AUTOMATION SYSTEM FOR CONTROLLING A MACHINE OR PLANT

Description

[0001] The invention relates to a machine control according to claim 1.

[0002] Such automation systems generally serve to control machines or systems. Machines or systems to which the present invention relates can be designed in a wide variety of forms, including, in particular, mobile systems such as robots or mobile machines.

[0003] Generally, a machine controller at a control level and a number of sensors and / or actuators at a sensor-actuator level are provided to control the machine or system. The sensors or actuators perform monitoring or process-control functions on the machine or system. These sensors and / or actuators are connected to the inputs and outputs of the machine controller. The machine controller then reads signals generated by the sensors and / or actuators and, particularly based on these signals, generates control commands to control the operation of the machine or system.

[0004] In common automation systems, a communication model of an automation pyramid is provided for controlling the machine or plant. This pyramid comprises additional levels in addition to the sensor-actuator level and the control level higher than this. This generally includes a process control level with a process control system that is higher than the control level. Above this, there is generally an operations control level with systems for production data acquisition and detailed production planning, as well as an even higher corporate level with systems for order processing and rough production planning.

[0005] One advantage of such automation systems is that the machine control system can also be used to carry out fast processes, particularly real-time control and regulation processes for the machine or system.

[0006] A disadvantage of the hierarchically structured communication model of an automation pyramid is that, on the one hand, all sensors and / or actuators are connected to the machine control system and, on the other hand, communication with systems in the higher levels also runs via the machine control system, which makes the effort for the machine control system undesirably high, particularly with regard to its input and output structure.

[0007] Leuze: "Leuze Electronic cooperates with Microsoft," February 1, 2017, XP055452447, found online at: URL: http: / / www.git-sicherheit.de / printpdf / 23260 (D1), describes sensors integrated into an automation system. The sensors have interfaces enhanced with an OPC UA communication model. This makes it possible to exchange data between the sensors directly with a cloud. Tamper-proof data exchange takes place via the interfaces, in which the data to be transmitted is secured with authentication, authorization, encryption, and data integrity with signatures.

[0008] US 2016 / 024 62 94 A1 (D2) concerns an automation system with field devices that are integrated into a network with a computer unit. A plant model is specified for the automation system, which is controlled by the computer unit. The field devices can be designed as sensors. The computer unit is, in particular, a cloud computer. The field devices can exchange data directly with the computer unit.

[0009] US 2017 / 0075343 A1 concerns a system with a field device that can communicate directly with a cloud computer via an interface. The field device can be designed as a sensor.

[0010] In Messtec Drives Automation: "Smart Sensor business: No Industry 4.0 without intelligent sensor technology", March 7, 2017, XP055454942, found on the Internet: URL: http: / / www.md-automation.de, the integration of sensors into a cloud-based control model is described.

[0011] US 2013 / 0211547 A1 relates to a method for integrating at least one field device into an automation technology network consisting of several field devices distributed throughout an automation system, which are interconnected via at least one data bus running a bus protocol. Access to the field devices is via a field access unit that communicates with at least one automation / integration platform and at least one web server of a service provider.

[0012] DE 10 2010 042 716 A1 relates to a system for operating an automation system with several field devices (F1, F2, F3) distributed at the field level, which are interconnected via at least one data bus (DB) running a bus protocol. Access to the field devices (F1, F2, F3) is via a field access unit (PAP) connected to at least one automation / integration platform and at least one web server (OPC-UA server) of a service provider. The business-relevant logic (BI1, BI2, BI3, BI4) is stored at least partially in at least one of the field devices (F1, F2, F3) and / or in the field access unit (PAP).

[0013] EP 3 070 548 A2 relates to a cloud-based controller that controls physical units or processes of an automation system. The controller can analyze information and generate control instructions based on the analysis results.

[0014] US 2014 / 0148969 A1 concerns a cloud-based system with multiple spatially distributed cooling devices equipped with temperature sensors. Process data from the cooling devices is stored in a cloud. Modules for performing temperature controls are also provided there.

