COMMUNICATION DEVICE AND METHOD OF TRANSFERRING DATA FROM A CONTROL LOOP

Abstract

A communication device for a control loop is provided having a control device and an actuator that is connected to the control device via a connection line and that has a sensor for determining a control variable. In this respect, the communication device has a first interface for connecting to the control line for a connection to the control device, a second interface for a connection to the actuator, and a third interface for a connection to a third system to transfer at least some of a communication on the connection line or data acquired therefrom to the third system.

Claims

1. A communication device for a control loop, the communication device comprising: a control device and an actuator that is connected to the control device via a connection line and a sensor for determining a control variable, wherein the communication device has a first interface for connecting to the control line for a connection to the control device, a second interface for a connection to the actuator, and a third interface for a connection to a third system to transfer at least some of a communication on the connection line or data acquired therefrom to the third system.

2. The communication device in accordance with claim 1, wherein the actuator is a motor, the sensor is a rotary encoder, and the control device is a servo controller.

3. The communication device in accordance with claim 1, wherein the third interface is a wired or wireless interface for data communication in accordance with a standardized data communication protocol.

4. The communication device in accordance with claim 3, wherein the standardized data communication protocol is a network protocol.

5. The communication device in accordance with claim 1, wherein the third system is a computer for the analysis of a system having the actuator, a network of the system, or a cloud.

6. The communication device in accordance with claim 1, wherein the control device and the actuator communicate over the connection line in accordance with the standard HIPERFACE DSL® or IO-Link.

7. The communication device in accordance with claim 1, wherein at least one of the first interface and the second interface is configured in accordance with the standard HIPERFACE DSL® or IO-Link.

8. The communication device in accordance with claim 1, wherein the connection line in the communication device is continued between the first interface and the second interface and transmits signals of the connection line.

9. The communication device in accordance with claim 8, wherein the connection line transmits the signals of the connection line while amplifying the signals.

10. The communication device in accordance with claim 1, wherein the communication device has a master/slave unit that is connected to the first interface and to the second interface.

11. The communication device in accordance with claim 10, wherein the master/slave unit is configured in accordance with the standard HIPERFACE DSL® or IO-Link.

12. The communication device in accordance with claim 1, that has a communication control that is configured to evaluate the signals transmitted on the connection line between the actuator and the control device and to decide which signals and/or data are output at the first interface, at the second interface, and/or at the third interface.

13. The communication device in accordance with claim 12, wherein the communication control is configured to filter, sort, and/or pre-process the data that are output to the outside via a third interface.

14. The communication device in accordance with claim 12, wherein the communication control is configured to compare the signals and/or data with an expectation.

15. The communication device in accordance with claim 12, wherein the communication control is configured for a protocol adaptation between the first interface and the second interface.

16. The communication device in accordance with claim 15, wherein the protocol adaptation comprises a change of the resolution and/or data rate.

17. The communication device in accordance with claim 12, wherein the communication control is configured to at least partially replace the data flow from the actuator and/or control device.

18. The communication device in accordance with claim 12, wherein the communication control is configured to request additional data from the sensor that the control loop does not require.

19. The communication device in accordance with claim 12, that has at least one connector for an additional sensor.

20. A method of transferring data from a control loop having a control device and an actuator that is connected to the control device via a connection line and that has a sensor for determining a control variable, wherein a communication device is connected via a first interface in the connection line to the control device and via a second interface in the connection line to the actuator; and wherein the communication device transfers at least some of a communication on the connection line or data acquired therefrom via third interface to a third system.

21. The method according to claim 20, wherein the communication device comprises the control device and the actuator that is connected to the control device via the connection line and the sensor for determining a control variable, wherein the communication device has the first interface for connecting to the control line for a connection to the control device, the second interface for a connection to the actuator, and the third interface for a connection to said third system to transfer at least some of a communication on the connection line or data acquired therefrom to the third system.

Description

[0025] The invention will be explained in more detail in the following also with respect to further features and advantages by way of example with reference to embodiments and to the enclosed drawing. The Figures of the drawing show in:

[0026] FIG. 1 a schematic representation of a communication device;

[0027] FIG. 2 a schematic representation of a communication device in the connection line of a control loop;

[0028] FIG. 3 a block diagram of a communication device in an embodiment as a splitter;

[0029] FIG. 4 a block diagram of a communication device in an embodiment with a master and a slave;

[0030] FIG. 5 a schematic representation of the arrangement of a communication device in the control loop of a servo motor for data transfer to a local network;

[0031] FIG. 6 a representation in accordance with FIG. 5, now with a data transfer to a cloud;

[0032] FIG. 7 a representation in accordance with FIG. 6, now with a data transfer to a dedicated analysis/diagnosis processor;

[0033] FIG. 8 a representation of a conventional control loop in a servo motor; and

[0034] FIG. 9 a schematic representation of the transfer of data from a system control in accordance with the prior art that is higher ranking than the control loop.

