Method for operating an automation system, and automation system
Centralized processing in automation systems using a digital network reduces costs and enhances flexibility by eliminating separate processing units at each output stage, facilitating integration and scalability with neural network data analysis.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- SEW EURODRIVE GMBH & CO KG
- Filing Date
- 2025-11-20
- Publication Date
- 2026-06-25
AI Technical Summary
Existing automation systems require multiple processing units for each consumer, leading to increased costs and limited flexibility in system integration and positioning.
A centralized processing unit controls multiple consumers via a digital network, eliminating the need for separate processing units at each output stage, and allows for flexible system integration and positioning using a digital network, including Ethernet or the Internet, with optional neural network evaluation for long-term data analysis.
Reduces hardware costs, enhances system flexibility, and enables integration with existing systems while providing cost-effective and scalable automation solutions.
Smart Images
Figure EP2025083649_25062026_PF_FP_ABST
Abstract
Description
[0001] Methods for operating an automation system and automation system
[0002] Description:
[0003] The invention relates to a method for operating an automation system comprising a central processing unit, at least one output stage, and at least one consumer. The invention also relates to an automation system operated by means of the method according to the invention.
[0004] Automation systems are used in technical installations to control and monitor machines, such as motors, conveyor belts, or production machines. An automation system comprises a central unit, field devices, and loads. The field devices contain power electronics to supply the load, for example, an electric motor, with electrical energy.
[0005] The central unit, for example a programmable logic controller (PLC), communicates with the field devices via a fieldbus. The field devices, for example inverters, each have a fieldbus interface and a processing unit for controlling the variables of a connected load, for example, the speed of an electric motor.
[0006] From DE 102021 001 792 B3, an automation system is known which comprises a control unit, a system bus, and several field devices. The field devices communicate with each other and with the control unit via the system bus.
[0007] The invention is based on the objective of further developing a method for operating an automation system as well as an automation system.
[0008] The object of the invention is achieved by a method for operating an automation system with the features specified in claim 1. Advantageous embodiments and further developments are the subject of the dependent claims. The object of the invention is also achieved by an automation system with the features specified in claim 14.
[0009] ISI \ EIDOPAT 20.11.2025 A method for operating an automation system comprising a central processing unit (CPU), at least one output stage, and at least one load is proposed. The output stage includes power electronics for supplying the load with electrical energy. The CPU communicates with the output stage via a digital network. The CPU includes a processing unit for controlling at least one control variable of the load. The CPU sends a manipulated variable for the load to the output stage via the digital network, and the CPU receives the control variable of the load from the output stage via the digital network. The processing unit determines an actual value from the control variable, and the processing unit determines the manipulated variable from the difference between the actual value and a setpoint.
[0010] Therefore, only one processing unit in the central unit is required to control multiple consumers. All device functions for the consumers exist within the central unit and can be instantiated multiple times. The output stages do not require separate processing units. The control of the consumers' variables is performed via the digital network. This significantly reduces the costs for the output stages and, consequently, the costs for the automation system.
[0011] According to an advantageous embodiment of the invention, the consumer is designed as an electric motor. The manipulated variable is a torque, the controlled variable is an angle of rotation, the actual value is an actual rotational speed, and the setpoint is a target rotational speed.
[0012] According to another advantageous embodiment of the invention, the load is designed as a DC / DC converter. The manipulated variable is a voltage, the controlled variable is a current, the actual value is an actual voltage, and the setpoint is a setpoint voltage.
[0013] According to a further advantageous embodiment of the invention, the consumer is designed as a contactless energy transmission system, in particular as a system for inductive energy transmission. The manipulated variable is a voltage, the controlled variable is a current, the actual value is the current, and the setpoint is the target current.
[0014] According to an advantageous embodiment of the invention, the central unit has a network interface for communication via the digital network and a fieldbus interface for communication via a fieldbus. The central unit sends the manipulated variable for the consumer to the output stage via the network interface over the digital network and receives the controlled variable of the consumer from the output stage via the network interface over the digital network. Communication with other central units or with conventional field devices is also possible via the fieldbus. The automation system can thus be integrated into existing systems.
[0015] According to an advantageous embodiment of the invention, the final stage has signal electronics which receive measured values from the consumer, determine the controlled variable from the received measured values, and communicate with the central unit via the digital network.
[0016] The final stage sends the controlled variable of the consumer to the central unit via the digital network using the signal electronics and receives the manipulated variable for the consumer from the central unit via the signal electronics using the digital network.
[0017] According to an advantageous embodiment of the invention, the signal electronics comprise a Field Programmable Gate Array, and the Field Programmable Gate Array comprises a control circuit for controlling at least one measured value received from the consumer.
[0018] If the load is an electric motor, the measured value to be controlled is, for example, a current. The Field Programmable Gate Array (FGA) therefore includes, for example, a current control circuit.
[0019] According to an advantageous embodiment of the invention, the digital network is designed as a Local Area Network, in particular Ethernet.
[0020] The central processing unit (CPU) is therefore not necessarily located in close proximity to the power amplifiers. The CPU is connected to the power amplifiers via the digital network. Thus, it is possible to position the CPU at a distance from the power amplifiers.