[0015] EP 3 070 548 A2 relates to an automation system to which a cloud-based industrial controller is assigned. The controller controls units and processes of the automation system. To do so, the controller collects information from the automation system via a gateway. Based on this information, the controller generates control instructions for the automation system.

[0016] US 2014 / 148969 A1 concerns a cloud-based system for refrigeration units. Each refrigeration unit has a microprocessor with firmware as its control unit. The firmware evaluates sensor data and monitors the states of actuators. These functions are controlled by a cloud.

[0017] US 2004 / 0249651 A1 concerns a process control system for operating a technical installation. The process control system comprises a process control computer as the central controller and several decentralized field devices in which control software is implemented. This allows units of the technical installation to be monitored and controlled.

[0018] The invention is based on the object of providing an automation system with high functionality.

[0019] To achieve this object, the features of claim 1 are provided. Advantageous embodiments and expedient developments of the invention are described in the dependent claims.

[0020] The automation system according to the invention serves to control a machine or system and comprises a machine controller at a control level and a number of sensors and / or actuators assigned to the machine or system at a sensor-actuator level. Sensor signals from the sensors and / or actuator signals from the actuators are fed to the machine controller. Control commands for the machine or system are generated in the machine controller. The sensors and / or actuators exchange information directly with a computer network having at least one computer unit via the Internet using tamper-proof protocols, wherein the sensors are identifiable by the computer network using a unique identifier. Control commands for the machine or system are generated in the computer network and transmitted to at least one sensor or actuator.Each sensor or actuator contains control means for controlling the machine or system in response to a control command from the computer network. Memory means for storing the identifier and communication means for communicating with the computer network are provided. The control means control the machine or system directly, without going through the machine control system, in response to a control command from the computer network.

[0021] The basic idea of ​​the invention is therefore that the sensors and / or actuators assigned to the machine or system are not controlled solely by the higher-level machine control system. Rather, the sensors and / or actuators are connected via the internet to a distributed computer network, i.e., one that is not locally connected to the machine. This means that the sensors and / or actuators communicate with a cloud, thereby generating additional control commands in addition to those in the machine control system.

[0022] It is crucial that the sensors and / or actuators communicate with the cloud, not via the machine control system, but directly with the cloud. This allows the machine control system to have a simpler structure, as its functionality can be limited to a few essential basic functions. This leads, in particular, to a structural simplification of the machine control system, particularly in that the number of costly inputs and outputs in the machine control system can be limited.

[0023] Depending on the required response times for control commands, these are particularly advantageously generated by the machine control system or by the computer network.

[0024] In particular, control commands with short response times are carried out by the machine control system and control commands with longer response times are carried out by the computer network.

[0025] Since the machine control system can perform rapid control and regulation processes, especially in real time, such processes are carried out using this machine control system. Less time-critical processes, such as starting or stopping the machine or system, are performed via the cloud, thus reducing the load on the machine control system.

[0026] The automation system according to the invention thus utilizes the functions of both a local machine control system and a cloud, i.e., a distributed computer network connected via the Internet, in such a way that their functionalities complement each other optimally. The distribution of the tasks to be performed by the machine control system and the computer network is expediently carried out via the computer network. For this purpose, an authorized user can, for example, make corresponding entries in the computer network.

[0027] An essential prerequisite for the function of the automation system according to the invention is that control means, storage means and communication means are integrated in each sensor or actuator, whereby the machine or system can be controlled by means of the control means in dependence on a control command of the computer network, whereby the identifier is stored in the storage means, and whereby communication with the computer network takes place by means of the communication means.

[0028] This means that the sensors and actuators are configured to communicate with the cloud. By storing unique identifiers, especially addresses, these sensors and actuators can be uniquely identified in the cloud.

[0029] The communication means provided in the sensors or actuators enable them to exchange information bidirectionally with the computer network.

[0030] Communication is conveniently carried out via standardized software protocols, such as the OPC UA protocol, with corresponding software modules being available in the sensors or actuators as a means of communication.

