Fallshaw Trinity Electric Braking Castors Technical Support Document

Fallshaw Holdings Pty Ltd
ABN 74 005 237 525
www.fallshaw.com.au
www.liftmastermh.com.au
Fallshaw
Trinity Electric Braking Castors
Technical Support Document
Revision B
Head Office & Factory
VICTORIA
NEW SOUTH WALES
QUEENSLAND
+61 3 9300 8555
Freecall: 1800 333 002
[email protected]
PO Box 125
Sunshine, VIC, 3020
Australia
+61 3 9300 8555
[email protected]
2A Ayton Street
Sunshine, VIC, 3020
Australia
+61 2 4721 8254
[email protected]
1/14 Holbeche Rd,
Arndell Park NSW 2148
Australia
+61 7 3865 2756
[email protected]
453 Newman Road
Geebung, QLD, 4034
www.fallshaw.com.au
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
www.fallshaw.com.au
Introduction
This document provides Technical Support information for Fallshaw Trinity ‘Electric Braking’ Castors, and
is intended to be used as a sales support and technical fault finding document.
Section 1 of this document contains information about castor construction.
Section 2 of this document contains an overview of system operation.
Section 3 of this document contains an overview of system assembly.
Section 4 contains a summary of castor testing undertaken (see test report S6459 for details)
Section 5 contains information on failure modes and a troubleshooting guide for reference
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
www.fallshaw.com.au
1 Castor Construction
EBC Connector Cable
• Yellow Grommet indicates
Motion or ‘Autobrake’ castor
• Grey Grommet indicates
standard castor
Pintle Mounting Adapter
Material: Steel (Zinc Plated)
EBC Manual Brake Pedal
Material: 25% Glass Filled Nylon 6
Trinity Wheel (x2)
Wheel Material: Nylon 6
Tyre Material: Polyurethane (90 Shore A)
EBC Housing
Material : 25% Glass Filled Nylon 6
Trinity Castor Frame
Material: 25% Glass Filled Nylon 6
Trinity Hubcap
Material: ABS
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
www.fallshaw.com.au
EBC Manual Brake Pedal
Material: 25% Glass Filled Nylon 6
EBC Housing
Material : 25% Glass Filled Nylon 6
Trinity Castor Frame
Material: 25% Glass Filled Nylon 6
Trinity Spindle
Material: Zinc Plated Steel
Trinity Spindle Bearing
Material: 3/8 GR5 Carbon Ball Bearing
Trinity Spindle Support Bush
Material: Zinc Plated Steel
Trinity Pintle Adapter Bolt
Material: Zinc Plated Mild Steel
Trinity Housing Support Ring
Material: Zinc Plated Mild Steel
Trinity Brake Location Detents
Trinity Brake Location Detents
Trinity Swivel Brake Slider
Material: 25% Glass Filled Nylon 6
Trinity Slider Lifter Pins (150 only)
Material: Nylon 6
Trinity Spindle Bearing (150 only)
Type: HK2020 Roller Bearing
Trinity Spindle
Material: Zinc Plated Steel
Trinity Direction Lock
Material: 25% Glass Filled Nylon 6
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
www.fallshaw.com.au
Trinity Wheel Brake Plunger
Material: Nylon 6
Trinity Wheel Brake Rocker
Material: 25% Glass Filled Nylon 6
Trinity Wheel Brake Engager
Material: 50% Glass Filled Nylon 6
Trinity Castor Frame
Material: 25% Glass Filled Nylon 6
Trinity Inner Wheel Bearing
Type: 6202 (150), 608 (100)
Trinity Antistatic Conductor
(Motion Castor Only)
Material: 304 Stainless Steel
Trinity Outer Wheel Bearing
Type: 608 (150), 608 (100)
Trinity Tyre (x2)
Material: Polyurethane (90 Shore A)
Trinity Wheel (x2)
Material: Nylon 6
Trinity Hubcap
Material: ABS
EBC Drive Servo
Gearing: Metal, 2 Ball Bearings
Housing Material: Nylon
EBC Servo Horn
Material: 25% Glass Filled Nylon 6
EBC Status Feedback Switches
EBC Control PCB
Motion Sensing for ‘Autobrake’
or
Standard connector board
EBC Connector Cable
• Yellow Grommet indicates
Motion or ‘Autobrake’ castor
• Grey Grommet indicates
standard castor
EBC Housing Fastening Screw
Material: Zinc Plated Mild Steel
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
www.fallshaw.com.au
2 Overview of System Operation
The Fallshaw’s Electric Braking Castor System is intended to replace traditional (mechanical) central
locking castor systems on hospital beds, and provide opportunities for central locking braking on floor beds,
as desired by industry.
