METHOD FOR REPLACING A CONTROL UNIT IN A CONVEYING DEVICE
20180203438 ยท 2018-07-19
Assignee
Inventors
Cpc classification
B65G23/08
PERFORMING OPERATIONS; TRANSPORTING
G05B19/41845
PHYSICS
H04L43/10
ELECTRICITY
B65G13/07
PERFORMING OPERATIONS; TRANSPORTING
G05B19/4184
PHYSICS
H04L41/0668
ELECTRICITY
H04L61/5038
ELECTRICITY
Y02P90/02
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B65G43/10
PERFORMING OPERATIONS; TRANSPORTING
International classification
G05B19/418
PHYSICS
B65G43/10
PERFORMING OPERATIONS; TRANSPORTING
B65G23/08
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method is disclosed for replacing a defective control unit in a conveying device interconnected by a bus.
Conveying devices are used in logistics processes for fully automated and semi-automated conveying of goods by means of conveyor segments. These conveyor segments are controlled and monitored by control units. In order to minimise the downtimes of the conveyor device, the described method for replacing a defective control unit in a conveying device interconnected by a bus can be used to ensure that a control unit can be replaced promptly and reliably.
The method according to the invention allows automatic detection of a defect in a control unit, as well as initial configuration of a replacement control unit with an individual bus address or additional parameters.
Claims
1.-48. (canceled)
49. A method for replacing a defective control unit in a conveying device interconnected by a bus, said conveying device comprising a first control unit having a first bus address and at least one second control unit having a second bus address, wherein the first control unit controls a first conveyor segment and the second control unit controls a second conveyor segment, and the first control unit and the second control unit are interconnected via bus communication, said method comprising the steps of: (i) detecting the defect in the second control unit by means of the first control unit; (ii) switching the first control unit into a configuration mode when the first control unit detects a defect in the second control unit; (iii) integrating a third control unit into the bus communication after the first control unit has been put into the configuration mode; (iv) transferring a configuration from the first control unit to the third control unit or from the third control unit to the first control unit; and (v) storing the configuration transferred from the first control unit in the third control unit, or storing the configuration transferred from the third control unit in the first control unit.
50. The method pursuant to claim 49, wherein steps (iv) and (v) further comprise the steps of: (iv) transferring an individual bus address from the first control unit to the third control unit; and (v) storing the individual bus address transferred from the first control unit in the third control unit.
51. The method pursuant to claim 49, wherein the second control unit sends an activity signal via the bus communication and the first control unit receives the activity signal from the second control unit and the defect in the second control unit is detected in step (i) by the first control unit failing to receive the activity signal from the second control unit, in that the second control unit sends an activity signal at regular, predetermined intervals and a defective control unit is detected by the failure to receive the activity signal within the predetermined interval after receiving a preceding activity signal.
52. The method pursuant to claim 51, wherein the first control unit is put into the configuration mode by the failure to receive the activity signal.
53. The method pursuant to claim 51, wherein an error message is generated by the first control unit and transmitted via bus communication if the activity signal is not received in the first control unit.
54. The method pursuant to 50, wherein the third control unit transmits a presence signal after being integrated into the bus communication, and the first control unit is put into the configuration mode by receiving the presence signal from the third control unit.
55. The method pursuant to claim 50, wherein the third control unit is integrated, and wherein the second control unit is removed or the second control unit remains.
56. The method pursuant to claim 50, wherein in step (v), the third control unit stores a second bus address only if the third control unit receives from the first control unit a message which contains the first bus address of the first control unit and an individual bus address to be allocated to the third control unit.
57. The method pursuant to claim 50, wherein a third conveyor segment comprises a fourth control unit having a fourth bus address and the third control unit stores the individual bus address in step (v) only if the third control unit receives two messages, wherein the first message has been sent from the first control unit and contains the first bus address of the first control unit to be allocated to the third control unit, and the second message has been sent from the fourth control unit and contains the fourth bus address of the fourth control unit and the bus address to be allocated to the third control unit, wherein the individual bus address to be allocated to the third control unit is identical in both messages.
58. The method pursuant to claim 50, wherein the second bus address of the second control unit has been stored in the first control unit in a previous backup step and the first bus address of the first control unit has preferably been stored in the second control unit, and the third control unit is configured by means of the stored bus address from the second control unit, said method comprising the following steps: (a) transmitting the stored second bus address of the second control unit and said bus address being received by the third control unit; (b) storing in the third control unit the second bus address of the second control unit received by the third control unit; and (c) storing the first bus address of the first control unit in the third control unit.