[0031] It is essential that this communication is tamper-proof, which is achieved in particular by securing the transmitted information with checksums.

[0032] The transmitted information preferably contains data and metadata. The data can, for example, be measured values ​​from a sensor, which are transmitted in the form of numerical values. The associated metadata defines the type of measured values, for example, distance values ​​with a specific unit such as mm or cm.

[0033] It is also essential that each sensor or actuator contains control means. These control means allow the machine or system to be controlled directly, without going through the machine control system, depending on a control command from the computer network. In the simplest case, the control means comprise a control output, via which a signal—in the simplest case, a binary switching signal—is output to the machine or system.

[0034] The sensors and / or actuators thus have extended functionality.

[0035] According to an advantageous embodiment, signal propagation times for communication with the computer network are periodically determined by at least one sensor or actuator, and depending on the signal propagation time, software modules defining the application-specific functionality of the sensor or actuator are stored in the computer network or loaded into the sensor or actuator.

[0036] This further expands the functionality of the sensors and / or actuators. Depending on the signal propagation times determined, the respective sensor and / or actuator can determine whether functions, especially those relevant to the machine or system, are performed by the computer network or by the respective sensor or actuator itself. This makes it easy to optimize the interaction of the individual components of the automation system.

[0037] According to an advantageous embodiment, status information generated in a sensor or actuator is transmitted to the computer network with or without a self-test.

[0038] The status information can include measured values ​​recorded by the sensors, current states of the actuators, and parameters of the sensors and actuators.

[0039] Based on this status information, control commands can be generated in the cloud and passed on to at least one sensor or actuator for execution. Such a control command can, for example, start or stop the operation of the machine or system. For example, the cloud can use the status information to check whether all sensors and / or actuators are present and in certain states, which then generates a control command to start the machine.

[0040] According to an advantageous further development, machine- or system-relevant data is stored in the computer network and can be transmitted to sensors and / or actuators.

[0041] This data could, for example, be data from the operator of the machine or system. This data may be stored as confidential data in the computer network in such a way that it is accessible only to authorized users. Depending on the application, this data, or subsets of it, can be loaded into a sensor and / or actuator.

[0042] According to a particularly advantageous embodiment of the invention, the control level and the sensor-actuator level are part of a communication model of an automation pyramid with further levels, whereby the computer network communicates directly with systems in the further levels.

[0043] For example, based on the status information from the sensors and / or actuators, information can be obtained about necessary maintenance of system components or the need to reorder equipment or machines. Depending on this, an order processing or production planning system at a higher level, such as the operational management or corporate level, can be addressed via the cloud to trigger the necessary actions.

[0044] According to a further advantageous embodiment of the invention, the computer network communicates directly with sensors and / or actuators or systems in further levels of a communication model of an automation pyramid of different machines or systems.

[0045] This extends the automation system to multiple systems or machines. The advantage here is that the cloud can collect information from sensors and / or actuators across systems and evaluate this information together to generate control commands specifically for certain machines or systems.

[0046] According to an advantageous embodiment of the invention, the sensors are wholly or partly optical sensors, in particular for object detection, object identification or for the geometric measurement of an object distance, a surface contour or an object volume.

[0047] The invention is explained below with reference to the drawings. They show: Figure 1: Schematic diagram of the automation system according to the invention. Figure 2: Schematic diagram of a sensor for the automation system according to Figure 1Figure 3: First embodiment of the automation system according to the invention. Figure 4: Second embodiment of the automation system according to the invention.

[0048] Figure 1 shows the basic structure of the automation system 1 according to the invention. In this case, two systems 2 are controlled by the automation system 1 according to the invention. In general, machines of all types can be controlled by the automation system 1. Furthermore, the automation system 1 can also control just one or more than two machines or systems 2.