The system offers the following benefits;
•
Ease of push button controls (panel or pendant)
•
Full ‘central’ control of all 4 castors via individual castor pedal (option for no pendant or panel)
•
Opportunity for visual indicators of individual or system castor brake status
•
Reduced complexity and cost in bed manufacture for OEM’s (no mechanical ‘hex rod’ system)
•
Increased flexibility in bed design for OEM’s
•
Possibility of using central locking castors on ‘floor bed’ style beds
•
Improved bed handling with possibility of increased steer functions
o Steer from Head or Foot end options
•
FULL manual castor control (via pedals) under power failure or system fault circumstances
•
Autobrake feature (standard but optional) providing decreased risk of falls
2.2 Castor Electric Braking Drive System
Servo motors have been specifically selected to operate the mechanical castor system. When powered
servo’s are capable of the drive torque required to change the brake state of the Fallshaw Trinity castors, but
when unpowered will allow for manual brake changes (via override pedal) in case of; pedal operation
preference, power fail or control system failure.
Each ‘Complete Brake’ Castor has three states;
• ‘Steer’ – able to roll, but swivel locked into a predefined direction
• ‘Neutral’ – able to swivel and roll
• ‘Brake’ – not able to swivel or roll
It is recommended for hospital beds that the Castor System has four states;
• ‘Neutral’
• ‘Steer (head end)’
• ‘Steer (foot end)’
• ‘Brake’
Note:
• Floor Beds may not require either of the Steer functions
• Castors are also available configured as Total Brake castors, which are not capable of ‘Steer’
functionality for this purpose.
For ‘Power Saving’ purposes the control system has 2 ‘Modes’
• ‘Awake’ - monitoring all castor status signals and motion sensing (for autobrake, if fitted) and
displaying status feed back to user.
• ‘Sleep’ – power saving mode, monitoring only the feedback signals in order to react to a pedal drive
input.
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
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The system will enter ‘sleep’ mode automatically when either the ‘brake’
function is selected OR the ‘Autobrake’ is activated. It will return to the ‘awake’ state upon selection of a
brake function from the handset or control panel OR manual (pedal) selection of a new brake status.
System Configurations
• Standard System (Autobrake Capable)
o 4 castors = 3 x Standard castors + 1 x Motion Sensing castor
The following systems are possible and may be required by OEM’s (require specific control software).
• Budget System (NO Autobrake)
o 4 castors = 4 x Standard castors
• No Steer System (Autobrake Capable)
o 4 castors = 3 x Standard castors + 1 x Motion Sensing castor (all factory modified for Total
Brake Only)
• No Steer System (NO Autobrake)
o 4 castors = 4 x Standard castors (all factory modified for Total Brake Only)
2.3 Controls – User Interface
Panel/ Pendant Buttons
• Press ‘neutral’ - places all castors into ‘free’
• Press ‘steer from head end’ - places foot end castors into ‘steer’ and head end castors into ‘free’
• Press ‘steer from foot end’ - places head end castors into ‘steer’ and foot end castors into ‘free’
• Press ‘brake’ - places all 4 castors into ‘brake’
Pedal Operation
• Manually place 1 castor in ‘neutral’ - places all 4 castors into ‘free’
• Manually place 1 castor in ‘steer’ - places the other castor at the same end into ‘steer’ and both
castors at the other end into ‘neutral’
o (note: When ‘steer’ is manually activated user will have to walk to OTHER end to push)
o (note: it is possible to configure system to only place 1 castor at each end into steer as is the
preference of some OEM’s)
• Manually place 1 castor in ‘brake’ - places all 4 castors into ‘brake’
LED indicators
All LED’s are illuminated ONLY whilst the system is ‘awake’
•
•
Castor Status LED – (located next to each selection button on handset or panel) indicates the status
of the castor system - ‘brake’, ‘steer from head end’, ‘steer from foot end’ or ‘neutral’
Error Indicator – If the castor system encounters an error, such as inconsistencies detected between a
drive request and feedback signal, All relevant handset or panel LED’s will flash until a selection
without error is chosen OR Brake (including Autobrake) is activated and the system goes into ‘sleep’
mode. The system will continue to operate as normal.
2.4 Power Save
System will ‘wake’ at the input of any status change request (pedal, panel or pendant) and ‘sleep’ after
‘brake’ has been selected OR Autobrake is applied. This is for power saving purposes, and to allow pedal
activated changes.
