Drive system for simulating the operation of the drive device

Abstract

Drive system (1), comprising a control device (30) for controlling the drive operation of a drive device (10) for driving a driven element into a drive movement, at least one safety function, and a control device (50) for controlling several operating modes of the drive device (10), wherein The several operating modes include a simulation mode in which no drive movement of the driven element takes place and a reaction of the drive device (10) to predetermined setpoints is simulated, which are entered into the control device (30) by the control device (50), wherein in the simulation mode only the communicative connection of the drive device (10) to the control device (50) is simulated and tested and the mechanical function of the drive device (10) is excluded, wherein in the simulation operating mode at least one safety function with regard to safe data transmission between the control device (50) and the drive device (10) can be activated, so that an unintended drive movement caused by the drive device (10) is reliably prevented and the drive device (10) is switched to safe operation.

Description

[0001] The invention relates to a drive system for simulating the operation of the drive device.

[0002] Drive devices are required in many technical systems to power rotating parts or, via a suitable transmission, push and / or pull rods. When commissioning a technical system, it is usually necessary to ensure the safe operation of all its components. In particular, the safe operation of the parts moved by the drive device is essential to prevent damage to the drive device and / or the technical system.

[0003] Modern drive systems offer a multitude of functionalities, parameterization options, and safety features, some of which interact and are mutually dependent, thus complicating the commissioning of these drive systems. For example, with a conventional drive system, the functionality of the communication link between the drive and its controller cannot be tested independently of mechanical aspects such as resonance or backlash, or the fundamental function of the drive system itself. This means that if a fault occurs during testing, it is usually difficult or impossible to determine the cause of the fault. A fault in the communication link between the drive and its controller, for example, an external controller, could lead to...For example, if a PLC (Programmable Logic Controller) is damaged, the mechanics of the drive device may be damaged.

[0004] To test and confirm the correct operation of all functions and parameterization options of such a drive device, it is useful to commission it step by step, in which all aspects relating to the drive device, including electrical systems, mechanics, programming and communication, can be checked and optimized separately.

[0005] German patent application DE 10 2006 025 165 A1 discloses a device and a method for controlling the motion of a machine element. The device includes a setpoint calculation tool that determines setpoints and outputs them to a drive unit for controlling a motor. Furthermore, the device includes a setpoint calculation tool model that determines model setpoints and outputs them to an evaluation tool, wherein the model setpoints are determined by the setpoint calculation tool model and output to the evaluation tool prior to the actual setpoints.

[0006] Another publication, DE 102 48 991 B4, discloses a device for simulating the control and machine behavior of machine tools or production machines, wherein actual axis values ​​can be calculated from target axis values ​​using mathematical models of the drives and the mechanics of the machine. The target axis values ​​can be output from a numerical control system to a downstream computer, and the actual axis values ​​can be calculated by the downstream computer and forwarded to a machine model. Status signals generated by the machine model can be fed back to the numerical control system, and controlled and uncontrolled axes can be simulated simultaneously.

[0007] The object of the present invention is to provide a drive system for simulating the operation of a drive device, which solves the preceding problems of the prior art, and in which, in particular, the functions of the drive device can be tested individually.

[0008] This problem is solved by the drive system according to claim 1. The drive system according to the invention comprises a control device for regulating the drive operation of a drive device for driving a driven element into a drive movement and a control device for controlling several operating modes of the drive device. The several operating modes include a simulation mode in which no drive movement of the driven element takes place and a reaction of the drive device to predetermined setpoints, which are input into the control device by the control device, is simulated.According to the invention, the drive system has at least one safety function which puts the drive device into safe operation, wherein in the simulation mode at least one safety function with regard to safe data transmission between the control device and the drive device can be activated, so that an unintentional drive movement caused by the drive device is safely prevented.

[0009] Advantageous embodiments of the drive system are set out in the dependent patent claims.

[0010] Preferably, the control device comprises a speed controller for controlling the speed of the drive movement to be effected by the drive device, wherein the speed controller is activated in simulation mode and the control device derives an actual speed value entered into the speed controller from a predetermined target speed value.

[0011] Preferably, the control device comprises a position controller for controlling the position of the driven element during the drive movement to be effected by the drive device, wherein the position controller is activated in simulation mode and the control device derives an actual position value entered into the position controller from a predetermined target position value.

[0012] In simulation mode, the speed controller and position controller can be operated without being enabled by a current controller, which serves to regulate the current supplied to the drive device in order to drive the element to be driven.