[0021] According to an advantageous embodiment of the invention, the digital network is configured as a wide area network, in particular the Internet. The general data bandwidth of the Internet makes it possible to offer a central processing unit (CPU) as a service. The hardware costs of a high-performance CPU are therefore not borne directly by the end customer. The necessary functionality of the CPU for operating the automation system can, for example, be purchased by the end customer via a paid subscription.
[0022] According to an advantageous embodiment of the invention, the digital network comprises a radio connection.
[0023] This eliminates the need for a wired network. Furthermore, the central unit and power amplifiers can be flexibly positioned within the technical installation.
[0024] According to an advantageous embodiment of the invention, the central unit has a storage unit in which manipulated variables and / or controlled variables and / or actual values and / or setpoint values are stored.
[0025] According to an advantageous embodiment of the invention, the central unit has an evaluation unit which evaluates data stored in the storage unit.
[0026] By evaluating the stored data, information about the operation of the automation system can be obtained in the long term.
[0027] According to an advantageous embodiment of the invention, the evaluation unit comprises a neural network. The neural network evaluates the history of the stored data based on previously acquired training data.
[0028] A neural network allows for the analysis of transmitted and stored data over extended periods. In particular, a neural network is capable of detecting age-related changes in the stored data. For example, the neural network is designed as a convolutional network, which has an input layer, multiple convolutional layers, and an output layer. Specifically, the neural network is preferably implemented as a CNN (Convolutional Neural Network) with an autoencoder structure. The layers are arranged sequentially and linked together via mathematical convolution operations. A convolution operation is performed from one layer to the next. The convolution operators used to perform these operations are determined by processing training data fed into the neural network.
[0029] An automation system according to the invention comprises a central unit, at least one output stage, and at least one consumer. The automation system according to the invention is operated using the method according to the invention.
[0030] The invention is not limited to the combination of features stated in the claims. For a person skilled in the art, further meaningful combinations of claims and / or individual claim features and / or features of the description and / or the figures will become apparent, in particular from the problem statement and / or the problem arising from a comparison with the prior art.
[0031] The invention will now be explained in more detail with reference to the illustrations. The invention is not limited to the embodiments shown in the illustrations. The illustrations only depict the subject matter of the invention schematically. They show:
[0032] Figure 1: a schematic representation of an automation system.
[0033] Figure 1 shows a schematic representation of an automation system. The automation system comprises a central unit 10, several power stages 70, and several loads 60. The automation system also includes a digital network 14 to which the central unit 10 and the power stages 70 are connected. Furthermore, the automation system includes electrical lines by means of which the power stages 70 are connected to each of the loads 60.
[0034] The central processing unit (CPU) 10 is, for example, a digital computer, a PC, or a server. It is also conceivable to use a virtual server as the CPU 10. The CPU 10 runs on a real-time operating system.
[0035] The central unit 10 communicates with the power amplifiers 70 via the digital network 14. The central unit 10 has a network interface 24 for communication via the digital network 14. Each of the power amplifiers 70 has a signal electronics unit 74. The signal electronics unit 74 communicates with the central unit 10 via the digital network 14. The digital network 14 is implemented as a local area network, specifically Ethernet.
[0036] The signal electronics 74 of a power amplifier 70 also records measured values from the connected load 60. Such recorded measured values include, for example, current, voltage, temperature, and rotation angle.
[0037] The central unit 10 also has a fieldbus interface 22 for communication via a fieldbus 12. In this case, the automation system is connected to a fieldbus 12.
[0038] The central processing unit 10 has a processing unit 20. The processing unit serves, among other things, to control at least one control variable of the consumer 60. Furthermore, the
[0039] The central processing unit 10 has a storage unit 26 in which data is stored. The central processing unit 10 also has an evaluation unit 28, which evaluates the data stored in the storage unit 26.
[0040] The output stages 70 each have power electronics 72 for supplying the respective connected load 60 with electrical energy via the electrical lines. The loads are, for example, designed as electric motors. The power electronics 72 in this case have the functionality of a converter.
[0041] During operation of the automation system, the central unit 10 sends a control variable for the consumer 60 via the digital network 14 to one of the output stages 70. In this case, the control variable is a torque of the consumer 60, which is designed as an electric motor. The output stage 70 receives the control variable from the central unit 10 via the digital network 14.
[0042] The output stage 70 then controls the load 60 with the received control variable. In this case, the output stage 70 specifies the torque of the electric motor. The signal electronics 74 of the output stage 70 acquires measured values from the load 60 and determines a controlled variable from these measured values. In this case, the controlled variable is the rotation angle of a rotor of the electric motor.
[0043] The output stage 70 sends the controlled variable of the consumer 60 to the central unit 10 via the digital network 14. The central unit 10 receives the controlled variable of the consumer 60 from the output stage 70 via the digital network 14. In this case, the central unit 10 thus receives the rotation angle of the rotor of the electric motor as the controlled variable.