[0035] FIG. 1 shows a schematic representation of a communication device 10. It has a first interface 12 and a second interface 14 to be used thereby in a connection line of a control loop. The connection line is then internally continued in the communication device 10 between the first interface 12 and the second interface 14. A third system can be connected in a wireless or wired manner to a third interface 16 to transfer data from the connection line to the third system or conversely to transfer data from the third system over the first or second interface o the connection line, in particular processing results based on the data previously transferred from the control loop. A communication control 18 coordinates the respective data transfer and optionally also already performs pre-processing and the like.

[0036] FIG. 2 shows the communication device 10 installed in a control loop. A controller 20 in the control loop controls an actuator 22 in real time or at least in very short cycles. To acquire the control variable, an encoder 24 is provided at the actuator 22, with some actuators 22 also taking over its function. The communication of the respectively acquired control variable required for the control (fast loop communication) or the controls required for the subsequent regulation takes place via a connection line 26a-b that is split over sides of the actuator to also include the encoder 24. This division takes place, for example, by a corresponding association of the individual lines of a multi-core connection line 26a-b. The connection line 26a-b can moreover supply the actuator 22. The controller 20 is connected to a control 28 example via a fieldbus

[0037] The communication device 10 is connected to the controller 20 via the first interface 12 and to the actuator 22 via the second interface 14. The connection line 26a-b is divided into two sections in this manner. The communication device 10 establishes the connection internally between the two sections 26a-b. In addition, at least some of the communication with the encoder 24 or with the controller 20 or data led off thereon is output to a third system via the third interface 16.

[0038] FIG. 3 shows a further embodiment of the communication device 10. The connection line 26a-b is here practically only led through on an internal section 26c. The first and second interfaces 12, 14 can remain restricted to physical plugs or jacks for continuing the connection line 26a-b. The communication between the controller 20 and the actuator or the encoder 24 remains functionally unchanged. However, additional modifications are conceivable here such as signal amplification and the like. The two single lines shown stand by way of example for a plurality of connection strands, for instance for the two communication directions, and can in turn have a plurality of cores.

[0039] In this embodiment, the communication on the connection line 26a-c is practically only overheard by a signal splitter 30 in any desired technical design. The communication control 18 select that information that is to be transmitted via the third interface 16 outwardly to the third system. There are different possibilities here, from a transfer of raw data signals, to a translation of the data communicated on the connection line 26a-c into a different data protocol, up to a pre-processing or even an analysis and diagnosis of these data.

[0040] FIG. 4 shows a further embodiment of the communication device 10. Unlike FIG. 3, the first and second interfaces 12, 14 are here formed as complete interfaces with a master unit 32 or with a slave unit 34. The communication device 10 therefore in this case interrupts the communication and actively conducts it on the two sections of the connection line 26a-b. The first and second interfaces 12, 14 together with their master units and slave units 32, 34 are configured for that protocol that is also otherwise used without the communication device 10 in the control loop on the connection line 26a-b.

[0041] In this embodiment, the communication device 10 has full control over contents and protocols. It can thus not only work as a splitter, but also as a translator, or furthermore also provide additional functions. Communication contents can thus also be selectively changed, filtered, or passed on within the control loop on the connection line 26a-b. Information can thereby be directly blocked; information can also be transferred that the control loop does not originally transfer; a data rate or a resolution and the like can be adapted. In principle, the communication device 10 could also use completely different protocols on the part sections of the connection line 26a-b. There is preferably no intervention in the communication for the actual control function. If this nevertheless takes place, it should be ensured that the communication device 10 only influences the control in a manner provided in the system. Such an intervention is then absolutely justifiable, for example to subsequently provide functional safety in the control loop by test processes and the like.

[0042] FIG. 5 shows the arrangement of an embodiment of the communication device 10 in the control loop of a servo motor. The embodiment in accordance with FIG. 1 is here shown purely by way of example; other embodiments are equally conceivable. The general design within the control loop corresponds to FIG. 9 already explained in the introduction. Two control loops are shown here purely by way of example, with instead only one control loop being possible and conversely, the number also being able to be a great deal higher in dependence on the system. While one respective communication device 10a-b per control loop is provided in FIG. 5, it would also be conceivable to provide additional connectors having a plurality of first and second interfaces 12, 14 for a plurality of control loops in only one single communication device 10a-b, but here preferably only to provide one common third interface 16.

[0043] The actuators in the servo motors are in each case motors 22a-b and the controllers are the associated servo controllers 20a-b. A motor feedback system as a respective encoder 34 preferably belongs to the motors 22a-b. The control loop therebetween communicates on a connection line 26a1, 26a2, 26b1, 26b2 into which the respective communication device 10a-b is hooked. Every single control loop can preferably be designed such as has been explained with respect to FIG. 8 in the introduction. The protocol in the control loop is then preferably HIPERFACE DSL®.

