. In this case, a linear solenoid, which in normal use when electrical power is available, holds the plate in its "off condition by means of an actuator rod 421, but when electrical power is not available exerts little or no force on the elongate plate and thus allows it to pivot under the action of gravity so that the edge of the hole contacts the brake shaft and/or the output shaft and causes the brake shaft to frictionally engage and jam with the edge of the hole as it tries to drop, also under the action of gravity. Alternatively, the elongate plate is biased to jam against the brake shaft, i.e. in the "on" condition, and the actuator rod is arranged to disengage the elongate plate, more particularly the hole of the elongate plate from the brake shaft in the "off condition.

Movement of the elongated plate is by freely pivotally coupling the elongated plate, more particularly an end of the elongate plate to the actuator rod so that vertical movement of the actuator rod causes movement of the elongate plate. In the particular embodiment of the present invention, the actuator rod comprises a retaining groove 422 into which the plate sits. Other coupling means are included in the scope of the present invention, for example, a ball and socket joint. A vertical solenoid offers advantages over the rotary solenoids used in conventional brake systems. In rotary solenoids, the brake inhibitor rotates downward when there is no electrical power available, therefore the action of gravity is transmitted through the pivot point which introduces resistance. For linear solenoids, the actuator rod drops under gravity without resistance from a pivot point or otherwise. Its acceleration is therefore closer to that of gravity, resulting in earlier engagement of the brake with the brake shaft.

It is important that in the "off condition the brake imparts no friction to the brake shaft as shown in Fig. 9a. This is achieved in the present invention by means of a limit stop 430 fixed to the frame and against which the brake inhibitor presses the plate. To increase the sensitivity of the mechanical brake to frictionally engage with the brake shaft, it is necessary that the hole of the elongate plate is accurately positioned in close proximity with the brake shaft. Accurate positioning of the hole with respect to the brake shaft is achieved using an insert 440 which fits in the hole of the elongate plate. The insert comprises a space, wherein the space according the present invention may include, but is not limited to a bore, an opening, a cut-out, an aperture, a slot (made by any suitable means) through which the brake shaft and/or output shaft passes. For descriptive purposes, the space of the insert is herein described as a bore 441. When the brake is in the "on" condition, the edge of the bore binds or jams against the brake shaft, thereby preventing further movement of the brake shaft. In the particular embodiment of the present invention as shown in Fig. 9b, the elongate plate tilts about a fulcrum positioned on a resilient member 450. In the 'off condition, the limit stop prevents titling of the insert and thereby, ensures that there is clearance between the edge of the bore of the insert and the brake so permitting the brake shaft and/or the output shaft to travel through the bore and/or the hole. In the particular embodiment of the present invention, the insert comprises a projecting portion having an external surface that cooperates with the limit stop. In one example of the present invention, the external surface of the projecting portion has a frusto-conical shape that is arranged to be received in a complementary profile of the limit stop.

The insert is an optional addition, the same function could be achieved by shaping a portion of an upper surface of the plate to a profile that cooperates with the profile of the limit stop. In the present invention, the insert comprises a material suitable for providing a braking effect on the brake shaft such as rubber. In an option of the present invention, the insert comprises phosphor bronze. In another option, the insert comprises a ceramic.

In an option of the present invention, the plate comprises aluminium or another suitable stiff material, in an option of the present invention, the plate comprises a ceramic. When the elongate plate comprises ceramic, the insert may also be ceramic or another braking material and the plate and insert can be integrally formed as a single body.

The present invention further differs from conventional brakes such as that of EP 2054219 B1 (MEAD, Graham) 6" May 2009 in that the elongated plate pivots about a fulcrum encouraged or biased by a resilient member 460. The resilient member is arranged to provide a force acting to rotate the plate into its "on" condition as shown in Fig. 9b. In an option of the present invention, the resilient member is a spring or another suitably elastic member. The resilient member can be a compression spring, such that when the brake is in the 'off condition the spring is compressed by the action of the actuator rod lifting the plate. In the "on" condition, the spring decompresses, increasing the rate at which the plate accelerates downward.

In an alternative option, the resilient member is an extension spring, positioned below a lower surface of the plate such that when the brake is in the 'off condition the spring is extended by the action of the actuator rod lifting the plate. In the "on" condition, the spring returns to a non-extended state, increasing the rate at which the plate accelerates downward. In an option of the present invention, the resilient member comprises both an extension spring positioned below a lower surface of the plate and a compression spring positioned above an upper surface of the plate.

The inclusion of the resilient member has the additional effect such that when the brake is disengaged from the brake shaft, the impulse exerted by the brake on the brake shaft is reduced.