59. The method pursuant to claim 58, wherein a configuration of the second control unit has been stored in the first control unit in a previous backup step, a configuration of the first control unit has been stored in the second control unit, and the third control unit is configured by means of the configuration of the second control unit stored in the first control unit.
60. The method pursuant to claim 58, wherein the bus address, either alone or in combination with the configuration of the second control unit, has been stored in a previous backup step in a control unit of a conveyor segment that is not immediately adjacent, and the bus address, either alone or in combination with the configuration of the control unit which is not immediately adjacent, has been stored in the second control unit.
61. The method pursuant to claim 58, wherein the bus address, either alone or in combination with the configuration of the second control unit, has been stored in a previous backup step in a plurality of control units, and the bus addresses, either alone or in combination with the configurations of the plurality of control units, have been stored in the second control unit.
62. The method pursuant to claim 50, wherein in a previous backup step, the second bus address of the second control unit, either alone or in combination with the configuration of the second control unit, has been stored in a backup unit, has been stored in a programmable logic controller, or has been stored on a web server, and wherein the individual bus addresses, either alone or in combination with the configurations of all the control units integrated in the bus communication, have been centrally stored in one unit.
63. The method pursuant to claim 49, wherein the configuration includes the full operating software of a control unit.
64. The method pursuant to claim 49, wherein the configuration includes one or more parts of the operating software of a control unit.
65. The method pursuant to claim 52, wherein the configuration includes a unique version identifier, by means of which the up-to-dateness of the configuration can be determined, in that a unique version identifier is allocated to an individual firmware version or software version of the operating software of a control unit.
66. The method pursuant to claim 54, wherein step (v) is carried out and step (vi) is added as follows: (v) comparing the version identifier of the configuration of the first control unit with the version identifier of the configuration of the third control unit, preferably in the first or the third control unit; (vi) if the version identifier of the first control unit is more up-to-date that the version identifier of the third control unit, then storing the configuration transferred from the first control unit; or, if the version identifier of the first control unit is more up-to-date than the version identifier of the third control unit then: (a) transferring the configuration of the first control unit to the third control unit; and (b) storing the transferred configuration of the first control unit in the third control unit.
67. The method pursuant to claim 54, wherein step (v) is carried out and step (vi) is added as follows: (v) comparing the version identifier of the configuration of the first control unit with the version identifier of the configuration of the third control unit, preferably in the first or the third control unit; (vi) if the version identifier of the first control unit is more up-to-date than the version identifier of the third control unit, then: storing the configuration transferred from the first control unit to the third control unit, otherwise: (a) transferring the configuration of the third control unit to the first control unit, and (b) storing the transferred configuration of the third control unit in the first control unit; or, if the version identifier of the third control unit is more up-to-date than the version identifier of the first control unit, then: storing the configuration transferred from the third control unit to the first control unit, otherwise: (a) transferring the configuration of the first control unit to the third control unit, and (b) storing the transferred configuration of the first control unit in the third control unit.
68. The method pursuant to claim 65, wherein steps (v) and (vi) are carried out and steps (vii) and (viii) are added as follows: (v) comparing the version identifier of the configuration of the first control unit with the version identifier of the configuration of the third control unit, preferably in the first or the third control unit; (vi) retrieving the state of a configuration direction setting in the first or third control unit by means of the first or third control unit; (vii) determining the configuration having the more up-to-date version identifier or having the older version identifier, depending on the detected state of a configuration direction setting; and (viii) if the configuration with the more up-to-date version identifier is not the configuration of the first or third control unit: (a) transferring the configuration with the more up-to-date version identifier from the first or third control unit to the third or first control unit, and (b) storing the transferred configuration of the first or third control unit in the third or first control unit; or, if the configuration with the older version identifier is not the configuration of the first or third control unit, (a) transferring the configuration with the older version identifier from the first or third control unit to the third or first control unit; and (b) storing the transferred configuration of the first or third control unit in the third or first control unit.
69. The method pursuant to claim 49, wherein steps (iv) and (v) are carried out as follows: (iv) the first or third control unit retrieves the state of a configuration direction setting in the first or third control unit; (v) if the configuration direction setting has a first state, transferring the configuration of the first control unit to the third control unit and storing the transferred configuration in the third control unit; or if the configuration direction setting has a second state, transferring the configuration of the third control unit to the first control unit and storing the transferred configuration in the first control unit.