[0044] The processing unit 20 of the central processing unit 10 determines an actual value from the received control variable. In this case, the actual value is the actual rotational speed of the electric motor's rotor. The processing unit 20 compares the determined actual value with a predefined setpoint.
[0045] In this case, the computing unit 20 compares the actual rotational speed of the electric motor's rotor with a target rotational speed.
[0046] The processing unit 20 determines the manipulated variable from the difference between the actual value and the setpoint. In this case, the processing unit 20 thus determines the torque from the difference between the actual rotational speed and the setpoint rotational speed. During operation of the automation system, a control loop is formed, comprising a controller, a controlled system, and feedback. The processing unit 20 of the central processing unit 10 acts as the controller, sending the manipulated variable to the controlled system. The output stage 70 and the load 60 form the controlled system, which feeds the controlled variable back into the system. An actual value is calculated from the fed-back controlled variable. The controller determines the manipulated variable from the difference between the actual value and the setpoint. The setpoint is specified externally as a reference input, for example, via the fieldbus 12.
[0047] The signal electronics 74 of the output stage 70 features a field-programmable gate array (FGA). The FGA includes a control circuit for regulating measured values from the load. In this case, the FGA includes a current control circuit for regulating a motor current.
[0048] The control circuit within the final stage 70 thus represents an inner control loop. This inner control loop is superimposed on the control loop described above. The automation system therefore comprises two superimposed control loops, which is also known as a cascade control loop.
[0049] The central processing unit 10 stores the manipulated variables, the controlled variables, the actual values, and the setpoints in storage unit 26. The evaluation unit 28 of the central processing unit 10 evaluates the data stored in storage unit 26. The evaluation unit incorporates a neural network for this purpose. During the evaluation, the neural network assesses the history of the stored data based on previously acquired training data.
[0050] Reference symbol list
[0051] 10 Central unit 12 Fieldbus
[0052] 14 digital network
[0053] 20 computing units
[0054] 22 Fieldbus interface
[0055] 24 Network interface 26 Storage unit
[0056] 28 evaluation units
[0057] 60 consumers
[0058] 70 Power stage
[0059] 72 Power electronics 74 Signal electronics
Claims
Patent claims:
1. Method for operating an automation system comprising a central unit (10), at least one output stage (70) and at least one load (60), wherein the output stage (70) has power electronics (72) for supplying the load (60) with electrical energy, and wherein the central unit (10) communicates with the output stage (70) via a digital network (14), characterized in that the central unit (10) has a computing unit (20) for controlling at least one controlled variable of the load (60), and that the central unit (10) sends a manipulated variable for the load (60) to the output stage (70) via the digital network (14), and that the central unit (10) receives the controlled variable of the load (60) from the output stage (70) via the digital network (14), and that the computing unit (20) determines an actual value from the controlled variable, and that the computing unit (20) determines the manipulated variable from a difference between the actual value and a setpoint.
2. Method according to claim 1, characterized in that the consumer (60) is designed as an electric motor, and that the manipulated variable is a torque, and that the controlled variable is an angle of rotation, and that the actual value is an actual rotational speed, and that the setpoint is a set rotational speed.
3. Method according to claim 1, characterized in that the consumer (60) is designed as a DC / DC converter, and that the manipulated variable is a voltage, and that the controlled variable is a current, and that the actual value is an actual voltage, and that the setpoint is a setpoint voltage.
4. Method according to claim 1, characterized in that the consumer (60) is designed as a contactless energy transmission system, and that the manipulated variable is a voltage, and that the controlled variable is a current, and that the actual value is an actual current, and that the setpoint is a setpoint current.
5. Method according to one of the preceding claims, characterized in that the central unit (10) has a network interface (24) for communication via the digital network (14) and a fieldbus interface (22) for communication via a fieldbus (12).
6. Method according to one of the preceding claims, characterized in that the final stage (70) comprises signal electronics (74) which takes measurements from the consumer (60), determines the control variable from the taken measurements, and communicates with the central unit (10) via the digital network (14).
7. Method according to claim 6, characterized in that the signal electronics (74) comprises a Field Programmable Gate Array, and that the Field Programmable Gate Array comprises a control circuit for controlling at least one measured value recorded by the consumer (60).
8. Method according to one of the preceding claims, characterized in that the digital network (14) is configured as a Local Area Network, in particular Ethernet.
9. Method according to one of claims 1 to 6, characterized in that the digital network (14) is designed as a Wide Area Network, in particular the Internet.
10. Method according to one of the preceding claims, characterized in that the digital network (14) comprises a radio link.
11. Method according to one of the preceding claims, characterized in that the central unit (10) has a storage unit (26) in which Control variables and / or actuated variables and / or actual values and / or setpoints are stored.
12. Method according to claim 11, characterized in that the central unit (10) has an evaluation unit (28) which evaluates data stored in the storage unit (26).
13. Method according to claim 12, characterized in that the evaluation unit (28) comprises a neural network, and that a progression of the stored data is evaluated by the neural network on the basis of previously determined training data.
14. Automation system comprising a central unit (10), at least one output stage (70) and at least one consumer (60) wherein the automation system is operated by means of the method according to any of the preceding claims.