[0049] In a communication model of an automation pyramid 3, each system 2 is assigned hierarchically structured systems arranged at specific levels. A sensor-actuator level 4 contains sensors 11 that monitor processes in system 2, and actuators that support or control processes in system 2. A control level 5, which is higher than the sensor-actuator level 4, contains a machine control system to which the sensors 11 and / or actuators are connected via inputs and outputs. The machine control system is designed to control system 2. A further higher-level process control level 6 contains a process control system. A further higher-level operational control level 7 can contain systems for detailed production planning and production data acquisition. A further higher-level company level 8 can contain systems for rough production planning and order processing.

[0050] According to the invention, the sensors 11 and / or actuators of the automation system 1 are connected via the internet to a distributed computer network 9 comprising several decentralized computer units. In the present case, only one computer unit is provided. The internet connections 10 can be wireless or wired. The computer network 9 integrated via the internet forms a cloud.

[0051] How Figure 1 As shown, the sensors 11 and / or actuators are directly connected to the computer network 9 via internet connections 10, allowing them to communicate directly, i.e., without detours, with the computer network 9. Communication via the internet connection 10 occurs via standardized software protocols, such as the OPC UA protocol. This data transmission is tamper-proof, particularly because the transmitted information is protected by check numbers.

[0052] Data and metadata are transmitted as information, with metadata being intended to characterize or specify certain transmitted data.

[0053] Figure 2 shows schematically the structure of a sensor 11 for the automation system 1 according to Figure 1 The sensor 11 comprises, in a known manner, a sensor element 12 for object detection and an evaluation unit 13 for evaluating sensor signals from the sensor element 12. If the sensor 11 is designed for distance measurement, the sensor element 12 generates distance values ​​that can be transmitted as data in the form of numerical values ​​to the computer network 9. Metadata is assigned to this data, which, for example, defines that the data are distance values ​​in mm or cm.

[0054] The sensor 11 further comprises a communication means 14, a storage means 15, and a control means 16. Communication with the computer network 9 takes place via the internet connection 10 by means of the communication means 14. An identifier, in particular an address, is stored in the storage means 15, by means of which the sensor 11 can be uniquely identified. The control means 16 serves to control the system 2. For example, the control means 16 can be formed by a control output.

[0055] One of the Figure 2 All other sensors 11 and / or actuators of the automation system 1 have a corresponding structure.

[0056] The sensors 11 and / or actuators transmit status information via the internet connection 10 to the computer network 9, where it is stored. Furthermore, customer-specific data of the operator of the system 2 can be stored in the computer network 9. If this data is confidential, it can, for example, only be stored by an authorized user.

[0057] According to the invention, control commands for controlling the respective system 2 are generated not only in the machine control system, but also in the computer network 9, where, in particular, the status information and / or customer-specific data stored there can be used to generate the control commands. The distribution of tasks between the machine control system and the computer network 9 is advantageously carried out via the computer network 9, for example, an authorized user entering corresponding commands into the computer network 9.

[0058] In the present case, each machine control system carries out rapid control and regulation processes, which particularly take place in real time, whereby the machine control system generates corresponding control commands for this purpose, particularly as a function of sensor signals from the sensors 11.

[0059] Non-time-critical processes, however, are controlled by the computer network 9. In particular, the start of the respective system 2 is generated based on the status information from the sensors 11 and / or actuators for this system 2. In this case, the computer network 9 checks whether all sensors 11 and / or actuators are present. Alternatively or additionally, the computer network 9 can generate a control command for a system 2 based on status information from sensors 11 and / or actuators assigned to another system 2. Accordingly, the computer network 9 can also generate control commands to stop a system 2.

[0060] The control commands of the computer network 9 can also be used to optimize the operating parameters of sensors 11. For example, information about the operating parameters of multiple sensors 11 or the operating history of sensors 11 can be stored in the computer network 9. Depending on this, the computer network 9 can send control commands to a sensor 11 to optimize the operating parameters. Examples of this are the exposure times of distance-measuring sensors 11, the amplification of received signals from the receiver or transmission power of transmitters of sensors 11, the optional color distributions of contrast sensors that emit light in different colors, or even parameters of sensors 11 for code detection, such as module widths or distances between codes to be detected.