70. The method pursuant to claim 68, wherein step (vi) is carried out as follows: (a) the first or third control unit retrieves the state of a configuration direction setting in the first or third control unit; (b) the third or first control unit signals, by means of an optical or acoustic signal unit, whether the version identifier of the configuration of the third control unit has a more up-to-date or an older, an identical version identifier compared to the version identifier of the configuration of the first control unit; (c) a user changes the state of the configuration direction setting in the first or third control unit; and (d) the first or third control unit retrieves the state of the configuration direction setting in the first or third control unit.
71. The method pursuant to claim 70, wherein the state of the configuration direction setting in the first or third control unit is changed by operating a contact, a switch or a sensor at and/or in a control unit, or is changed by a central unit via bus communication.
72. The method pursuant to claim 49, wherein the configuration stored in the first control unit is transferred in a downstream distribution step from the first or third control unit to a plurality of control units and is stored in said plurality of control units.
73. A conveying device, comprising a first control unit having a first bus address and at least a second control unit having a second bus address, wherein the first control unit monitors and controls a first conveyor segment and the second control unit monitors and controls a second conveyor segment, the first control unit and the second control unit being interconnected via bus communication, wherein: (i) the first control unit is adapted to detect a defect in the second control unit; (ii) the first control unit is adapted to switch into a configuration mode when the first control unit detects the defect in the second control unit; (iii) the first control unit is adapted to be put into a configuration mode; (iv) the first control unit is adapted to transfer a configuration from the first control unit to a third control unit, and the third control unit is adapted to transfer a configuration to the first control unit; and (v) the third control unit is adapted to store the configuration transferred from the first control unit, and the first control unit is adapted to store the configuration transferred from the third control unit.
74. The conveying device pursuant to claim 73, wherein features (iv) and (v) are adapted as follows: (iv) the first control unit is adapted to transfer an individual bus address from the first control unit to the third control unit; and (v) the third control unit is adapted to store the individual bus address transferred from the first control unit.
75. The conveying device pursuant to claim 74, wherein: the second control unit is adapted to transmit an activity signal via bus communication; the first control unit is adapted to detect a defect in the second control unit on the basis of its not receiving an activity signal from the second control unit; and the first control unit is adapted to detect a defect in the second control unit on the basis of its not receiving an activity signal within a predetermined interval after receiving a preceding activity signal.
76. The conveying device pursuant to claim 74, wherein the first control unit is adapted to be put into the configuration mode by the failure to receive the activity signal.
77. The conveying device pursuant to claim 74, wherein the first control unit is adapted such that an error message is generated by the first control unit and transmitted via the bus communication if the activity signal is not received in the first control unit.
78. The conveying device pursuant to claim 74, wherein the third control unit is adapted to transmit a presence signal after it has been integrated into the bus communication, and the first control unit is adapted to be put into the configuration mode by receiving the presence signal from the third control unit.
79. The conveying device pursuant to claim 74, wherein the second conveyor segment is adapted to integrate the third control unit, wherein: the second control unit is removed from the second conveyor segment, or the second control unit remains in the second conveyor segment.
80. The conveying device pursuant to claim 74, wherein the third control unit is adapted to store an individual bus address in step (v) only if the third control unit receives a message from the first control unit containing the first bus address of the first control unit and the second bus address to be allocated to the third control unit.
81. The conveying device pursuant to claim 74, wherein the conveying device includes a third conveyor segment and a fourth control unit having a fourth bus address and the third control unit is adapted to store the individual bus address in step (v) only if the third control unit receives two messages, wherein the first message has been sent from the first control unit and contains the first bus address of the first control unit and the second bus address to be allocated to the third control unit, and the second message has been sent from the fourth control unit and contains the fourth bus address of the fourth control unit and the second bus address to be allocated to the third control unit; and wherein the second bus address to be allocated to the third control unit is identical in both messages.
82. The conveying device pursuant to claim 74, wherein the first control unit is adapted to store the second bus address of the second control unit in a backup step carried out before step (i), the second control unit is adapted to store the first bus address of the first control unit, and the third control unit is adapted to be configured by means of the stored bus address of the second control unit, wherein: the first control unit is adapted to transmit the stored second bus address of the second control unit; the third control unit is adapted to store the received second bus address of the second control unit; and the third control unit is adapted to store the bus address of the first control unit.