The resilient member can be included in the conventional brake designs such as that of EP 2054219 B1 (MEAD, Graham) 6th May 2009, in which rather than a linear solenoid, a rotary solenoid is used.

When electrical power is restored, i.e. the brake is instructed to release, a high force is required and it is preferred to inject a pulse of energy from one or more capacitors into the solenoid to release the brake.

The mechanical brake of the present invention further comprises a means for limiting the degree of braking force which can be generated by the pivoting plate arrangement to enable ready resetting of the apparatus. This is achieved by arranging a first end of the plate to pivot about the fulcrum that is resiliently mounted by means of a spring 451, or another resilient member, and a second end of the plate provided with a projection arranged to be spaced from a surface 404 of the actuator or a mechanical brake housing positioned below the plate. The spring provides a biasing force acting in a direction opposite to the force of gravity. In this way, should excess force be applied in a downward direction after the brake has been activated, the plate can be pulled downwards against the spring force until the projection contacts the surface whereupon the elongate plate will tend to pivot about the projection against the spring force so as to permit movement of the brake shaft and/or the elongate shaft through the hole and/or the bore. It will be appreciated that should this excess force be removed, the braking action will be immediately restored and the brake shaft held in its new position. The spring limits the braking force to a value which can be readily released simply by activating the solenoid.

The present invention, provides an improvement to the mechanical brake of EP 2054219 B1 (MEAD, Graham) 6th May 2009. Throughout the working life of the brake, the abrasion between the plate and the brake shaft results in the wearing down of the surface of the plate (or, if present, the insert). As the shape of the hole in the plate changes shape and size, the brake angle at which the plate lies when the brake is in the "on" condition increases. Therefore, late in the useable life of the brake, there comes a point at which the projection contacts the surface below the plate even though the brake has vet to engage the brake shaft. In the present invention, this surface is adjustable such that the surface can be lowered and/or raised. Therefore, restoring the distance between the projection and the surface and extending the useable life of the brake, in another option of the present invention, the projection comprises an adjustable length.

Rather than the plate comprising the projection, instead, in another option of the present invention, the surface comprises a stop 452 for contacting the lower surface of the plate. The 15 height of the stop is adjustable. The means for adjustment may be via a screw mechanism or any other suitable means. The stop having identical function to that of the projection.

The object of the fifth aspect of the present invention is to provide a mechanical brake performance monitor that enables improved monitoring of the mechanical brake.

The performance monitor comprises a controller configured for receiving signals corresponding to the position of the output shaft. in an option of the present invention, the position of the output shaft is determined by the encoder.

During normal use, the actuation of the mechanical brake has several phases: 1. arming -comprises removing power from the solenoid such that the plate pivots and engages with the brake shaft; during the "aim" phase the brake shaft is held in place by the electro-magnetic linear motor.

2. loaded -comprises removing power from the linear motor such that motion of the brake shaft under gravity is only arrested by the action of the mechanical brake.

During the loaded phase, the brake shaft of a linear motor 'drops', this is due to mechanical stresses within the brake plate. Drop is an intrinsic property of brake, a result of the materials chosen and the energy of the system, it is not a constant however, the variance over time is minimal. When in the braking phase, there is another effect that may result in motion of the brake shaft; the effect may be due to excessive wear of the brake or a change in the frictional coefficients of the portion of the brake plate engaging the brake shaft and the brake shaft itself The degree of 'slip' -the distance through which the brake shaft moves when in the loaded phase not attributable to 'drop' -needs to be monitored as increased 'slip' indicates a need to service or replace the brake.

The performance monitor is configured to determine the 'slip' of the brake shaft. Owing to 'drop' variance being minimal but ever-present, the performance monitor determines slip' plus 'drop'. In the present discussion, the term 'travel' is understood to include the drop distance (i.e. travel = slip + drop). Wherein travel corresponds to the displacement of the output shaft over the duration of actuation of the mechanical brake. Following the method steps shown in Fig. I 0, the performance monitor monitors the travel of the output shaft: Step B1 -recording a first position corresponding to a position of the output shaft when the mechanical brake is initially actuated such that the mechanical brake is engaged with the output shaft.

Step B2 -recording a second position corresponding to a position of the output shaft at a predetermined time after the first position is recorded or when the output shaft comes to rest.

Step B3 -determining the travel, by calculating the distance between the first position and the second position and/or storing the travel.

Step B4 -comparing the travel with a predetermined slip threshold.

Step B5 -alerting a user to the degree of travel if the travel exceeds the predetermined travel threshold.