[0061] Furthermore, the room lighting of a camera sensor can be optimized in this way, for example. The camera of the camera sensor captures image information, which it sends to the computer network 9. The computer network 9 calculates a region of interest required for an application and sends a software module for evaluating this region of interest to the camera sensor. The camera sensor updates its evaluation software accordingly, controls RGB lighting accordingly so that the image contrast of the images is optimal for a particular color, and communicates the optimal parameter setting to the computer network 9, where it is saved.

[0062] Furthermore, it is possible for at least one sensor 11 or actuator to periodically determine signal propagation times for communication with the computer network 9, and for software modules defining the application-specific functionality of the sensor 11 or actuator to be stored in this computer network 9 or loaded into the sensor 11 or actuator, depending on the signal propagation time.

[0063] This allows the distribution of tasks between sensors 11 and / or actuators on the one hand and the computer network 9 on the other hand to be changed.

[0064] The functionality of the automation system 1 can be expanded by determining, based on the data stored in the computer network 9, in particular the status information of the sensors 11 and / or actuators, whether maintenance of the system is necessary or whether individual sensors 11 and / or actuators are at risk of failure. The computer network 9 then generates control commands that are output directly via internet connections 10 to systems of the automation system 1, in particular systems of the corporate level 8 or operational control level 7, in order to initiate maintenance or trigger ordering processes for sensors 11 and / or actuators.

[0065] Figure 3shows an embodiment of the automation system 1 according to the invention for controlling a processing machine 17 used to process workpieces. The processing machine 17 has several processing stations 17a to 17d through which the workpieces pass. For process control, several binary sensors 18a to 18e, such as light barriers, are provided. These sensors are connected to the machine control system (not shown) and to the computer network 9 (also not shown) via the internet connections 10.

[0066] A first binary sensor 18a at the input of the processing machine detects a workpiece to be machined. The binary sensor 18a sends the corresponding sensor signal to the computer network 9, which then detects the operational readiness of the processing machine and sends a control command to the binary sensor 18a, which starts the processing machine 17 via its storage means 15. The binary sensor 18a also determines the signal propagation time for transmitting information over the Internet.

[0067] As a result, the binary sensor 18a activates a binary sensor 18e at the output of the processing machine via the computer network 9, which can detect the end of the machining process of the workpiece. As soon as this binary sensor 18e detects the end of the machining process, it reports this to the computer network 9. The computer network 9 then generates a control command, which is sent to the first binary sensor 18a, so that it shuts down the processing machine 17 after a timeout period specified by the computer network 9 and dependent on the signal propagation time.

[0068] Figure 4shows a further embodiment of the automation system 1 according to the invention. In this case, the automation system 1 serves to control a packaging machine 19, which has a machine control system (not shown) and an arrangement of sensors 11 and actuators connected to the machine control system. Furthermore, the sensors 11 and actuators are connected to the computer network 9 via the Internet connection 10 (in Figure 4 also not shown). This also applies to a sensor 11 in the form of a light grid 20, which is designed as a measuring light grid 20.

[0069] The light curtain 20 calculates the number of items present in a storage space 21, which are to be further processed into bundles in the packaging machine 19. The computer network 9 informs the light curtain 20 via the internet connection 10 how many items a bundle should contain. If the light curtain 20 detects a sufficient number of items, the packaging machine 19 is started via the light curtain 20. The packaging machine 19 also receives information from the light curtain 20 regarding how many items should be combined into a bundle.

[0070] If the light grid 20 detects errors in the storage space 21, it reports this to the computer network 9, which then triggers a service call.

[0071] Figure 5shows a further embodiment of the automation system 1 according to the invention. In this case, a distance sensor 22 is provided for detecting the dimensions of objects 23. The objects 23 are fed to a packaging machine 24 for further processing, which in turn has an associated machine control system of sensors 11 and / or actuators connected to a computer network 9 via the internet connections 10.

