Method of improving safety of industrial input / output assembly and input / output assembly

Abstract

The invention relates to a method for increasing the safety of an industrial input / output assembly and to an input / output assembly, wherein on the input / output assembly (1) a mechanical load (B) acting from the outside onto the input / output assembly (1) is derived by means of an acceleration sensor (BS), wherein it is checked whether the load (B) exceeds a predetermined limit value (GW) and, for the case of an excess, the value of a load sum (BSS) is increased in accordance with the degree of the excess (H), wherein the load sum (BSS) is continuously compared with a maximum load value (B Max ) characterizing the service life (L) of the input / output assembly (1) and, for the case that the load sum reaches the maximum load value (B Max ), a maintenance message (WM) is issued.

Description

Technical Field

[0001] The present invention relates to a method for improving the reliability of industrial input / output components, wherein the mechanical load acting on the input / output components from the outside is determined by means of an accelerometer, wherein it is checked whether the load exceeds a predetermined limit value, and if it does, the value of the total load is increased accordingly based on the degree of exceedance.

[0002] Furthermore, the present invention relates to an input / output component including an acceleration sensor, a measuring device designed for measuring an externally applied mechanical load by means of the acceleration sensor, and a checking mechanism designed for checking whether the load exceeds a predetermined limit value. Background Technology

[0003] Industrial input / output components are used in industrial automation, particularly as distributed peripherals for driving actuators and reading sensors. These components or modules for distributed peripherals are classified as IP20 or IP67 protection ratings, depending on the application. IP67 protection rating components are represented by companies such as Siemens AG, and also by the ET 200eco PN, ET 200AL, and ET 200ecoPN M12-L series. These components can be installed directly in the field without a control cabinet, for example, on a robot arm or other machine part. IP67 protection rating components are very common for small, localized automation tasks such as door control or robot arm applications. These modules are typically used under very high mechanical loads exceeding specified values. This can lead to premature component failure. Summary of the Invention

[0004] The purpose of this invention is to provide a method for improving the reliability of input / output components.

[0005] Furthermore, an object of the present invention is to provide an input / output component that can be used with improved reliability, particularly in mechanical stress environments.

[0006] This objective is achieved by checking whether the load exceeds a predetermined limit value according to the method, and if so, increasing the value of the total load accordingly based on the degree of exceedance. The total load is continuously compared with the maximum load value characterizing the lifespan of the input / output component, and a maintenance message is issued when the total load reaches the maximum load value. If the input / output component is subjected to such a large load on a rapidly moving robot arm that the mechanical load acting on the input / output component with respect to acceleration exceeds the vibration test according to IEC 60068-2-6, as a result of this method, impending system failures are identified early for the input / output component, and condition-based maintenance is avoided. This is because industrial input / output components are subjected to intense vibration and shock tests, in which a constant acceleration of 20G is performed, for example, in each of three mutually perpendicular axes, at a vibration cycle of 10 scans per axis. For example, in the case of a half-sine wave shock load, a 30G shock is applied for 18μs. Here, during the test, the shock is also applied as a load to each of the three mutually perpendicular axes respectively.

[0007] A further improvement to this method is proposed, which uses an accelerometer to record a time-continuous signal curve and calculates the total load based on the integral.

[0008] The method also proposes to perform a statistical evaluation of the measured values ​​of the mechanical load. The measurements provided by the accelerometer are statistically evaluated after readout, for example by averaging, in order to obtain information from the environment of the input / output components.

[0009] The method is further improved by considering the mass of the input / output components when calculating the total load. Since the load is typically caused by acceleration, and the self-weight of the input / output components is crucial, forces related to the self-weight of the components can be taken into account.

[0010] It is also advantageous to consider the temperature of the input / output components when calculating the total load. This is because if the input / output components are subjected to shock and vibration at extreme temperatures, small cracks can easily appear between the printed circuit board and the connected parts, potentially leading to malfunction of the entire electronic device. Therefore, considering temperature improves the probability of fault prediction.

[0011] The maximum load value can also be determined through experimental vibration and shock tests. This will be derived from vibration testing, and moreover, this is equivalent to vibration testing that far exceeds the requirements performed according to IEC 60068-2-6 and IEC 60068-2-27, because in this test, the component is subjected to shock until the component actually fails. This is equivalent to the actual failure limit, which is derived from experimental vibration and shock tests, and the actual failure limit value is used in the input / output components for outputting alarm messages.

[0012] In summary, this method can determine the mechanical load on input / output components and provide an indication of their mechanical aging. This information can then be used to implement monitoring and maintenance alerts with configurable thresholds.

