DE102021120239B4 - Distributor for cylinder control with preprocessing logic - Google Patents

Abstract

An intelligent distributor 1 is provided for the automatic integration of several cylinders 2 into an automation system, with several connection ports APn, APn+1, which are designed for energy and signal transmission for connecting sensors 5 and/or actuators 6. The distributor 1 also has a power connection 10 for power consumption, an interface 11 for communication with a higher-level controller 20, and a display element 20 for each connection port APn, APn+1, wherein a pre-processing logic 15 is integrated into the distributor 1 and the distributor 1 has a mode that is initially activated when a device 5, 6 is connected, the mode automatically determines, checks the plausibility of and assigns the actuators 6 and sensors 5 of a cylinder 2 by connecting the respective connection line to the distributor 1. Furthermore, the logic 15 initiates the sending and receiving of specific auxiliary currents via the connection ports APn, APn+1 and these auxiliary currents are further evaluated via the logic 15 in the distributor 1. The logic 15 is designed in such a way that the distributor 1 can determine a control valve type and/or a cylinder type using appropriate combinatorics and automatically assign it to a corresponding connection port APn, APn+1. Furthermore, the logic 15 of the distributor 1 can initiate a diagnosis via a target-actual comparison and/or over a period of time and display corresponding error codes directly on the distributor 1 via a display element 30 on the respective connection port APn, APn+1 and transmit them to a higher-level controller 20, whereby the logic 15 of the distributor also automatically recognizes which control leads to which end position of the cylinder 2.

Description

The invention relates to a distributor module for the automatic integration of several cylinders into an automation system according to claim 1.

To control automation processes in the automation industry, field devices, i.e. the actuators and/or sensors of a process, are often not connected individually to a central control unit, but bundled to the controller via a pre-distribution board. This keeps the wiring effort to a minimum. The distributor supplies energy and bundles all incoming and outgoing signals. The controller mainly handles control and safety processes. Due to the large number of devices connected to a controller, the complexity and programming effort is often very high. A process always consists of several individual process steps and is defined by the order and chronological sequence of these steps in relation to one another.

Today's sensors and/or actuators do not just monitor a process step in binary form, but also record data continuously. With appropriate processing, additional information about the process can be obtained by analyzing and combining the data, which can be converted into diagnostic information and provides information about the individual process step and/or the system health of a process.

However, this type of information still far too rarely finds its way into a higher-level control authority.

From the DE 102012112427 A1 A method for operating a field device for automation technology is known, with which operating software is transferred to a higher-level processing unit when the field device is put into operation. However, such a transfer of software can be error-prone. Overall, the method is considered to be too complex.

Furthermore, the DE 102021127384 A1 A distributed process control system for controlling an industrial process is known, which allows a process to be controlled by means of data transmission.

From the EN 102013107964 A1 A measuring arrangement is known that is connected wirelessly to a higher-level data processing device via a radio link. Radio links are susceptible to interference.

From the EP3612900B1 A method for plant monitoring is known in which several communication networks are connected to each other, which is complex and error-prone.

A decentralized distributor that uses the “plug & play” principle to automatically collect data from the connected field devices, link this data and convert it into diagnostic information for analyzing the system health of the process is not known.

An object of the invention is to eliminate the above-mentioned disadvantages and to provide a less complex and at the same time user-friendly distributor module for cylinder analysis and control.
The distributor reduces the complexity of data assignment and/or processing in a central control system by bundling relevant data, automatically assigning control signals via pre-processing intelligence and transmitting the analyzed, pre-processed data to a higher-level control instance.

The object is achieved by the features specified in claim 1. Advantageous further developments of the invention are specified in the subclaims.

An intelligent distributor is provided for the automatic integration and detection of several cylinders in an automation system, with several connection ports designed for energy and signal transmission for connecting sensors and/or actuators.

The distributor also has a power connection for power consumption, an interface for communication with a higher-level control system, and a display element for each connection port.

Furthermore, a pre-processing logic is integrated into the distributor and the distributor has a mode that is initially activated when a field device is connected.

It is particularly advantageous that the field devices do not have to be specifically designed as IO-Link devices for the function according to the invention, since initialization does not take place via IO-Link. According to the invention, field devices without IO-Link functionality can therefore also be used.

If the mode is activated by connecting a field device, the mode automatically determines the actuators and sensors of a cylinder using auxiliary currents, checks their plausibility and assigns them to the process steps.

In a first step, the logic initiates the sending and receiving of specific auxiliary currents via the connection ports. It is intended that these auxiliary currents are evaluated in a second step via the logic in the distributor.