[0072] In this case, the dimensions determined by the distance sensor 22 are sent to the computer network 9. There, the determined dimensions are linked to empirical values, i.e., values ​​from previous measurements, in order to obtain, for example, a measure of the reliability of the measured values ​​of the distance sensor 22. This data is transmitted via the computer network 9 to the processing machine 24, so that the work processes of the processing machine 24 are selected based on this data. List of reference symbols

[0073] (1)Automation system (2)Systems (3)Automation pyramid (4)Sensor-actuator level (5)Control level (6)Process control level (7)Operations control level (8)Corporate level (9)Computer network (10)Internet connection (11)Sensor (12)Sensor element (13)Evaluation unit (14)Communication means (15)Storage means (16)Control means (17)Processing machine (17a-17d)Processing stations (18a-18e)Binary sensors (19)Packaging machine (20)Light grid (21)Storage space (22)Distance sensor (23)Object (24)Processing machine

Claims

1. An automation system (1) for controlling a machine or an installation (2), with a machine controller in a control level (5) and a number of sensors (11) and / or actuators assigned to the machine or installation (2) in a sensor-actuator level (4), wherein sensor signals from the sensors (11) and / or actuator signals from the actuators are fed to the machine control system and control commands for the machine or installation (2) are generated in the machine control system, wherein the sensors (11) and / or actuators exchange information directly with a computer network (9) comprising at least one computer unit via the Internet by means of tamper-proof protocols, wherein the sensors (11) can be identified by the computer network (9) by means of a unique identifier, and wherein control commands for the machine or installation (2) are generated in the computer network (9), which are transmitted to at least one sensor (11) or actuator, characterised in that in each sensor (11) or actuator there are control means (16) which are designed to control the machine or installation (2) as a function of a control command from the computer network (9) and memory means (15) for storing the identifier and communication means (14) for communicating with the computer network (9), whereby the control means (16) are used to control the machine or installation (2) directly and without a diversion via the machine control system, depending on a control command from the computer network (9).

2. An automation system (1) according to claim 1, characterised in that status information generated in a sensor (11) or actuator is transmitted to the computer network (9) with or without a self-test.

3. An automation system (1) according to claim 1, characterised in that data relevant to the machine or installation are stored in the computer network (9), which data can be transmitted to sensors (11) and / or actuators.

4. An automation system (1) according to claim 1, characterised in that the control level (5) and the sensor-actuator level (4) are part of a communication model of an automation pyramid (3) with further levels, wherein the computer network (9) communicates directly with systems in the further levels.

5. An automation system (1) according to one of claims 1 to 4, characterised in that the computer network (9) communicates directly with sensors (11) and / or actuators or systems in further levels of a communication model of an automation pyramid (3) of various machines or installations (2).

6. An automation system (1) according to one of claims 1 to 5, characterised in that, depending on the required response times for the execution of control commands, these are generated by the machine controller or by the computer network (9).

7. An automation system (1) according to claim 6, characterised in that control commands with short response times are executed by the machine controller and control commands with longer response times are executed by the computer network (9).

8. An automation system (1) according to one of claims 1 to 7, characterised in that signal propagation times for communication with the computer network (9) are periodically determined by at least one sensor (11) or actuator, and in that software modules defining the application-specific functionality of the sensor (11) or actuator are stored in the computer network (9) or loaded into the sensor (11) or actuator as a function of the signal propagation time.

9. An automation system (1) according to one of claims 1 to 8, characterised in that communication with the computer network (9) takes place via standardised software protocols, in particular via OPC UA protocols.

10. An automation system (1) according to claim 9, characterised in that information containing data and metadata characterising the data is exchanged between the computer network (9) and other participants, in particular sensors (11) and / or actuators.

11. An automation system (1) according to claim 10, characterised in that the transmitted information is secured with check numbers.

12. An automation system (1) according to one of claims 1 to 11, characterised in that the sensors are wholly or partially optical sensors, in particular for object detection, object identification or for geometric measurement of an object distance, a surface contour or an object volume.