Method and control and / or monitoring of a valuable material compacting device

Abstract

A method is proposed for controlling and / or monitoring a recyclable material compacting device which is designed and intended to compact recyclable materials. The recyclable material compacting device comprises: a compacting element operated via a hydraulic or pneumatic system, in particular a compacting ram; one or more actuators for actuating the compacting element; one or more sensors for detecting an operating parameter of the recyclable material compacting device; and an integrated control device connected via interfaces to the one or more actuators and the one or more sensors. The operating behavior of the recyclable material compacting device is learned via an analysis algorithm, wherein the analysis algorithm comprises at least a first analysis step and a second analysis step.

Description

[0001] The invention relates to a method for controlling and / or monitoring a recyclable material compacting device which is designed and intended to compact recyclable materials, and wherein the recyclable material compacting device has a compacting element operated via a hydraulic or pneumatic system, in particular a compacting stamp, one or more actuators for actuating the compacting element, one or more sensors for detecting an operating parameter of the recyclable material compacting device and an integrated control device which is connected via interfaces to the one or more actuators and the one or more sensors.

[0002] Today, recyclable material compaction devices are used in different locations, for different materials, and for different purposes. There is a need for more targeted monitoring and evaluation of the operating conditions of such recyclable material compaction devices. A relatively simple monitoring approach is traditionally achieved by operating personnel checking the functionality of the recyclable material compaction device and, for example, responding to error signals.

[0003] The object of the present invention is to further improve the monitoring and / or control of a recyclable material compacting device compared to this prior art.

[0004] This object is achieved by a method according to the features of claim 1. Specifically, it is proposed that the operating behavior of the recyclable material compacting device is learned via an analysis algorithm, wherein the analysis algorithm comprises at least a first analysis step and a second analysis step, that in a first analysis step the signals at the interfaces between the integrated control device and the actuators on the one hand and between the control device and the sensors on the other hand are recorded in various operating states of the recyclable material compacting device, and that in a second analysis step the interfaces of the integrated control device are subjected to excitation signals S and the reactions of the integrated control device and / or the recyclable material compacting device to these excitation signals S are recorded,wherein, based on the information obtained from the first analysis step and the second analysis step, a model of the operating behavior of the recyclable material compacting device is generated, and wherein the model of the operating behavior of the recyclable material compacting device is used to control and / or monitor the recyclable material compacting device.

[0005] The model of the recyclable material compaction device generated in the manner of a digital twin based on the information obtained from the first analysis step and the second analysis step helps to develop an understanding of the operating behavior of the recyclable material compaction device and, based on this, to take further steps, namely to influence the control of the recyclable material compaction device and / or to monitor the recyclable material compaction device, for example with regard to occurring error states, with regard to impending maintenance dates (predictive maintenance) or with regard to the procurement of replacements or extensions.

[0006] In a preferred embodiment, the interfaces of the integrated control device are subjected to excitation signals S(t) having a predetermined upper and lower limit and a predetermined temporal profile. Such predetermined upper and lower limit values ​​can be defined, for example, by a deviation of ± 10% from a predetermined mean value. The temporal profile can be, for example, a periodic profile, in particular a sawtooth profile or a sinusoidal profile.

[0007] In a specifically preferred embodiment, the analysis algorithm records operating parameters of the recyclable material compaction device. At the same time, however, other parameters can also be recorded, in particular structural parameters such as the type and number of connected sensors, the type and connection of the installed motors, and the power capacities of the installed motors or the recyclable material compaction device as a whole.

[0008] In a preferred embodiment, at least the following operating parameters of the recyclable material compaction device are recorded via the analysis algorithm: the temporal behavior of the current consumption of at least one actuator I(t), the vibration behavior of the material compacting device VIB(t), a pressure p(t) detected in the hydraulic or pneumatic system.

[0009] The three aforementioned operating parameters are particularly significant operating parameters in order to represent the operating behavior of the recyclable material compaction device as accurately as possible within the framework of the model according to the invention.

[0010] In a special embodiment, the parameters I(t), VIB(t) and p(t) are read out in real time, i.e. within a precisely defined maximum time span between the event itself and its detection.

[0011] In a preferred application, the parameters can also be measured at least in part via MEMS sensors (Micro-Electro-Mechanical Systems) or via MOEMS sensors (Micro-Opto-Electro-Mechanical Systems).