The logic is designed in such a way that the distributor uses appropriate combinations to clearly determine a control valve type and/or a cylinder type and automatically assigns it to a corresponding connection port. The control valve type refers to a 3/2-way valve or 5/3-way valve and the distinction between the two. The cylinder type also refers to the mode of operation and the distinction between bidirectionally driven or spring-returning.

Furthermore, the logic of the distributor can initiate a diagnosis via a target-actual comparison and/or over a period of time and display corresponding error codes directly on the distributor via a display element on the respective connection port and transmit them to a higher-level control system, whereby the logic of the distributor also automatically recognizes which control leads to which end position of the cylinder.

The solution consists of a decentralized distributor module to which the actuators and sensors of a cylinder-controlled automation process are connected. The distributor is suitable for controlling and monitoring one or more independently operating cylinders of a process.

Both pneumatic and hydraulic cylinders or a combination of both energy forms can be connected to the distributor. In a particularly advantageous manner, cylinders of both energy forms can also be connected in parallel to a distributor and operated together via this.

In the distributor, incoming data and signals are collected at the inputs, bundled and assigned to the outputs accordingly. Communication to a higher instance takes place directly with just one connection line.

In addition, it is intended that the distributor can be placed in the immediate vicinity of the process due to its tightness in the process environment. This results in short connection lines to the distributor. In particular, if several cylinders are connected, the cabling effort to the central control is reduced and the number of IO modules that would otherwise be required there is reduced.

Overall, smaller cable ducts can be used with this solution. The cabling is reduced to plugging the actuators and/or sensors of the process into a connection port of the distributor. Programming the interface is not necessary, as the connected components are automatically recognized and linked together. The usual programming effort for interfaces is completely eliminated with the distributor module according to the invention.

Advantageously, the distributor can detect whether a sensory element is connected based on the operating current consumed by the sensory element.

The distributor can also use a test current to detect whether a corresponding valve is connected. However, the test current is much smaller than the valve could be switched. These auxiliary currents can also be used to detect which valves and/or which sensory element can be controlled and read out for automatic assignment. These auxiliary currents can also be used to detect during normal operation whether the sensory element or valve has been disconnected from the distributor. This makes it possible to detect errors such as damage caused by a broken cable, a loose connection or an intentional disconnection, etc. In this case, the distributor can transmit an error message to a higher-level control instance connected to the central control system. By specifying the exact error, e.g. "cable break on cylinder xx", "sensor yy", "valve zz", the defect can be precisely identified. The error can therefore be quickly identified and rectified.

The distributor can also automatically assign control signals to the end positions of a cylinder. By operating a control valve, the distributor automatically recognizes which control leads to which end position.

In a particularly advantageous way, the distributor automatically recognizes the connected control valve type and/or cylinder type and can thus make a clear assignment. The control valve type means a 3/2-way valve or 5/3-way valve and the distinction between the two. The cylinder type also means the mode of operation and the distinction between bidirectionally driven or spring-returning. Depending on the control valve type, the distributor also recognizes combinations of both outputs.

Furthermore, the cylinder type and the control method can be recorded using the assignments determined in this way. The cylinders in the car's system The cylinders in the automation process and the valves for controlling the cylinders are clearly and automatically recorded by the control module and assigned to the components. Using the assignments determined in this way, the central control only needs to tell the control module in which position the cylinder should be, e.g. whether the cylinder should be in the first end position or the second end position.

Furthermore, in the aforementioned modes, the time required for the corresponding cylinder to move from the first to the second end position and back can be determined.

Likewise, if the desired end position is changed, the control module can record the time until the change is reached. The time measurement starts when a control valve is switched. The time measurement stops when the desired end position is reached. The central control communicates the desired end position to the distributor, e.g. via the PDout. The distributor switches the control valves accordingly. In a detection mode, the time period from switching a control valve to reaching a preset end position is determined. There are two ways to do this.

Autosetup: the distributor automatically controls everything that is closed and recognizes which end position can be reached with which control valve. Reference times are also recorded for these movements and assigned to individual process steps.

PLC-Teach: similar to Autosetup A, with the difference that the control signal is not triggered by the distributor, but by the central control itself and is looped through the distributor. This teaching method is particularly advantageous for complex systems in which several actuators interact with one another. It can also be carried out during production and therefore under normal load. If the time period deviates from the time period determined in detection mode by more than an adjustable tolerance, then certain errors can be inferred, e.g. loss of auxiliary energy (compressed air, hydraulic pressure), blockage, lack of load, wear, etc. These error messages are passed on to the central control.

The invention is explained in more detail below using embodiments with reference to the drawings.

• 1 ein erfindungsgemäßer Verteiler in zwei Ansichten;
• 2 ein direkt an eine zentrale Steuerung angeschlossener Zylinder;
• 3 ein schematischer Aufbau zur Einbindung mehrere Zylinder in ein Automatisierungssystem mittels einem erfindungsgemäßen Verteiler.