[0013] In simulation mode, a current controller for regulating the current supplied to the drive device to produce a predetermined force can be deactivated, whereby in simulation mode: an actual current value to be entered into a current controller is replaced by a setpoint current value determined by the control device; an actual velocity value to be entered into a velocity controller is formed by integrating the fictitious acceleration of the drive device, which results from the torque setpoint determined by the control device and the inertial mass of the load with which the drive device is subjected; and an actual position value of elements to be driven by the drive device, entered into a position controller, is formed by integrating the formed velocity setpoint.

[0014] In simulation mode, a speed controller for regulating the speed of the drive movement caused by the drive device can be deactivated, whereby in simulation mode: an actual speed value entered into the speed controller is replaced by a setpoint speed determined by the control device, and an actual position value of elements to be driven by the drive device, to be entered into a position controller, is replaced by the integrated setpoint speed.

[0015] It is possible that the drive device has a motor for driving the element to be driven, wherein the motor has a stationary stator and a rotor that is movable relative to the stator, and wherein movement of the rotor is prevented in the simulation operating mode.

[0016] The drive device can drive multiple axes, with the simulation mode being executable separately for each axis.

[0017] The drive device can have at least one diagnostic function which serves to diagnose the drive device, whereby in simulation mode all diagnostic functions are available and the simulated actual values ​​are used for the diagnosis.

[0018] The drive device can have at least one technology function that uses the simulated actual values, with at least one technology function being available during simulation operation.

[0019] In the drive system described below, the drive device may be absent or not connected to the control unit, and the results obtained in the simulation mode can be output to the control unit in real time.

[0020] The multiple operating modes include a simulation mode in which no drive movement of the element to be driven takes place and a reaction of the drive device to predetermined setpoints, which are entered into the drive device by the control unit, is simulated.

[0021] In the drive device, the mechanical part and / or the power part may be absent or not connected to the control unit, and the results obtained in the simulation mode can be output to the control unit in real time.

[0022] A simulation method used to simulate the operation of a drive device may include the following steps: inputting predetermined setpoints from a control device to a drive device; performing a simulation mode in which no drive movement of the driven element takes place and a reaction of the drive device to the input setpoints is simulated; and outputting the results obtained in the simulation mode to the control device in real time.

[0023] The simulation mode of the drive device described above allows for the correct communication between the drive device and the control device, as well as the basic functionality of the drive device, to be ensured during commissioning, without having to address mechanical problems such as resonances or backlash. This approach disregards the actual behavior of the drive device on the machine mechanics, as an ideal drive is simulated. This simulation takes place in the real drive and in real time, while the control device specifies setpoint values ​​according to the executed program.

[0024] The drive device described above eliminates a number of parameterization errors that could damage the mechanics. Furthermore, errors in motion programming, for example in a higher-level control device, can be detected and corrected with greater certainty in simulation mode, without causing dangerous movements due to the drive device.

[0025] In this way, it can be ensured that any errors that occur are caused only by the mechanics themselves or by the parameterization of the control loops of the controllers and not by the control of the drive device when, in a next step, the motor(s) or more precisely the rotor(s) of the drive device are supplied with power and the mechanical part of the drive device moves.

[0026] With the control device described above, all its functionalities, with the exception of the drive mechanism's mechanics, can be tested as soon as only the drive controllers are operational. Therefore, testing of the drive's control system can be performed in the laboratory using only the drive controllers, but without the power electronics and motor. This makes commissioning the drive, and consequently the entire technical system into which the drive can be integrated, simpler, safer, faster, and therefore more cost-effective.

[0027] The invention is described in more detail below with reference to the accompanying drawing. It shows: Fig. 1 a block diagram of a drive system according to the invention; (First embodiment)

[0028] The in Fig. The drive system 1 shown comprises a drive device 10, which has a measuring device 20 and a control device 30 and is connected to a control device 50 via a communication interface 40.

[0029] The drive device 10 has a mechanical part 11 and a power part 12, which serves to supply the mechanical part 11 with electrical current. The mechanical part 11 has a motor 13, which essentially has a stationary stator 14 and a rotatably mounted rotor 15. The rotor 15 is movable relative to the stator 14 and can drive an element that is positively connected to the rotor 15.

[0030] The measuring device 20 comprises a current sensor 21 for measuring or detecting an electric current supplied to the power unit 12 and for measuring or detecting an electric current flowing in the motor 13, a torque sensor 22 for measuring or detecting the torque or force of the drive movement effected by the drive device 10, a velocity sensor 23 for measuring or detecting the velocity of the driven element, and a position sensor 24 for measuring or detecting the position of the element driven by the drive device 10. The values ​​detected by the individual sensors 21, 22, 23, 24 are hereinafter also referred to as actual values.