[0012] In another possible embodiment, temporal correlations of the operating parameters are recorded, in particular a temporal correlation of the vibration behavior VIB(t) with the current consumption I(t) or of the vibration behavior VIB(t) with the pressure curve p(t). The recording of such correlations is particularly useful for analyzing the structure and operating behavior of the recyclable material compaction device in general or with regard to a specific fault diagnosis.

[0013] In a possible further development, the temporal progression of the recorded parameters, in particular the vibration behavior VIB(t), can be subjected to a Fourier transformation F(VIB(t)), and the Fourier analysis can be taken into account when creating the model of the operating behavior of the recyclable material compaction device. By breaking down the vibration behavior into specific frequency ranges, conclusions can be drawn, for example, about the affected components or possible causes of failures.

[0014] According to one possible embodiment, the model of the operating behavior of the recyclable material compacting device is automatically incorporated into a control process that controls the operation of the recyclable material compacting device.

[0015] Likewise, in a possible embodiment, it is conceivable that the model is evaluated via the operating behavior of the recyclable material compaction device with regard to maintenance scheduling and / or error analysis.

[0016] In one possible embodiment, the analysis steps are performed by an analysis module connected to or within the recyclable material compaction device. The analysis module can thus start and / or control the analysis algorithm and also exchange data with the control unit of the recyclable material compaction device or with a remote data processing device.

[0017] In a preferred embodiment, bidirectional data exchange is carried out between the analysis module connected to or in the recyclable material compacting device and a data processing device located remotely from the recyclable material compacting device, and the remote data processing device, in particular, carries out or forwards evaluations, for example for fault diagnosis, for adaptive maintenance, based on usage and load profiles or for maintenance planning, or forwards control commands, in particular a shutdown command, to the recyclable material compacting device via the connected analysis module. In this respect, the analysis module can be connected to the data processing device, for example, via the Internet. The remote data processing device can comprise cloud-based data processing and / or a computer and / or a mobile device, such as a tablet or a smartphone.

[0018] It is conceivable that the first and second analysis steps are carried out in parallel, especially if the first analysis step is not yet completed when the second analysis step begins. However, it is also possible to carry out the second analysis step after the first analysis step.

[0019] Finally, an analysis module is claimed which is designed and intended to carry out the analysis steps according to the invention.

[0020] The invention will be explained in more detail below with regard to further features and advantages by means of the description of exemplary embodiments and with reference to the accompanying drawings: Figure 1 shows a schematic structure of an arrangement showing an analysis module for carrying out the method according to the invention; Figure 2 shows a schematic illustration to illustrate the interaction between the analysis module and the control device of the recyclable material compacting device; Figure 3 shows an exemplary implementation of the system that interacts between the recyclable material compacting device and a remote data processing device using an analysis module according to the invention; Figure 4 shows an exemplary overview of possible fields of application of the model generated according to the invention regarding the operating behavior of the recyclable material compacting device; Figure 5 shows an exemplary overview of possible fields of application using the generated model regarding the operating behavior of the recyclable material compacting device.Figure 6 shows an embodiment of a material compacting device designed as a pressing device for carrying out the method according to the invention.;

[0021] In Figure 1 A schematic structure of an arrangement for carrying out the method according to the invention is shown. A recyclable material compacting device 20 has a compacting element (not shown) operated via a hydraulic or pneumatic system, as well as one or more actuators for actuating the compacting element (also not shown). Furthermore, one or more sensors (not shown) for detecting an operating parameter of the recyclable material compacting device, as well as an integrated control device 10, which is connected via interfaces to the one or more actuators and the one or more sensors of the recyclable material compacting device.

[0022] An analysis module 30 is connected to interfaces 11 of the control device 10. The analysis module 30 can learn the operating behavior of the recyclable material compaction device using an analysis algorithm and, in this regard, carries out at least a first analysis step and a second analysis step. In a first analysis step, signals at the interfaces 11 of the integrated control device 10 are detected, and in a second analysis step, the interfaces of the integrated control device 10 are subjected to excitation signals S, and the reactions of the integrated control device 10 and / or the recyclable material compaction device 20 to these excitation signals S are detected.Based on the information obtained from the first analysis step and the second analysis step, a model 40 of the operating behavior of the recyclable material compacting device 20 is generated, wherein the model 40 of the operating behavior of the recyclable material compacting device 20 is used to control and / or monitor the recyclable material compacting device.