They show schematically:

• 1 a distributor according to the invention in two views;
• 2 a cylinder directly connected to a central control system;
• 3 a schematic structure for integrating several cylinders into an automation system by means of a distributor according to the invention.

In the following description of the preferred embodiments, like reference numerals designate like or comparable components.

1 shows a distributor 1 according to the invention in a top view and side view with dimensions in millimeters. The distributor 1 has several connection ports APn, APn+1, a power connection 10 for power consumption, an interface 11 for communication with a higher-level control, and a display element assigned to each connection. The connection ports APn, APn-1 are provided as an interface for connecting sensors 5 and/or actuators 6 of a cylinder control process comprising several cylinders 1, so that a process consisting of several cylinders 2 can be connected holistically to a distributor 1. A preprocessing logic 15 is integrated into the distributor 1. The distributor 1 has a mode that is initially activated when a cylinder-controlling or cylinder-monitoring field device is connected. The mode provides for automatic detection, plausibility check and assignment of the connected field devices to the process steps, so that the programming effort is simplified compared to conventional wiring and programming and the diagnosis is carried out holistically across the entire cylinder control process. The process steps or the control sequence, the direction of movement as well as the state “open”, “closed” and/or “an intermediate position” of the cylinder are recorded automatically.

2 shows a cylinder 2 which is connected in a known manner to a central control system (PLC) 20 according to the state of the art. The two end positions of the cylinder 2 are each monitored by sensors 5 in the end positions. The cylinder is controlled directly by the central control system 20 via an appropriately connected actuator 6.

3 shows schematically a structure for integrating several cylinders 2 into an automation system by using the distributor 1 according to the invention according to 1 . The dashed area shows a self-contained cylinder control and/or monitoring process consisting of more than one cylinder 2. The distributor 1 centrally monitors the process, converts incoming sensor and actuator signals into diagnostic information, analyses the cylinder control process completely uniform and provides the connected central controller 20 with holistic information about the system health of the process. The actuators 6 and sensors 6 required for cylinder control and cylinder monitoring are connected to the distributor 1 via connecting cables. All cylinder end positions are monitored by sensors 5 which are attached to the cylinders 2 in the area of the cylinder end positions. To actuate a cylinder 2, an associated actuator 6, i.e. a control valve, is switched6 through which a pressure-transmitting medium, e.g. compressed air or hydraulic oil, flows. The distributor 1 can control the cylinders 2 via the valves 6 and read out the sensor-detected cylinder position of each cylinder 2 via the sensors 5 attached to the cylinder 2. Information about target and actual states is brought together in the distributor 1 so that deviations and diagnostic data, e.g. compressed air loss, wear and tear, missing load, etc. are determined and evaluated using a pre-processing logic 15 integrated in the distributor 1. The distributor 1 is connected to a central controller 20 via a direct line. The communication between the distributor 1 and the central controller 20 takes place bidirectionally via this line.

3 shows an example of a process structure with four cylinders. Of course, other designs are also conceivable, which have more or fewer cylinders, but at least two cylinders. The functions of the invention and other embodiments are explained in more detail below.

The invention relates to a decentralized distribution module 1 for controlling, and thus for operating and monitoring cylinders 2. The cylinders 2 can be both pneumatic and hydraulic cylinders, or a combination of both.

A cylinder 2 whose function is monitored typically has a sensory element 5 at both ends, e.g. a cylinder switch, which indicates when the cylinder piston has reached an end position.

To actuate cylinder 2, a control valve is usually switched through which a pressure-transmitting medium, e.g. compressed air or hydraulic oil, flows.

The distributor 1 can control cylinder 2 via pilot valves 6 and read the sensor-detected cylinder position of each cylinder 2. Information about target and actual states is collected in the distributor 1 so that deviations and diagnostic data, e.g. loss of compressed air, wear and tear, lack of load, etc. can be determined and evaluated in the distributor 1 using a pre-processing logic 15.

Advantageously, the distributor 1 can control and monitor not just one but several cylinders 2 independently of one another. The distributor module 1 provides two inputs for sensor detection and two outputs for actuating a control valve 6 per cylinder 2.

The distributor 1 ensures the power supply and communication of the devices 5, 6 connected via the distributor 1. The distributor 1 is connected to the central control 20 via a communication interface using a direct line and can also be partially supplied with power via this. A separate, second power supply, such as IO-Link master port B, is provided to operate the control valves 6. The communication between the distributor 1 and the central control 20 takes place via the line using a direct connection such as IO-Link or via a bus system.