[0031] The control device 30 comprises a current controller 31 for controlling the magnitude of the electric current supplied to the power unit 12 and for controlling the electric current flowing in the motor 13, a torque controller 32 for controlling the torque or force of the drive movement effected by the drive device 10, a speed controller 33 for controlling the speed of the driven element, and a position controller 24 for controlling the position of the element driven by the drive device 10. The individual controllers 31, 32, 33, 34 of the control device 30 use the actual values ​​detected by the sensors 21, 22, 23, 24 for their control operation and adjust these values ​​to setpoint values ​​determined by the control device 50.

[0032] The individual controllers 31, 32, 33, 34 of the control unit 30 are designed to output status messages and results of the control they perform to the control device 50 via the communication interface 40.

[0033] The control device 50 serves to control several operating modes of the drive device 10. These operating modes include, for example, cyclic speed control, cyclic position control, torque control, drive stop, positioning, etc. The operating modes may vary in type and number for different drive devices and are not described in detail here.

[0034] Furthermore, the multiple operating modes include a simulation mode that is in Fig. The drive device 10 shown in Figure 1 does not perform any drive movement of the element to be driven. The simulation mode will be described in more detail later.

[0035] The drive system 1 also has technological functions or peripheral functions that use the actual position and speed values. Examples of such technological functions include a cam switch, a measuring probe, encoder emulators, etc., which are integrated into Fig. 1 are not shown in each case.

[0036] Furthermore, the drive system 1 has communication and diagnostic functions with which the drive device 10 can be diagnosed. One such diagnostic function is, for example, the display of the operating mode performed by the drive device 10 and its respective status messages via a display device, such as an oscilloscope or CCD, etc. The diagnostic functions can use simulated actual values, which are entered into the control unit 30.

[0037] According to the invention, the drive system 1 also has safety functions which reliably prevent an unintended drive movement caused by the drive device 10 when this is desired or necessary. According to the invention, this is a safety function with regard to secure data transmission between the control device 50 and the drive device 10.

[0038] The simulation mode of the first embodiment will now be described in more detail.

[0039] As mentioned previously, the simulation mode in Fig. In the drive device 10 shown in Figure 1, no driving movement of the element to be driven is produced. That is, no movement is induced in the mechanical part 11 of the drive device 10 during the simulation mode. This means that the rotor 15 of the motor 13 is not driven, and therefore any element positively connected to the rotor 15 is also not driven by the motor 13. The element driven by the motor 13 could, for example, be an axle shaft.

[0040] In simulation mode, the control unit 30 is enabled to execute a control operation of the drive device 10. Specifically, this enables the operation of the speed controller 32 and the position controller 33 without requiring activation by the current controller 31. Consequently, simulation mode can also be performed with a drive device 10 that does not yet have a power unit 12 for the motor 13 and / or no motor 13 and / or no sensor unit 20 and / or only some of the sensors 21, 22, 23, 24. Even if the motor 13 and its power unit 12 are present, no power supply or current input for the motor 13 is required in simulation mode. Likewise, an existing sensor unit 20 or existing sensors 21, 22, 23, 24 do not need to be supplied with power.

[0041] In the simulation mode according to the first embodiment, the speed controller 32 is activated, and the control device 50 derives an actual speed value entered into the speed controller 32 from a predetermined target speed value. In particular, the control device 50 sets the actual speed value to the predetermined target speed value.

[0042] Furthermore, the position controller 33 is activated, and the control device 50 derives an actual position value entered into the position controller 33 from a predetermined setpoint position value. Specifically, the control device 50 sets the actual position value to the predetermined setpoint position value. The setpoint values ​​are values ​​that the drive device 1 is intended to maintain or achieve during operation, and they relate to specific operating times or operating states, etc.

[0043] In this way, an ideal drive of the drive device 1 can be simulated and carried out, in which, however, no drive movement of an element to be driven by the drive device 1 is effected.

[0044] The simulated actual values ​​and status messages output by the drive device 1 are transmitted to the control device 50 in real time via the communication interface 10. Both the simulated actual values ​​and the status messages are results obtained during the simulation operation.

[0045] Therefore, in simulation mode, outputs from any existing measuring device 20 or measuring devices 21, 22, 23, 24 are not taken into account. Furthermore, error messages from a monitoring device (not shown) for monitoring the functions of motor 13 and measuring device 20 are ignored.

[0046] Furthermore, in simulation mode the function of the current controller 31, the function of a current limit for the motor 13 and the motor type are hidden.