[0023] The model 40 and / or the analysis module 30 are operatively connected to a remote data processing device 50, which may be a computer, in particular a personal computer, a laptop, or another locally limited computing unit, or a computing unit relocated to the cloud. The remote data processing device 50 may also interact with a display device, such as a mobile device, for example, a tablet or a mobile phone. A dashboard visualizing the operating states of the recyclable material compaction device can be called up on this display device 60.

[0024] In Figure 2A schematic illustration is shown to illustrate the interaction between the analysis module 30 and the control device 10 of the recyclable material compacting device 20. The analysis module 30 is connected via interfaces 11 to the control device 30, which in turn is connected to actuators and sensors of the recyclable material compacting device 20 via interfaces 12. The analysis module 30 records at least the parameters current consumption of at least one actuator I, preferably the temporal behavior of the current consumption of at least one actuator I(t), the vibration behavior VIB of the recyclable material compacting device 20, preferably the temporal course of the vibration behavior of the recyclable material compacting device VIB(t), and a pressure P recorded in the hydraulic or pneumatic system, preferably a pressure curve P(t) that is recorded in the hydraulic or pneumatic system.The analysis module 30 and / or the model 40 exchange data with a remote data processing device 50 via an interface 31.

[0025] In Figure 3An exemplary implementation of the system is illustrated, which interacts between the recyclable material compaction device 20 and a remote data processing device 50 using an analysis module 30 according to the invention. The recyclable material compaction device is in bidirectional data communication with the analysis module 30, which either directly reads operating parameters from the recyclable material compaction device 20, in particular from the control device 10, or alternatively or additionally records data from the recyclable material compaction device 20 via a data acquisition system 70. A model 40 of the operating behavior of the recyclable material compaction device 20 is created using the analysis module 30 and is constantly kept up to date, adapted, or improved. The model 40 thus represents a digital twin of the recyclable material compaction device.The model 40 can be stored in close proximity to the analysis module 30 or remotely, for example in the cloud.

[0026] The analysis module 30 can be operatively connected to a remote data processing device 50. The remote data processing device 50 can also visualize the operating behavior of the recyclable material compaction device via a display device.

[0027] Figure 4shows an exemplary overview of possible fields of application of the model 40 generated according to the invention regarding the operating behavior of the recyclable material compaction device 20. Initially, the model 40 can be viewed as a simulation model and, for example, can simulate different operating states of the recyclable material compaction device before, simultaneously with, or after a specific operating behavior over a specified period of time. A sensor-actuator solution can be seen in the fact that modes of action and protocols are increasingly designed to be integrated, up to the use of components in which sensors and actuators are combined in a single component.

[0028] Furthermore, the analysis algorithm can determine limit values ​​in such a way that permissible limit values ​​for certain parameters of the recyclable material compaction device are determined via the analysis module 30.

[0029] A fault network can map the operating behavior in certain fault states so that the real operating behavior can be compared with the faulty operating behavior simulated on the basis of the fault network and thus the suspected error can be determined.

[0030] Within the framework of predictive maintenance, possible maintenance appointments or maintenance scheduling can be carried out.

[0031] Cloud solutions can provide easy monitoring and storage of operating data from recyclable material compaction devices, especially from a variety of different recyclable material compaction devices. Finally, one aspect of the proposed solution is that it can be integrated into a complete system optimized for the user.

[0032] In Figure 5An exemplary overview of possible application fields using the generated model of the operating behavior of the recyclable material compaction device is illustrated. Such application fields initially include basic functions for the control or monitoring of a recyclable material compaction device, such as Device Manager, Identity Manager, Data Manager, Secure Message Broker.

[0033] With regard to the construction and use of the Model 40 of the recyclable material compaction device, at least the following applications can be realized: Adaptive maintenance based on usage and load profiles Predictive maintenance Process optimization Error and root cause analysis Alerting, especially related to the user or service staff Data hub, QA-assured data provision via app Dashboards, KPIs for service staff Dashboards for various users (workers, production managers, site managers, finance)

[0034] In a further possible embodiment, learned models of a specific recyclable material compacting device can also be compared with models of other recyclable material compacting devices and, from this comparison, further adjustments can be made with regard to the model of the recyclable material compacting device.