By means of a separate, dedicated power supply, the actuators 6 can advantageously switch to a defined, safe state, e.g. by emergency shutdown of the second power supply. Cylinder drives are generally installed in such a way that if the actuators 6 lose power, the spring return of a cylinder 2 or a control valve 6 brings the drive into a defined state. The sensors 5 connected to the control module, i.e. to the distributor 1, as well as the data analysis and diagnostics are not affected by this emergency shutdown - power-free state. The diagnosis of the connected sensors 5 can therefore continue in this situation. This means that even in the safe, power-free state, corresponding error states can be detected and transmitted without restriction to the central control 20.

Further advantages of the invention are:

a. Function and wiring detection

The distributor 1 detects the actuator 6 and sensor 5 connected to the distributor 1 using auxiliary currents. The auxiliary currents indicate whether actuator 5 or sensor 6 is connected. The movement enables the distributor 1 to automatically assign related signals, e.g. assign a sensor 5 to a corresponding control valve 6.

When connecting the actuators 5 and sensors 6, a plausibility-checked assignment prevents confusion between the two sensor inputs or between the two actuator outputs. The assignment takes place automatically in distribution list 1.

Another advantage is that when planning or programming the central control system, it is no longer necessary to distinguish between 3/2-way valves and 5/3-way valves, as the distributor can automatically determine and recognize the corresponding control valve type (3/2-way valve or 5/3-way valve) using appropriate combinations. The programmer therefore only has to distinguish between the first end position and the second end position and can ignore the intermediate logic or wiring.

b. Cable break detection

By monitoring operating and auxiliary currents, the distributor 1 detects whether a cable to the sensors 5 and control valves 6 is loose, broken or disconnected. This enables precise diagnosis and faster fault indication and contributes to faster fault tracking and rectification. In summary, this query can be used to reduce the downtime of the system in the event of a fault.

c. Diagnosis

All recorded information as well as the target and actual values are collected decentrally at the distributor 1. This information enables the distributor 1 to create a detailed diagnosis of the status and functionality of each individual cylinder 2 and to transfer this specific cylinder information into a higher-level diagnosis so that comprehensive diagnostic information is available for all field devices connected to the distributor 1 about the cylinder control process to be monitored. In particular, a lack of auxiliary energy, e.g. compressed air or hydraulic pressure, blockage, lack of load or wear can be diagnosed, analyzed and processed from a value comparison.

d. low cabling and programming effort

The decentralized connection of sensors 5 and actuators 6 to the distributor 1 results in shorter connecting cables, smaller cable ducts and a smaller number of IO modules on the central control system. This means that four cylinders 2 can be managed with one cable instead of the previous sixteen cables.

The automatic assignment via distributor 1 reduces the programming effort compared to conventional wiring and programming. With distributor 1, the construction of a system for cylinder monitoring and cylinder control is made much easier. At the same time, a less complex process based on the "plug & play" principle is provided.

List of reference symbols

1

Distributor, distributor module

2

cylinder

5

Sensor, sensor technology

6

Actuator, actuators, valve

10

Energy connection

11

interface

15

preprocessing logic

20

central, higher-level control

30

Display element

APn

connection, port, IO-Link connection

APn+1

additional connections, ports, IO-Link connections

Claims (1)

Distributor (1) for the automatic integration of several cylinders (2) into an automation system, wherein the control of the cylinders (2) is carried out via an actuator (6) and the monitoring of the cylinders (2) is carried out via sensors (5), with several connection ports (APn, APn+1) which are designed for energy and signal transmission for connecting sensors 5 and/or actuators (6), with a power connection (10) for current consumption, with an interface (11) for communication with a higher-level control (20), and with a display element (20) for each connection port (APn, APn+1), wherein a pre-processing logic (15) is integrated into the distributor (1) and the distributor (1) has a mode which is initially activated when a cylinder-controlling or cylinder-monitoring field device (5, 6) is connected, the mode automatically determines, checks the plausibility of the actuators (6) and sensors (5) of a cylinder (2) by connecting the respective connection line to the distributor (1). to each other, wherein the logic (15) initiates the sending and receiving of specific auxiliary currents via the connection ports (APn, APn+1) and these auxiliary currents are evaluated via the logic (15) in the distributor (1), wherein the logic (15) is designed such that the distributor (1) determines a control valve type and/or a cylinder type by means of appropriate combinatorics and automatically assigns it to a corresponding connection port (APn, Apn+1), wherein the logic (15) of the distributor (1) uses a target-actual comparison and/or over a period of time to determine a Diagnosis is initiated and corresponding error codes are displayed directly on the distributor (1) via a display element (30) on the respective connection port (APn, APn+1) and transmitted to a higher-level control system (20), whereby the logic (15) of the distributor automatically recognizes which control leads to which end position of the cylinder (2).

Images