Step B6 -shutting down the test apparatus if the travel exceeds the predetermined travel threshold until the test apparatus has been serviced and/or the mechanical brake examined.

In an option of the present invention, the time between the first and second measurements is between 0 and I seconds, optionally 0.25 s.

In an option of the present invention, the predetermined travel threshold is between 0 and 10 mm, optionally 2 mm.

In an emergency event, the output shaft undergoing uncontrolled movement, the performance monitor records the position at which the mechanical brake receives the instruction to brake as the first position rather than position once the brake is armed.

The performance monitor may also monitor and/or record the number of actuations of the mechanical brake.

By monitoring the number of actuations and/or the travel of the mechanical brake, the performance monitor can more accurately determine when the mechanical brake is not fit for purpose and could cause injury or damage. The performance monitor is configured to alert an operator and/or third party when the mechanical brake is a risk to the operator's safety.

Each option presented in any of the aspects above can be combined any other option of any aspect of the present invention unless specifically disclosed as alternatives.

There now follows a series of numbered clauses defining further aspects of the

disclosure:

1. A method for controlling a braking system of a electromagnetic motor, the electromagnetic motor having a moveable output shaft, comprising the steps of: receiving a velocity signal and/or an acceleration signal based on movement of the output shaft, said velocity signal and/or acceleration signal having a respective frequency spectrum; identifying an event from the velocity and/or the acceleration signal using the respective frequency spectrum, wherein said event corresponds to an uncontrolled movement of the output shaft and has a characteristic frequency spectrum.

2. The method of clause 1, wherein identifying the event comprises filtering the velocity and/or acceleration signal to attenuate one or more frequency components of the frequency spectrum.

3. The method of clause 2, wherein the one or more frequency components attenuated by the filter represents a part or a whole of a frequency profile of the uncontrolled movement of the output shaft that does not pose a risk to an operator.

4. The method of clause 3, wherein uncontrolled movement of the output shaft up to a predetermined movement threshold corresponds to the uncontrolled movement of the output shaft that not pose a risk to the operator.

5. The method of clause 4, wherein the predetermined movement threshold is in the range 0 mm to 200 mm or 0 mm to 60 mm.

6. The method of any of the preceding clauses, wherein the velocity signal and/or acceleration signal corresponding to the movement of the output shaft is determined from at least one of the following: i) a displacement detector, ii) a velocity detector, or iii) an acceleration detector.

7. The method of any clause 2 to 6, wherein filtering the frequency spectrum comprises directing the velocity signal and/or acceleration signal through a finite impulse response low-pass filter.

8. The method of any clause 2 to 7, wherein identifying said event comprises comparing a filtered velocity signal and/or filtered acceleration signal with a predetermined velocity threshold and/or acceleration threshold.

9. The method of clause 8, wherein the predetermined velocity threshold is in the range 0 mm/s to 100 mm/s for linear movement and/or in the range 0 deg/s to 360 deg/s for rotary movement.

10. The method of clause 9, wherein the predetermined velocity threshold is about mm/s for linear movement and/or 30 deg/s for rotary movement.

11. The method of clause 8, wherein the predetermined acceleration threshold is in the range 5 mm/s2 to 30 mm/s2 for linear movement and/or in the range 0 deg/s2 to 500 deg/s2 for rotary movement.

12. The method of clause 11, wherein the predetermined acceleration threshold is about 30mm/s2 for linear movement and/or 90 deg/s2 for rotary movement.

13. The method of any preceding clause, wherein upon identifying said event, arresting the output shaft, comprising the step of applying an electrical braking effect using the coil assembly and/or actuating a mechanical brake.

14. The method of clause 13, wherein arresting the output shaft involves actuating a solid state relay switch.

15. A control system for controlling the braking system of a electromagnetic motor having a moveable output shaft, using the method of any preceding clause, comprising: a safe speed monitor (SSM) comprising a filter.

16. The control system of clause 15, wherein the SSM comprises a comparator for comparing a velocity and/or acceleration of the output shaft with a predetermined velocity and/or acceleration threshold.

17. The control system of clause 15 or 16, wherein the SSM comprises a decimator for reducing the sample rate of an input signal, the input signal comprising the velocity signal and/or acceleration signal.

18. The control system of any clause 15 to 17, comprising a Safe Torque OFF (STO) device for actuating a brake system to arrest the output shaft.

19. A test apparatus comprising: the control system of any clause 15 to 18; a electromagnetic motor having a moveable output shaft; and a braking system for arresting the output shaft.