[0035] In Figure 6An embodiment of a pressing device is illustrated, which represents a possible example of a recyclable material compacting device 20. Other recyclable material compacting devices are, for example, compactors with rotary compression units or shredding systems. The pressing device is connected to a hydraulic control 80 via hydraulic lines 81. The control device 10 is operatively connected to the hydraulic control 80 and can thus initiate or prevent a flow of hydraulic fluid to the pressing device, specifically to a pressing piston 21 of the pressing device. The flow of hydraulic fluid can also be gradually adjusted by the hydraulic control 80 in order to specify a feed rate of the pressing piston 23.

[0036] The hydraulic control 80 and the hydraulic lines 81 are supplied with hydraulic fluid via a hydraulic circuit 82. A pump 84 driven by an electric motor 83 is provided in the hydraulic circuit 82. The delivery rate of the pump 84 is preferably continuously adjustable via the electric motor, which can interact, for example, with a frequency converter. Furthermore, a pressure relief valve 85 and a pressure sensor 86 are provided in the hydraulic circuit 82. The pressure curve P(t) of the hydraulic circuit 82 can be recorded via the pressure sensor 86. The recorded pressure values ​​are transmitted to the control device 10 for logging the pressure curve P(t).

[0037] The recyclable material compacting device 20, designed as a pressing device, has a pressing chamber 22 filled with recyclable materials and a pressing ram 23 that is movable within the pressing chamber 22. The recyclable materials are compacted by the movement of the pressing ram 23 within the pressing chamber 22 via the pressing ram 23, which is driven by the pressing piston 21. Specifically, the control device 10 starts the movement sequence of the recyclable material compacting device 20, designed as a pressing device. The control device 10 controls the hydraulic control 80 and the electric motor 83 in order to supply the pressing piston 21 with hydraulic fluid and, in parallel, reads sensors, in particular the pressure sensor 86, a current consumption sensor 87, which detects the current consumed by the electric motor 83, and a vibration sensor 88, which measures the vibrations transmitted by the recyclable material compacting device 20 in real time during operation.A temporal resolution of the signals detected by the pressure sensor 86, the current consumption sensor 87 and the vibration sensor 88 is preferably kept ≤ 10 ms in order to be able to detect and evaluate correlations between the signals with high resolution.

[0038] If the recorded values ​​indicate an anomaly, such as a pressure signal from pressure sensor 86 not being reached after a predetermined period of time or in correlation with the travel path of press ram 23, an anomaly is detected and thus a pressure / volume flow loss in the system. This occurs with all sensors, in particular the pressure sensor 86, the current consumption sensor 87 and the vibration sensor 88 - as already mentioned - in real time, so that any deviations in operating behavior can also be traced at the component level. In this respect, the control system exchanges data with all sensors via a predetermined transmission protocol. The same applies to the actuators, such as the press piston 21 in this case, which also exchanges data with the control system, for example via a position sensor 24.

[0039] The Figure 6The control device illustrated can be housed in a control housing 25 of the recyclable material compacting device 20, which is designed as a pressing device. Other control components required for the operation of the pressing device, such as power units, motor apron, etc., as well as a module for data transmission and readout, which may also operate with AI support, can also be provided in the control housing 25.

[0040] The invention described above makes it possible to create a simulation model of the recyclable material compaction device in the form of a digital twin. This opens up various advantages and options. First, the physical relationships between the components and processes in the technical status of the recyclable material compaction device, as well as the ongoing processes, are better recorded and monitored. This enables reliable fault detection and monitoring of aging and changes in components and ongoing processes, and can also be implemented as predictive maintenance. Artificial intelligence and deep learning can further improve the control and monitoring routines.

[0041] The simulation model has a modular structure. Automatic, dynamic adaptation and thus a mapping of aging and changes in individual components or the entire recyclables compaction device can be captured and implemented.