[0047] In contrast, the control device 50 can activate all other operating modes of the drive device in simulation mode. Furthermore, all previously mentioned technology functions and peripheral functions, communication and diagnostic functions, and safety functions are available in simulation mode.

[0048] The simulation mode is terminated by explicitly deleting it. This can be done by a command issued by an operator or the control device 50.

[0049] According to the invention, in such a configuration, only the communicative connection of the drive device 10 to the control device 50 is simulated and thereby tested in the simulation mode, while the mechanical function of the drive device 10 is excluded. Furthermore, the basic function of the control of the drive device 10 can be simulated and tested in this way. (Second example)

[0050] The drive system 1 according to the second embodiment is constructed in the same way as in Fig. Figure 1 shows and was previously described in connection with the first embodiment. Therefore, identical parts in both embodiments are provided with the same reference numerals.

[0051] The simulation mode of drive system 1 is identical to that described in the first embodiment, except for the differences described below. Anything identical to the previously described first embodiment is not described again here.

[0052] The main difference between the first and second embodiments is that in the simulation mode according to the second embodiment, a simple speed controller 33 is simulated taking into account a parameterized load moment of inertia, and the current flowing in the motor 13 and the resulting heating of the motor 13 are also simulated.

[0053] In the simulation mode according to the second embodiment, the actual current, velocity, and position values ​​are set to a corresponding target value. Specifically, the actual current value determined by the current sensor 21 is replaced by a target current value determined by the control device 50.

[0054] Furthermore, an actual speed value determined by the speed sensor 23 is formed by integrating the fictitious acceleration of the drive device 10. This fictitious acceleration results from the torque setpoint determined by the control device 50 and the inertial mass of the load with which the drive device 10 is subjected.

[0055] Furthermore, an actual position value of the elements to be driven by the drive device 10, determined by the position sensor 24, is calculated by integrating the previously calculated speed setpoint. Subsequently, the actual values ​​determined by the current sensor 21, the speed sensor 23, and the position sensor 24 are ignored during further control of the drive device 10. The setpoints can be further processed, if necessary, to adapt them to the desired operating mode.

[0056] According to the second embodiment, the simulated actual speed takes into account the real current limit and thus comes much closer to reality. Furthermore, the current flowing in the motor 13 and the resulting heating of the motor 13 are also simulated. In this way, incompatibilities between the control program of the control device 50 and the capabilities of the drive device 10 can be identified before the moving parts of the drive device 10 are actually put into operation. (Third embodiment)

[0057] The drive system 1 according to the third embodiment is constructed in the same way as in Fig. Figure 1 shows and was previously described in connection with the first embodiment. Therefore, identical parts in both embodiments are provided with the same reference numerals.

[0058] The simulation mode of drive system 1 is identical to that described in the first embodiment, except for the differences described below. Anything identical to the previously described first embodiment is not described again here.

[0059] The main difference between the first and third embodiments is that in the simulation mode according to the third embodiment, the speed controller 33 is deactivated.

[0060] Accordingly, the actual speed value is replaced by a target speed value determined by the control device 50. Furthermore, the actual position value of elements driven by the drive device 10 is replaced by the integrated target speed value. (General)

[0061] The present invention is particularly advantageous for drive devices 10 that are installed in or are installed in a technical system, wherein the function of the drive device 10 is to be tested separately from the other function of the technical system.

[0062] The previously described configurations of the drive system 1, the drive device 10, and the simulation method can be used individually as well as in all possible combinations of the aforementioned individual configurations. Furthermore, the following modifications apply to all embodiments and are applicable in combination.

[0063] The drive device 10 can be a servo drive in which the rotor, and thus a driven element, can only rotate over a specific angular range of a circle, such as a windshield wiper motor, a measuring device with an analog display, etc. In particular, the servo drive can be a digital servo drive. Alternatively, the drive device 10 can be configured such that the rotor can complete multiple revolutions around a motor shaft, such as the drive shaft or wheel axle of a vehicle, a drill, or a lathe, etc. In such a drive device, the speed sensor measures the rotational speed of the drive device 10. As a further alternative, the drive device 10 can drive pushrods and / or pullrods via a suitable transmission.

[0064] The communication interface 40 can be connected to the drive device 10 and / or the control device 50 via a bus system. The bus system can be implemented using individual physical lines, either separate or in a common cable, or as a multi-channel line, such as an optical fiber.

[0065] The measuring device 20 is part of the drive system 1 of Fig. 1 is shown as part of the drive device 10. However, the measuring device 20 can also be arranged externally from the drive device 10. In addition, one or more measuring sensors 21, 22, 23, 24 can also be arranged externally from the drive device 10.