[0044] The third interface 16 communicates in this embodiment with a local network 36 of the system operator. There is preferably consequently a direct or indirect connection, not shown, in the background between the control 28 of the system and the local network 36. The third interface 16 can be configured for any desired network protocol, for example TCP-IP or UDP, and all known wired and wireless connections such as Ethernet, 3G, 4G, 5G, WiFi, Bluetooth, and other open or proprietary standards are conceivable for this purpose.

[0045] The data that are transferred over the third interface 16 into the local network 36 can be processed there using any desired analysis and diagnosis software. The system operator, the manufacturer of the servo motor, or the manufacturer of the encoders 24 or of the communication device 10 or a third party can provide the corresponding software. It is conceivable to transfer processing results back to the communication device, in particular to change configurations there or also to intervene in the control loop.

[0046] FIG. 6 is a similar representation to FIG. 5, with here the local network 36 again further being connected to a cloud 38. The third interface 16 could alternatively be directly connected to the cloud 38. A processing of the data from the control loop can take place ever very much more simply and more flexibly from the cloud 38. No local installation of software is necessary or this effort can at least be reduced by support from the cloud 38. A substantially more powerful and always up-to-date processing is possible. In addition, data can be acquired and analyzed together over a cloud 38 across a system over a plurality of systems. Analyses can become more and more exact and better by such measures, whether they are related to the system or are fed from a plurality of data sources, and critical states can, for example, be pointed out reliably and in good time.

[0047] FIG. 7 is again a similar representation to FIG. 5. Here, the third interface 16 is connected to an analysis/diagnosis processor 40 that is then optionally further connected to the local network 36. An additional connection to a cloud 38 is also possible, but it is an advantage of the arrangement in accordance with FIG. 7 that this is not necessary when the analysis/diagnosis processor 40 provides sufficient memory and processing power. The analysis/diagnosis processor 40 is adapted to cooperate with communication devices 10a-b and with the encoders 24 used. The required software packages to evaluate the data from the third interface 16 can there already be pre-installed by the manufacturer of the communication devices 10a-b, of the encoders 24, and/or of the servo motors. Alternatively, this installation takes place on site or is modified there. The advantage is at least that the analysis/diagnosis processor 40 represents a unit separate from the local network 36 that can also be under a different responsibility. Different technicians are thereby responsible for the analysis/diagnosis processor 40 and the local network 36. The system operator therefore to this extent does not have to take care of the installation and maintenance himself, but also does not have to let any outsiders intervene in his local network 36.

[0048] In the previous explanation, it has only generally been addressed that data from a control loop, in particular from a motor feedback control loop of a servo motor, can be expelled and possibly also transferred back by means of the communication device 10. Finally, some application examples should now be listed.

[0049] The data can be used for the diagnosis of the respective control loop and thus ultimately of the system. In this respect, comparisons with data of a specification, data from different operating times, or on different systems can take place as to whether indications of malfunctions, irregularities, required maintenance, or impending future failures result. The analysis can have the actuator 22, the encoder 24, or the application or system as its object and the actuator 22 or encoder 24 are integrated therein. This includes, for example, expectations on the behavior of the actuator 22 under load or an analysis of the processed load. Particularly such diagnosis functions can profit when they are supported on large data volumes and also make use of methods of machine learning, in particular deep neuronal networks. It is conceivable that the communication device 10 requests data over the connection line 26a-b that the controller 20 itself does not need and that are thus separately provided for the communication device 10 and thus the third systems 36, 38, 40. An additional diagnosis interface to the actuator 22 and the encoder 24 is thus provided.

[0050] It is furthermore conceivable, in particular with an embodiment in accordance with FIG. 4, that the communication device 10 for the controller 20 emulates the actuator 22 and the encoder 24 or conversely the controller 20 for the actuator 22 and encoder 24. The respective end points of the connection line 26a-b cannot distinguish what the source of the communication is. The makes further diagnoses possible and simplifies the further development because, for example, the actuator 22 does not have to be operated at all for tests.

[0051] The communication device 10 can act as a translator between different protocols on the sections of the supply line 26a-b. In this respect, only parameters can be modified in that, for example, the communication interface communicates with higher resolution to the one side than to the other side. It is, however, also conceivable to use completely different protocols to the controller 20 on the one side and to the actuator 22 and encoder 24 on the other side, in particular also different protocol versions. The communication interface thus makes it simpler to obtain the compatibility in the control loop.

[0052] In a further development of the communication device 10, not shown, at least one connector for an additional sensor is provided. The additional sensor does not directly belong to the control loop, but can acquire relevant values for it such as a temperature. The data of the additional sensor are included in the data analysis and in the decision as to which data are modified how and where they are transferred to. Alternatively, the communication device 10 for such further sensors can also only serve as loggers to transfer sensor data to the outside for very independent purposes.

[0053] For commercial applicability, there are a variety of options, in addition to the pure hardware of the communication device 10, for the evaluation of the data having become available therewith. Layered payment models are also conceivable in which only specific parts of the data are transferred or specific functions such as a higher measurement resolution are only made accessible via release keys. The communication device 10 facilitates the data output from the control loop both for new installations and in the event of an upgrading of an existing system.