[0042] The simulation model created also provides a database for implementing the aforementioned objectives in an even more effective manner through the use of artificial intelligence. Reference symbol list

[0043] 10Control unit 11Interfaces 12Interfaces 20Recyclable material compacting device 21Press piston 22Pressing chamber 23Pressure ram 24Position sensor 25Control housing 26Pressing chamber door 30Analysis module 31Interface 40Model 50Data processing device 60Display device 70Data acquisition system 80Hydraulic control 81Hydraulic lines 82Hydraulic circuit 83Electric motor 84Pump 85Pressure relief valve 86Pressure sensor 87Current consumption sensor 88Vibration sensor IActuator PPressure P(t)Pressure curve SExcitation signal S(t)Excitation signal I(t)Temporal behavior of the current consumption of an actuator VIBVibration behavior VIB(t)Vibration behavior of the recyclable material compacting device F(VIB(t))Fourier transformation

Claims

1. A method for controlling and / or monitoring a recyclable material compacting device which is designed and intended to compact recyclable materials, and wherein the recyclable material compacting device comprises - a compacting element operated via a hydraulic or pneumatic system, in particular a compacting stamp, - one or more actuators for actuating the compacting element, - one or more sensors for detecting an operating parameter of the recyclable material compacting device, and an integrated control device which is connected via interfaces to the one or more actuators and the one or more sensors, characterized in thatthe operating behavior of the recyclable material compacting device (20) is learned via an analysis algorithm, wherein the analysis algorithm comprises at least a first analysis step and a second analysis step, in that in a first analysis step the signals at the interfaces between the integrated control device and the actuators on the one hand and between the control device and the sensors on the other hand or at other interfaces (11) of the integrated control device (10) are detected in different operating states of the recyclable material compacting device (20), and in that in a second analysis step the interfaces of the integrated control device (10) are subjected to excitation signals S and the reactions of the integrated control device (10) and / or the recyclable material compacting device (20) to these excitation signals S are detected,wherein, based on the information obtained from the first analysis step and the second analysis step, a model (40) of the operating behavior of the recyclable material compacting device is generated, and wherein the model (40) of the operating behavior of the recyclable material compacting device is used to control and / or monitor the recyclable material compacting device.

2. Method according to claim 1, characterized in that the excitation signals S(t) are applied, which have a predetermined upper and lower limit value and a predetermined time course.

3. Method according to claim 1 or 2, characterized in that Operating parameters of the recyclable material compaction device (20) are recorded via the analysis algorithm.

4. Method according to one of claims 1 to 3, characterized in thatat least the following operating parameters of the recyclable material compacting device (20) are recorded via the analysis algorithm: - the temporal behavior of the current consumption of at least one actuator I(t), - the vibration behavior of the recyclable material compacting device VIB(t), - a pressure P(t) recorded in the hydraulic or pneumatic system.

5. Method according to claim 4, characterized in that the parameters I(t), VIB(t) and P(t) are read out in real time.

6. Method according to one of claims 1 to 5, characterized in that a temporal correlation of the operating parameters is recorded, in particular a temporal correlation of the vibration behavior VIB(t) with the current consumption I(t) or the vibration behavior VIB(t) with the pressure curve P(t).

7. Method according to one of claims 1 to 6, characterized in thatthe temporal course of the recorded parameters, in particular the vibration behavior VIB(t), is subjected to a Fourier transformation F(VIB(t)) and the Fourier analysis is taken into account when creating the model of the operating behavior of the recyclable material compaction device.

8. Method according to one of claims 1 to 7, characterized in that the model (40) of the operating behavior of the recyclable material compacting device (20) is automatically included in a control method that controls the operation of the recyclable material compacting device (20).

9. Method according to one of claims 1 to 8, characterized in that the model (40) of the operating behavior of the recyclable material compacting device (20) is evaluated with regard to maintenance scheduling and / or error analysis.

10. Method according to one of claims 1 to 9, characterized in thatthe model (40) of the operating behavior of the recyclable material compacting device is used with a view to expanding and / or adapting the recyclable material compacting device (20).

11. Method according to one of claims 1 to 10, characterized in that the analysis steps are carried out by an analysis module (30) which is connected to or within the recyclable material compaction device.

12. Method according to one of claims 1 to 11, characterized in thata bidirectional data exchange is carried out between the analysis module (30) connected to or in the material compacting device (20) and a data processing device (50) located remotely from the material compacting device, and the remote data processing device (50) in particular carries out or forwards evaluations, for example for fault diagnosis, for adaptive maintenance based on usage and load profiles or for maintenance planning, or forwards control commands, in particular a shutdown command, to the material compacting device via the connected analysis module.

13. Method according to one of claims 1 to 12, characterized in that the second analysis step is carried out after the first analysis step.

14. Analysis module designed and intended to carry out the analysis steps according to the method according to one of claims 1 to 13.

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