In the case of no Autobrake castor fitted or active, ‘sleep’ will occur after 1 minute of no system input.
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
www.fallshaw.com.au
2.5 Motion Sensing Castor (for Autobrake)
Using an accelerometer (to detect bed movement), a motion sensing castor can detect motion of the bed.
Motion signals are interpreted carefully in order to filter out signals generated by ramp angles, slight
movements in floor surface and movements of the patient.
The motion castor (1 of 4) reports ‘stationary’ until motion is detected. This information can them be acted
upon by the controller to apply ‘Autobrake’ when desired.
2.6 Autobrake
Autobrake function is primarily a ‘backup’ safety function intended to prevent the majority of ‘Fall’ injuries
resultant from people leaning on or alighting the hospital bed without the castors being locked (in ‘brake’
mode). It has been identified that this is a major cause of injuries within the hospital environment.
When the Autobrake sensor has detected a lack of motion for 60 seconds (intended but OEM variable) all
four castors will be put into ‘brake’, rendering the situation ‘safe’.
The ‘Autobrake delay’ enables usability of the bed as a transportable item, by leaving time before
automatically applying the brakes for pauses in transport and manoeuvring of the bed such as waiting for
lifts and passing traffic in halls.
It is expected that the Autobrake system will prevent a high percentage of accidents in hospitals. However
due to the Autobrake delay it is necessary that the primary responsibility for brake application remains with
the care staff, with the Autobrake system reducing the opportunity for human error causing an accident.
Autobrake delay time is programmable for each OEM, via the control system. Note: the motion castor is
reporting detection of motion only, it is the job and responsibility of the control system to apply the brakes
when required.
2.7 Manual Control
Every EBC castor is fitted with brake status monitoring micro switches. These switches can be used to;
• Detect an error if a castor has not driven correctly.
• Allow for manual ‘Pedal Inputs’ to be interpreted and status changes applied to all castors
accordingly. (ie if a pedal is put into Brake by an operators foot, all other castors are electrically
driven to Brake position).
2.8 Low Battery Warning
Battery power is handled and controlled by the castor control system, see your control system guide for
information relating to battery life and low battery warning.
Demonstration EBC systems (systems that control castors ONLY), will sound a warning beep, as a function
is selected via handset, if the battery is low, please charge immediately.
2.9 Power Requirements
The following information pertains to the power requirements of EBC castors.
•
•
•
•
System Asleep = approx 30 microamp
System Awake = approx 10 milliamp
System in Motion = approx 11 milliamp
During Status Change
o Average Current Draw = 8.35Amps
o Status Change Duration = 0.15Secs
o Status Change figures are per castor, but as castor drive is staggered current draw remains the
same but multiply duration by no of castors installed (ie 4 for most hospital beds and
stretchers, and 2 for most patient lifters).
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
www.fallshaw.com.au
3 System Assembly
Please see below for assembly information with regards to Linak’s 3 control system options.
Please note: Integration of EBC castors with existing bed control systems is likely to cause variations on these 3 layouts.
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
www.fallshaw.com.au
4 Castor Testing Summary
Trinity EBC castors have gone through rigorous testing to ensure durable performance over a long product
life, including;
4.1 Compliance to IEC 60601 3rd Edition - Mechanical Requirements (IEC 60601-2-52)
o Threshold Test (both 100 and 150mm sizes in pintle and washer mountings)
Test Requirement
• Test Load: 150kg
• Test Speed: 0.8m/s (2.88km/h)
• Cycles: 10 x forward and reverse over obstacle = 20 Obstacles
• Obstacle: 20mm High, 80mm wide, 90deg to travel, 1.5mm radius on edge
• Pass Criteria: No permanent deformation that adversely effects operation to
ISO 22882.
Brake Efficiency Test
Test Requirement
• Ramp Angle: 10deg.