20. A method for preventing motion of an output shaft, of an electromagnetic motor comprising a coil assembly, when a mechanical brake is released, comprising the steps of: determining the position of the output shaft; determining a current based on the position of the output shaft that when applied in the coil assembly induces a force on the output shaft to prevent motion of the output shaft when the mechanical brake is released; and applying the current to the coil assembly.

21. The method of clause 20, further comprising using a look-up table to determine the current applied to the coil assembly based on the position of the output shaft.

22. A method for generating a look-up table for correlating a current to be applied to a coil assembly of linear electromagnetic motor with a position of an output shaft of the linear electromagnetic motor so as to prevent movement of the output shaft when a mechanical brake is released, comprising the steps of: determining a first current needed to hold the output shaft in a first position; determining, a second current needed to hold the output shaft in a second position; storing the first and second positions together with the first current and second current in the look-up table.

23. A braking system for controlling displacement of a linear electromagnetic motor having a linearly moveable output shaft using the method of any clause 20 to 22, comprising: a mechanical brake, a controller for receiving the position of the output shaft and configured to apply an electrical current to the coil assembly to prevent motion of the output shaft when the mechanical brake is released.

24. The braking system of clause 23, wherein the mechanical brake comprises a resilient member for damping the release of the brake from the output shaft such that an impulse, experienced by the output shaft generated by the release of the brake is decreased.

25. A method for monitoring the performance of a mechanical brake for a linear electromagnetic motor, the linear motor having a linearly moveable output shaft, comprising monitoring travel of the output shaft over the duration of actuation of the mechanical brake and comparing said travel with a predetermined travel threshold.

26. The method of clause 26 wherein monitoring travel of the mechanical brake comprises: detecting a first position corresponding to the position of the output shaft when the mechanical brake is initially actuated such that the mechanical brake is engaged with the output shaft; detecting a second position corresponding to the position of the output shaft at a predetermined time or when the output shaft conies to rest after the first position is detected; determining the travel by calculating the distance between the first position and the second position.

27. The method of clause 25 or 26, comprising the step of: storing the travel.

28. The method of any preceding clauses, wherein if the travel exceeds the predetermined travel threshold, comprising: alerting a user to the degree of travel.

29. The method of any of the clauses 26 to 28, wherein detecting the first position is triggered by an optical sensor detecting that the mechanical brake is engaged with the output shaft.

30. The method of any of the preceding clauses, wherein the predetermined time is between 0.1 s and 1 s.

31. The method of clause 30 wherein the predetermined time is 0.25 s.

32. The method of any preceding clause, comprising the step of: counting the number of actuations of the mechanical brake.

33. The method of clause 32, comprising alerting a user of the number of actuations of the mechanical brake.

34. The method of any clauses 25 to 33, comprising the step of: communicating the travel and/or number of actuations to a third party for 25 monitoring.

35. The method of any preceding clause 25 to 34 wherein the predetermined travel threshold is between 0 mm and 10 mm.

36. The method of clause 35, wherein the predetermined travel threshold is about 2 mm.

37. A mechanical brake for arresting movement of the output shaft of a linear electric motor, comprising: a pivotally mounted plate having a space for receiving the output shaft of the motor; an electrically operated holding device contacting a free end of the plate and arranged to hold the plate in a condition to permit movement of the output shaft and to permit the plate to pivot to a jamming position; wherein the electrically operated holding device comprises a solenoid to control the movement of the plate.

38. The mechanical brake of clause 37 wherein the solenoid is a linear solenoid.

39. The mechanical brake of clause 38, wherein the solenoid acts on a rod, the rod freely coupled to the free end of the plate, wherein the rod is vertically moveable.

40. The mechanical brake of any preceding clause 37 to 39, wherein the electrically operated holding device is arranged to hold the plate in a condition to permit movement of the output shaft while electrical power applied to the device.

41. The mechanical brake of any preceding clause 37 to 40, wherein the electrically operated holding device is arranged to permit the plate to pivot to a jamming position in the absence of electrical power applied to the device.

42. The mechanical brake of any preceding clause 37 to 41, wherein the mechanical brake comprises a resilient member arranged to bias the plate towards the jamming position.

43. The mechanical brake of clause 42, wherein the resilient member is a spring.

44. The mechanical brake of clause 43, wherein the spring is a compression or extension 20 spring.

45. The mechanical brake of any clause 42 to 44 wherein the resilient member is coupled to the plate.

46. The mechanical brake of clause 45, wherein the resilient member is coupled to the free end of the plate.

47. The mechanical brake of any clause 37 to 46, wherein the mechanical brake comprises a stop spaced apart from a lower surface of the plate and arranged to contact the lower surface of the plate when a force acting on the plate by the output shaft exceeds a threshold.