83. The conveying device pursuant to claim 74, wherein the first control unit is adapted to store a configuration of the second control unit in a previous backup step, the second control unit is adapted to store a configuration of the first control unit in a previous backup step; and the third control unit is adapted to be configured by means of a stored configuration of the second control unit.
84. The conveying device pursuant to claim 74, wherein a control unit is adapted to store, in a previous backup step, the bus address, either alone or in combination with a configuration of a control unit of a conveyor segment which is not immediately adjacent, and the second control unit is adapted to store the bus address, either alone or in combination with a configuration of a control unit which is not immediately adjacent.
85. The conveying device pursuant to claim 74, wherein a control unit is adapted to store, in a previous backup step, the bus address, either alone or in combination with a configuration of the second control unit conveyor segment, in a plurality of control units, and the second control unit is adapted to store the bus address, either alone or in combination with a configuration, in a plurality of control units.
86. The conveying device pursuant to claim 74, further comprising: a backup unit, a programmable logic control, or a web server adapted to store the second bus address of the second control unit, either alone or in combination with the configuration of the second control unit, in a previous backup step, and is adapted to store in a central location the individual bus addresses, either alone or in combination with the configurations of all the control units integrated into the bus communication.
87. The conveying device pursuant to claim 75, wherein the configuration includes the full operating software of a control unit.
88. The conveying device pursuant to claim 75, wherein the configuration includes parts of the operating software of a control unit.
89. The conveying device pursuant to claim 87, wherein the configuration includes a unique version identifier, by means of which the development status of the configuration can be determined, wherein the version identifier is allocated to an individual firmware version or software version of the operating software of a control unit.
90. The conveying device pursuant to claim 89, wherein the first or third control unit is adapted to compare the version identifier of the configuration.
91. The conveying device pursuant to claim 89, wherein the first or third control unit is adapted to retrieve a state of a configuration direction setting in the first or third control unit, with regard to a first or second state.
92. The conveying device pursuant to claim 89, wherein the first or third control unit is adapted to transfer the configuration stored in the first control to a plurality of control units in a downstream distribution step, and said plurality of control units is adapted to store the transferred configuration.
93. The conveying device pursuant to claim 89, wherein the first or third control unit is adapted to determine the configuration having the more up-to-date version identifier or having the older version identifier.
94. The conveying device pursuant to claim 89, wherein the first or third control unit is adapted to change the state of the configuration direction setting in the first or third control unit by operating a contact, a switch or a sensor at or in a control unit, or to change the state of the configuration direction setting by means of a central unit via bus communication.
95. The conveying device pursuant to claim 89, wherein the first or third control unit is adapted to signal, by means of an optical or acoustic signal unit, whether the version identifier of the configuration of the third control unit has a more up-to-date or an older or an identical version identifier compared to the version identifier of the configuration of the first control unit.
96. The method pursuant to claim 49, wherein the configuration is formed by a bus address and a complete operating software, or part of an operating software.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0146] A preferred embodiment shall now be described with reference to the attached Figures, in which
[0147]
[0148]
[0149]
[0150]
[0151]
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0152] As referenced in the Figures, the same reference numerals may be used herein to refer to the same parameters and components or their similar modifications and alternatives. For purposes of description herein, the terms upper, lower, right, left, rear, front, vertical, horizontal, and derivatives thereof shall relate to the present disclosure as oriented in
[0153]
[0154] Control unit 12, 22 is also integrated into bus communication 70. By means of bus communication 70, it is possible for data to be transmitted between control units 12 and 22. An individual bus address 14, 24 is also assigned to each control unit 12, 22, respectively. This individual bus address 14, 24 is stored in a data store in control unit 12, 22.
[0155] In the event of a failure in second control unit 22 due to a defect, the method of the invention for replacing a control unit, as shown in the form of flow diagram in
[0156]
[0157] Control unit 1012 is also integrated into bus communication 70. By means of bus communication 70, it is possible for data to be transmitted to other control units (not shown). An individual bus address 1014 is assigned to control unit 1012 for addressing purposes. This individual bus address 1014 is stored in a data store in control unit 1012.