[0013] If the measured values ​​also have timestamps, they can indicate the past development of machine movement. Here, the ultimate load is identified through statistical processing of the measured data. By differentiating the measured acceleration value, the distance traveled can be described, and by integrating the measured value, the mechanical load over a period of time can be assessed. In particular, the integration of the measured values ​​can provide information about the load on contacts, solder joints, crimp connections, etc., during the lifespan of the input / output components. The internal temperature of the input / output components also plays an important role here. Therefore, the maximum service life of the input / output components can be determined based on the process.

[0014] This information is useful to customers so they can utilize the entire lifespan of input / output components, depending on usage conditions. This leads to sustainable resource utilization because there is no need to replace input / output components prematurely; these components have low loads and therefore longer lifespans.

[0015] The aforementioned objective is also achieved through an input / output component including an accelerometer, a measuring device designed to measure externally applied mechanical loads using the accelerometer, a checking mechanism designed to check whether the load exceeds a predetermined limit value, a load total calculator designed to add the degree of excess to the total load, and a monitoring mechanism designed to continuously compare the total load with a maximum load value characterizing the lifespan of the input / output component, and to issue a maintenance message when the total load reaches the maximum load value.

[0016] An input / output component has now been advantageously created that can identify impending system failures early on. The quality of this input / output component has been significantly improved because it can identify necessary maintenance and severe aging at an early stage. This, in turn, helps avoid failures in customers' automated systems, resulting in fewer failures in the manufacturing process.

[0017] The input / output component also has a recording mechanism that connects to the accelerometer and records a time-continuous signal curve, wherein an integration mechanism is present, which is designed to calculate the total load based on the integration of the signal curve.

[0018] In a further improvement to the input / output component, it has a processing module that converts time-continuous values ​​via an analog-to-digital converter, performs vibration analysis after the conversion within a frequency range, and statistically evaluates the measurements for mechanical loads.

[0019] The measurements provided by the accelerometer in the input / output components are statistically evaluated, for example by averaging, after being read, in order to obtain information from the module's environment.

[0020] To determine mechanical aging more accurately, parameterizable storage is provided within the component, allowing input / output of the component's mass into this storage space. The mass can also be queried to calculate the total load. Particularly in the case of moving mass, the component's own weight plays a decisive role in the mechanical load.

[0021] The temperature experienced by a component also plays a decisive role in its mechanical aging. Therefore, input / output components are equipped with temperature sensors, which can be used to query the temperature of the input / output components in order to calculate the total load.

[0022] In addition, the input / output components have additional parameterizable storage space, which can be used to input experimentally derived maximum load values ​​or actual performance limits.

[0023] In a preferred embodiment, the accelerometer is designed as a MEMS sensor.

[0024] Another customer application is to output pre-processed measurements via a fieldbus system so that customers can continue to use and process these measurements. For this purpose, the input / output components have a fieldbus interface and a transmitting device, where all measurements and maintenance messages can be transmitted to the fieldbus via the fieldbus interface and the transmitting device. Attached Figure Description

[0025] The accompanying drawings illustrate embodiments of the present invention, in which... Figure 1 The input / output components are shown. Detailed Implementation

[0026] according to Figure 1The diagram illustrates an input / output component 1 comprising an accelerometer BS, a measuring device ME, and a checking mechanism PM. The measuring device ME receives measurements from the accelerometer BS and checks whether these measurements exceed a predetermined limit value GW. For each instance of exceeding the predetermined limit value GW, the degree of exceedance H is accumulated in a load summation calculator BSS. To monitor these accumulated loads, a monitoring mechanism UM is also present, designed to compare the load summation BSS with a maximum load value B representing the lifespan L of the input / output component 1. Max Continuous comparisons are made, and the total load has reached the maximum load value B. Max In this situation, a maintenance message WM is sent.

[0027] In addition, the input / output component 1 has a recording mechanism AM, which is connected to the acceleration sensor BS and records the time-continuous signal curve S. (t) Among them, there exists an integrator IM, which is designed to integrate based on the signal curve S. (t) The integral calculation of the total load BSS' is performed.

[0028] The processing module VM is designed to convert time-continuous values ​​via an analog-to-digital converter and perform vibration analysis, such as fast Fourier transform, after transformation within the frequency range, and statistically evaluate the measurements for mechanical load B.

[0029] Regarding a more precise description of potential future failure times, input / output component 1 has parameterizable storage spaces 2, 3, and 4. The mass m of input / output component 1 can be stored in the first storage space 2. The experimentally determined maximum load value E... Max It can be stored in the second storage space 3 or can be parameterized externally. The practical limit Ex can be parameterized in the third storage space 4.

[0030] Stored values ​​such as mass m and experimentally obtained load value E Max The failure limit Ex can be included in the calculation of future effective time points.