48. The mechanical brake of clause 47, wherein the plate is pivotally mounted on a fulcrum supported by a resilient member which is capable of movement when the force acting on the plate by the output shaft exceeds the threshold such that the plate pivots about the stop and overcomes the biasing force of the resilient member and the plate is held to allow movement of the output shaft.

49. The mechanical brake of clause B47 or 48, wherein the spacing between the stop and the lower surface of the plate is adjustable.

50. A device for arresting an output shaft of an electromagnetic motor, said output shaft being moveable, comprising: a coil assembly circuit comprising a plurality of separate coil loops configured to cause movement of an output shaft of the linear motor while electrical power is applied; a switching device configured to form an electrical connection between the plurality of separate coil loops of the coil assembly circuit such that movement of the output shaft is arrested; and an opto-isolator for actuating the switching device.

51. The device of clause 50, wherein the opto-isolator comprises an LED and a photovoltaic cell.

52. The device of clause 50 or 51, wherein the switching device comprises at least one back to back MOSFET device electrically coupled to each of the separate coil loops such that in use, under normal operation, coil loop separation is maintained so as to prevent current flow through the MOSFET device.

53. The device of any clause 50 to 52, wherein the device comprises a TVS diode for protecting the MOSFET device from the current exceeding a threshold.

54. A test apparatus comprising: a control system of any clause 15 to 18; a electromagnetic motor having a moveable output shaft; and at least one of: a mechanical brake for arresting the output shaft according to any of the clauses 37 to 49; a device for arresting the output shaft according to clauses 50 to 53; or a braking system for controlling displacement of the linear motor according to clauses 23 to 24.

55. The test apparatus of clause 54 wherein the motor is arranged in a vertical and/or horizontal orientation.

Claims

CLAIMS: 1. A mechanical brake for arresting movement of the output shaft of a linear electric motor, comprising: a pivotally mounted plate having a space for receiving the output shaft of the motor; and an electrically operated holding device contacting a free end of the plate and arranged to hold the plate in a condition to permit movement of the output shaft and to permit the plate to pivot to a jamming position; wherein the electrically operated holding device comprises a solenoid to control the movement of the plate.
2. The mechanical brake of claim 1, wherein the solenoid is a linear solenoid.
3. The mechanical brake of claim 2, wherein the solenoid acts on a rod, the rod freely coupled to the free end of the plate, wherein the rod is vertically moveable.
4. The mechanical brake of any one of the preceding claims, wherein the electrically operated holding device is arranged to hold the plate in a condition to permit movement of the output shaft while electrical power applied to the device.
5. The mechanical brake of any one of the preceding claims, wherein the electrically operated holding device is arranged to permit the plate to pivot to a jamming position in the absence of electrical power applied to the device.
6. The mechanical brake of any one of the preceding claims, wherein the mechanical brake comprises a resilient member arranged to bias the plate towards the jamming position.
7. The mechanical brake of claim 6, wherein the resilient member is a spring.
8. The mechanical brake of claim 7, wherein the spring is a compression or extension 20 spring.
9. The mechanical brake of any one of claims 5 to 8 wherein the resilient member is coupled to the plate.
10. The mechanical brake of claim 9, wherein the resilient member is coupled to the free end of the plate.
11. The mechanical brake of any of the preceding claims, wherein the mechanical brake comprises a stop spaced apart from a lower surface of the plate and arranged to contact the lower surface of the plate when a force acting on the plate by the output shaft exceeds a threshold.
12. The mechanical brake of claim 11, wherein the plate is pivotally mounted on a fulcrum supported by a resilient member which is capable of movement when the force acting on the plate by the output shaft exceeds the threshold such that the plate pivots about the stop and overcomes the biasing force of the resilient member and the plate is held to allow movement of the output shaft.
13. The mechanical brake of claim 11 or claim 12, wherein the spacing between the stop and the lower surface of the plate is adjustable.
14. A test apparatus comprising: a control system comprising a safe speed monitor (SSM) comprising a filter; a electromagnetic motor having a moveable output shaft; and a mechanical brake for arresting the output shaft according to any of the preceding claims; wherein the control system is configured to: receive a velocity signal and/or an acceleration signal based on movement of the output shaft, said velocity signal and/or acceleration signal having a respective frequency spectrum; identify an event from the velocity and/or the acceleration signal using the respective frequency spectrum, wherein said event corresponds to an uncontrolled movement of the output shaft and has a characteristic frequency spectrum.
15. The test apparatus of clause 14, wherein the motor is arranged in a vertical and/or horizontal orientation.