[0066] Furthermore, the control device 30 is part of the drive system 1 of Fig. 1 is shown as part of the drive device 10. However, the control device 30 can also be arranged externally from the drive device 10. In addition, one or more of the controllers 31, 32, 33, 34 can also be arranged externally from the drive device 10.

[0067] The control device 50 can, for example, be arranged externally from the drive device in a (not shown) technical system.

[0068] The control device 50 can be an NC control device (NC: Numeric Control) or PLC control device that is superior to the drive device 1. In this case, the drive device 10 can also have its own control device (not shown), and the simulation mode can be executed either via the superior NC or PLC control device or via the drive device's own control device.

[0069] The in Fig.The communication interface 40 shown in Figure 1 can be present in both the drive device and the control device 50. In the case of a drive device's own control unit, the communication interface 40 can be provided between the drive device's own control unit and the higher-level NC or PLC control unit.

Claims

[1] Drive system (1), comprising a control device (30) for controlling the operation of a drive device (10) for driving an element to be driven into a drive movement, at least one safety function, and a control device (50) for controlling several operating modes of the drive device (10), wherein The several operating modes include a simulation mode in which no drive movement of the driven element takes place and a reaction of the drive device (10) to predetermined setpoints is simulated, which are entered into the control device (30) by the control device (50), wherein in the simulation mode only the communicative connection of the drive device (10) to the control device (50) is simulated and tested and the mechanical function of the drive device (10) is excluded, wherein in the simulation operating mode at least one safety function with regard to safe data transmission between the control device (50) and the drive device (10) can be activated, so that an unintended drive movement caused by the drive device (10) is reliably prevented and the drive device (10) is switched to safe operation. [2] Drive system according to claim 1, characterized by, that the control device (30) comprises a speed controller (32) for controlling the speed of the drive movement to be effected by the drive device (10), wherein the speed controller (32) is activated in simulation mode and the control device (50) derives an actual speed value entered into the speed controller (32) from a predetermined target speed value. [3] Drive system according to one of the preceding claims, characterized by , that the control device (30) includes a position controller (33) for controlling the position of the element to be driven during the drive movement to be effected by the drive device (10), wherein the position controller (33) is activated in simulation mode and the control device (50) derives an actual position value entered into the position controller (33) from a predetermined setpoint position value. [4] Drive system according to one of the preceding claims, characterized by, that in the simulation mode, operation of the speed controller (32) and the position controller (33) is enabled without release by a current controller (31), which serves to control the current supplied to the drive device (10) in order to effect a drive of the element to be driven. [5] Drive system according to any one of the preceding claims, characterized by, that in the simulation mode a current controller (31) for controlling the current supplied to the drive device (10) to effect a predetermined force is deactivated, wherein in the simulation mode an actual current value to be entered into a current controller (31) is replaced by a setpoint current value determined by the control device (50), an actual velocity value to be entered into a velocity controller (32) is formed by integrating the fictitious acceleration of the drive device (10), which results from the torque setpoint determined by the control device (50) and the inertial mass of the load with which the drive device (10) is subjected, and an actual position value of elements to be driven by the drive device (10) entered into a position controller (33) is formed by integrating the formed velocity setpoint. [6] Drive system according to any one of the preceding claims, characterized by, that in simulation mode a speed controller (32) for controlling the speed of the drive movement caused by the drive device (10) is deactivated, wherein in simulation mode an actual speed value entered into the speed controller (32) is replaced by a setpoint speed value determined by the control device (50), and an actual position value of elements to be driven by the drive device (10) to be entered into a position controller (33) is replaced by the integrated setpoint speed value. [7] Drive system according to any one of the preceding claims, characterized by , that the drive device (10) has a motor (13) for driving the element to be driven, wherein the motor (13) has a stationary stator (14) and a rotor (15) that is movable relative to the stator, and wherein in the simulation operating mode a movement of the rotor (15) is prevented. [8] Drive system according to any one of the preceding claims, characterized by , that the drive device (10) can drive several axes, wherein the simulation mode can be performed separately for each axis. [9] Drive system according to any one of the preceding claims, characterized by , that the drive device (10) has at least one diagnostic function which serves to diagnose the drive device (10), wherein all diagnostic functions are available in simulation mode and the simulated actual values ​​are used for diagnosis. [10] Drive system according to any one of the preceding claims, characterized by , that the drive device (1) has at least one technology function which uses the simulated actual values, wherein at least one technology function is available during the simulation operation. [11] Drive system according to one of the preceding claims, characterized by, that the drive device (10) is not present or is not connected to the control device (30) and the results obtained in the simulation mode are output to the control device (40) in real time.

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