[0031] In addition, the temperature sensor TS provides the current primary temperature T in component 1 as input / output. If the component's temperature T is also very high in addition to the mechanical load B, the mechanical aging caused by the mechanical load B will continue to increase, and the component may fail more quickly.

[0032] In order to transmit the recorded measurement values ​​to a higher level of automation system, the input / output component 1 has a fieldbus interface 5 and a transmitting device 6, wherein all measurement values ​​and maintenance messages WM can be transmitted to the fieldbus 7 via the fieldbus interface 5 by means of the transmitting device 6.

[0033] The mechanical load B acting on the input / output component 1 is typically performed on three axes in the x, y, z coordinate system. The component has first inputs E1 to fifth inputs E5 for receiving distributed process values, and first outputs A1 to fifth outputs A5 for outputting actuator values ​​for industrial processes.

Claims

1. A method for improving the fail-safety of an industrial input / output component (1), wherein, The mechanical load (B) acting on the input / output component (1) from the outside is obtained by means of an accelerometer (BS), wherein it is checked whether the load (B) exceeds a predetermined limit value (GW), and if it exceeds the limit value, the value of the total load (BSS) is increased accordingly according to the degree of exceedance (H). The total load (BSS) is calculated by adding the maximum load value (B) that characterizes the lifespan (L) of the input / output component (1). Max The system continuously compares loads, and if the total load reaches the maximum load value (BMax), it issues a maintenance message (WM). The total load (BSS) is presented as a cumulative value, representing the total amount of mechanical stress on the input / output components as it changes over time.

2. The method according to claim 1, wherein, The accelerometer (BS) is used to record a time-continuous signal curve (S). (t) ), and calculate the total load (BSS) based on the integral.

3. The method according to claim 1 or 2, wherein, The measured values ​​of the mechanical load (B) are statistically evaluated.

4. The method according to claim 1 or 2, wherein, The mass (m) of the input / output component (1) is taken into account in order to calculate the total load (BSS).

5. The method according to claim 1 or 2, wherein, The temperature (T) of the input / output component (1) is taken into account in order to calculate the total load (BSS).

6. The method according to claim 1 or 2, wherein, The maximum load value (B) was determined through experimental vibration and shock tests. Max ).

7. The method according to claim 1 or 2, wherein, The actual failure limit (Ex) is determined by experimental vibration and shock tests, and the value of the actual failure limit (Ex) is used in the input / output component (1) in order to output an alarm message.

8. An input / output component (1), comprising: Accelerometer (BS) The measuring device (ME) is designed to measure the mechanical load (B) acting from an external source using the accelerometer (BS). Inspection unit (PM) is designed to check whether the load exceeds a predetermined limit value (GW). The Load Sum Calculator (BSZ) is designed to add the excess level (H) to the load sum (BSS). The monitoring unit (UM) is designed to compare the total load (BSS) with the maximum load value (B) characterizing the lifespan of the input / output component (1). Max ) continuously compare, and for the sum of the loads to reach the maximum load value (B) Max In the event of a maintenance message (WM), a maintenance message is sent. The total load (BSS) is presented as a cumulative value, representing the total amount of mechanical stress on the input / output components as it changes over time.

9. The input / output component (1) according to claim 8, further comprising a recording mechanism (AM) connected to the accelerometer (BS) and the recording mechanism recording a time-continuous signal curve (S). (t) ),in, There exists an integrator (IM) designed to adjust the signal curve (S) based on the integrator's position. (t) The integral of the load sum (BSS) is used to calculate the total load.

10. The input / output component (1) according to claim 8 or 9 further comprises a processing module (VM) that performs vibration analysis after converting time-continuous values ​​via an analog-to-digital converter and after transformation within a frequency range, and performs a statistical evaluation of the measured values ​​of the mechanical load (B).

11. The input / output component (1) according to claim 8 or 9, wherein, There is a parameterizable storage space (2) that can input the mass (m) of the input / output component (1) into the storage space, and the mass can be queried in order to calculate the total load (BSS).

12. The input / output component (1) according to claim 8 or 9 further comprises a temperature sensor (TS), wherein, In order to calculate the total load (BSS), the temperature (T) of the input / output component (1) can be queried.

13. The input / output component (1) according to claim 8 or 9, wherein, There is an additional parameterizable storage space (3, 4) that can input the maximum load value (E) obtained from the experiment. Max The actual failure limit (Ex) is then transferred to the additional storage space.

14. The input / output component (1) according to claim 8, wherein, The accelerometer (BS) is designed as a MEMS sensor.

15. The input / output component (1) according to claim 8, having a fieldbus interface (5) and a transmitting device (6), wherein, All measurement values ​​and maintenance messages (WM) can be transmitted to the fieldbus (7) via the fieldbus interface (5) using the transmitting device (6).

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