[0158]
[0159] The method begins with step 100, followed by test step 102, in which the first control unit checks whether the second control unit is defective. If no defect in the second control unit is detected, the method ends in step 112. If a defect in the second control unit is detected, step 104 is carried out, in which the first control unit switches to a configuration mode. In this configuration mode, an individual bus address is transmitted at predetermined intervals via bus communication. In the following step 106, a third control unit is integrated into the bus communication. In step 108 that follows, the third control unit receives the individual bus address that is transmitted repeatedly by the first control unit. After the individual bus address has been received, it is stored in the control unit in step 110, and the method ends with step 112.
[0160]
[0161] After the method is started in step 200, the first control unit sends a request to the second control unit in step 202 to send an activity signal. In step 204, the first control unit checks whether an activity signal has been received from the second control unit. If the first control unit receives an activity signal from the second control unit within a first time interval, the method according to the invention ends with step 224. If the first control unit does not receive an activity signal from the second control unit within a first time interval, the first control unit switches into a configuration mode 206. In a step 208 which then follows, the first control unit transmits an error message via bus communication. This error message preferably contains the bus address of the second control unit detected as defective. All the units integrated into the bus communication can receive this error message and carry out predefined actions. In the following step 210, the first control unit transmits a configuration message containing the second bus address. Test step 212 checks for reception of an acknowledgement signal from the second control unit that the second bus address has been received. If the first control unit does not receive an acknowledgement signal in test step 212, step 210 is repeated. If the first control unit receives an acknowledgement signal from the second control unit in test step 212, the first control unit performs step 214 and sends a configuration message containing a configuration of the second control unit. In a test step 216, the first control unit checks whether an acknowledgement signal for successful of the second control unit has been received. If the first control unit does not receive this acknowledgement signal within a second time interval, step 214 is then repeated. If the first control unit receives an acknowledgement signal within a second time interval, it leaves the configuration mode in step 218 and the method ends with step 220.
[0162]
[0163] After the third control unit has been integrated into the bus communication, the method starts in step 300. The third control unit then proceeds to a test step 302, in which the third control unit waits to receive a bus address, preferably as the content of a configuration message. If the third control unit does not receive any bus address within a third time interval, test step 302 is repeated. If the third control unit receives a bus address in test step 302, this bus address is stored in step 304. The stored bus address is used in the following step 306. The stored bus address is preferably adopted during ongoing operation of the control unit, preferably without the control unit restarting. In step 308 that then follows, the third control unit stores the bus address of the first control unit, which was preferably transferred as part of the configuration message to the third control unit. In step 310, the third control unit sends an acknowledgement signal to the first control unit to confirm that it has received the bus address. In the following test step 312, the third control unit waits to receive a configuration. If the third control unit does not receive a configuration within a third time interval, step 312 is repeated. If the third control unit does receive a configuration within a third time interval, step 314 is carried out, and the received configuration is stored. In step 316, which then follows, the stored configuration is applied within the third control unit. This is preferably done during ongoing operation of the third control unit and preferably does not require the third control unit to restart. In step 318, an acknowledgement signal is then sent to the first control unit, this acknowledging to the first control unit that a configuration has been received in the third control unit. In test step 320 which then follows, the third control unit checks whether the first control unit is transmitting the configuration of the first control unit. If the third control unit does not receive the configuration of the first control unit within a fourth time interval, step 320 is repeated. If the third control unit does receive a configuration of the first control unit within a fourth time interval, step 322 is carried out, in which the received configuration of the first control unit is stored in the third control unit. In the following step 324, the third control unit sends an acknowledgement signal to the first control unit to confirm that the configuration of the first control unit has been received. In step 326 that follows, the third control unit terminates the configuration mode and switches to step 328, in which the method according to the invention is terminated.
[0164] It will be understood by one having ordinary skill in the art that construction of the described present disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.
[0165] For purposes of this disclosure, the term operably coupled (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.
[0166] For purposes of this disclosure, the term operably connected (in all of its forms, connect, connecting, connected, etc.) generally means that one component functions with respect to another component, even if there are other components located between the first and second component, and the term operable defines a functional relationship between components.
[0167] It is also important to note that the construction and arrangement of the elements of the present disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible, e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc. without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown in multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of the wide variety of materials that provide sufficient strength or durability, in any of the wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.
[0168] It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.
[0169] It is to be understood that variations and modifications can be made on the aforementioned structure and method without departing from the concepts of the present disclosure, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.