• Test Load: SWL of bed (250kg SWL typical + 150 kg of Bed = 400kg/4 =
o
100kg/castor
•
•
Test Duration: 1hr (castor Forwards) + 1hr (castor Reverse)
Pass Criteria: <10mm of bed movement
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
www.fallshaw.com.au
4.2 Compliance to ISO 22882 Hospital Bed Castor Standard
o Wheel Brake Test
Traction Load: 40% of Load Rating = 60kg
Hold Duration: Hold traction load for 10 seconds
Castor Load: Load Capacity Rating = 150kg
Repetitions: 3 x FWD, 3 x REV
Pass Criteria: No slip or ratcheting of brake under load, no permanent deformation
that adversely effects operation to brake components or tyre surface, fully operational
braking system to ISO 22882 at the completion of test.
o Swivel Load Test (in both Direction Lock and Total Brake)
Traction Load: 40% of Load Rating = 60kg
Hold Duration: Hold traction load for 10 seconds
Castor Load: Load Capacity Rating = 150kg
Repetitions: 3 x Total Brake + 3 x Direction Lock
Pass Criteria: No slip or ratcheting of swivel brake under load, no permanent
deformation that adversely effects operation to brake components or tyre surface,
fully operational braking system to ISO 22882 at the completion of test.
o Static Load Test
Static Load: 3 x load capacity (3 x 150kg = 450kg)
Test Duration: 1 hr
Pass Criteria: No permanent deformation that adversely effects operation of the
castor to ISO 22882 at the completion of test.
4.3 Fallshaw In House Testing
o 60,000 cycle brake on/off test
20,000 mechnical cycles
Then 40,000 electronic cycles
Cycle rate = 10 /minute
Pass criteria = completion of test with less than 0.5% feedback errors (200 errors in
40,000), maintaining full operation to completion
o 30,000 bump, long life run test
Test Load: 240kg(530lbs) trolley = 60kg(130lbs)/castor
Test Speed: 0.67m/s (2.4km/h)
Cycles: 5minutes running, 0.5minute resting per cycle
Swivel: Direction change at start of each cycle
No. of Obstacles: 30,000
Obstacle Requirement:
6.35mm (1/4") for wheel dia below 4" (<100mm)
9.5mm (3/8") for wheel dia 4" to 6" (100mm to 150mm)
12.7mm (1/2") for wheel dia above 6" (>150mm)
Obstacle for test: 10mm High, 80mm wide, 45deg to travel, 45deg chamfer on edge
Pass Criteria: No permanent deformation that adversely effects operation
o Dynamic Brake Test
Test Apparatus: Hospital Bed (150kg)
Test Load: 250kg (bags of plastic granules distributed evenly)
Total load = SWL of bed 250kg SWL typical + 150 kg of Bed = 400kg
Load per castor = 400kg/4 = 100kg
Test Speed: Walking pace (~5km/h or ~1.4m/s)
Cycles Required: 10
Pass Criteria: No permanent deformation that adversely effects mechanical or
electrical operation.
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
www.fallshaw.com.au
o Impact Testing
Side
•
•
•
Pedal
•
•
•
•
•
•
Impact Load: 2kg Pendulum swung from 0.5m height
No of impacts: 2
Pass Criteria: No permanent deformation that adversely effects mechanical or
electrical operation.
Impact Load: 2kg Pendulum swung from 0.5m height
No of impacts: 2
Rubber Mallet
Impact Load: 650g Rubber Mallet
No of impacts: 35
Pass Criteria: No permanent deformation that adversely effects mechanical or
electrical operation.
Frontal
•
•
•
•
•
•
•
Test Apparatus: Test Trolley (20kg)
Test Load: 180kg (bags of plastic granules distributed evenly)
Load per castor = 200kg/4 = 50kg
Test Speed: Fast Walking Pace (~6.5km/h or ~1.8m/s)
Impact Barrier: 10cm High Concrete Gutter
Impacts Required: 2
Pass Criteria: No permanent deformation that adversely effects mechanical or
electrical operation.
o High swivel cycle test
Test Load: 150kg
Test Speed: 0.5m/s (1.8km/h)
Cycles: 200 (includes up and back)
No of 180deg swivels: 400
No. of Obstacles: 400
Obstacle for test: 3mm High, 50mm wide, 90deg to travel, 1mm rad. on edge
Pass Criteria: No permanent deformation that adversely effects operation
o Swivel effort test
Load Capacity: 150Kg
Start Swivel Angle: 135deg from traction direction
Swivel Directions Required: CW + CCW
Pass Criteria:
• 100mm Wheel @ 100kg = </= 10kg
• 150mm Wheel @ 150kg = </= 10kg
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
www.fallshaw.com.au
5 Troubleshooting Guide
The following are a list of potential issues, causes and solutions for Trinity EBC castors.
Symptom
Lights are flashing on handset
Cause
1) 1 or more castors are not able to
reach the selected function.
(note: If cause 1 above, castors will
attempt to drive a second time, this
does not occur with a connection
error)
Solution
Check for external
obstructions to pedal
movement, remove and retry
Check for audible or visible
activity of all pedals, if none
present at a castor, check
connections and retry.
If no activity persists, replace
castor with like (std. or
motion) and retry
Castor/s attempt to drive to selected
mode twice – Why?
Castor brakes come on
automatically after 60 seconds
(OEM programmable)
Bed is moving and brakes come on
automatically
2) 1 or more castors are not plugged
in correctly
Check all castor connections
3) Handset LEDs will flash 3 times
(only) when a manual (pedal
activated) mode change is requested.
This is normal functionality
Feedback signal from 1 or more
castors is indicating a drive error,
(note: error lights should be flashing
on handset)
See ‘light flashing’ symptom
above
Autobrake system in operation
If system is Autobrake
capable and bed stationary the
castor brakes will engage 60s
after the last detected
movement. This is correct
operation of the system
Motion sensing castor missing
1) Check for presence and
correct connection of motion
castor (yellow grommet on
cable, at castor). If present
reconnect and retry
If castor not present,
exchange 1 castor for motion
castor and retry
2) If system is not specified
with Autobrake, contact
controls supplier for software
change to NON-Autobrake
version
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
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Autobrake is not activating after 60s Extreme movement of patient
Castor/s are non-responsive when
pressing handset controls
1) low/no battery power in control
system
2) 1 or more castors or system cable/
battery are not plugged in correctly
3) Castor servo has failed
Handset LEDs do not light and no
castor response when button
selected
Plug control system into
mains power and retry
Check all connections and
retry
Swap unresponsive castor to a
previously working cable and
retry, if still unresponsive
replace with like castor
(motion or standard).
If it responds, check and/or
replace cable and retry both
castors
1) Handset or system cable not
plugged in
Check all connections and
retry
2) Flat Battery
Plug charge cable into mains
power and retry
3) Faulty Handset / CB6 / Battery
Other castor/s are non-responsive
when manually selection function
via castor pedal
It is possible to delay
Autobrake function via
extreme patient movement,
the nature of this movement
however is difficult to sustain,
and it is expected that
Autobrake will be delayed
only momentarily.
1) This particular castor underwent a
feedback error in the last transition,
and has been excluded from manual
drive control until it undergoes a
‘correct’ feedback drive signal
originating from another source
2) Failure of feedback system to
register transition
Contact controls supplier for
troubleshooting/ replacement
parts
Press button on handset to
‘reset’ castor, check for
flashing error LEDs, if no
flashing occurs, check for
manual transition control
from previously nonresponsive castor.
Replace castor with like type
(std. or motion).
Fallshaw Holdings Pty Ltd
ABN 34 622 909 849
www.fallshaw.com.au
1) Castors assembled at factory or
specified incorrectly
Castors must be factory
aligned to 0 or 90deg (DL
direction to pedal mounting
direction), check castor
against order spec.
2) Castors fitted to bed frame
incorrectly
If 90deg castors are fitted
with pedals inline to bed
frame DL direction will be
transverse (and visa versa)
check fitting of castors to spec
3) Pintle retaining bolt hole not
aligned correctly
Check geometry of bed frame
Castors remain locked when pedals
have been changed to Neutral (or
steer)
Friction in the swivel and wheel
brake mechanism can cause the
castor to ‘lock’ if a traction load is
applied after the brake is applied.
Gently shake bed/trolley to
release friction lock
When I select ‘steer from head end’
(or foot end) near end castors go
into ‘steer’ and steering is very
difficult
Castor cables to MJB8 EBC control
box are incorrectly connected.
Swap castor cables from front
to rear of MJB8 (and visa
versa) to align castors with
handset controls
When I put system into Neutral no
LED status light is ON?
There is no LED indicator for
Neutral function
This is normal system
operation
3/8 GR5 carbon ball may have been
omitted during factor assembly
Check for clearance between
head housing and castor
frame, if no clearance present,
replace castor with like (std.
or motion)
Castor pedal locked in position, and
cannot be manually driven
Servo motor gearbox locked
Attempt to drive castor via
other castor pedal or handset
and recheck, if remains
locked, replace castor with
like (std. or motion)
I can hear servo in castor driving on
button press but pedals do not
respond
Servo horn or pedal lever broken
Replace castor with like (std.
or motion)
1) It’s hard to manually get a castor
into neutral.
2) I keep missing neutral and
selecting steer instead when driving
with pedal
The advanced servo drive system
requires small rotations and light
detent between castor functions
This is normal operation of
the EBC castors
Direction Lock is not aligned with
Bed
Castor swivel effort is very high