WO2006026870A1

WO2006026870A1 - Method for controlling/regulating machine sequences or processes, and corresponding control/regulating unit

Info

Publication number: WO2006026870A1
Application number: PCT/CH2005/000371
Authority: WO
Inventors: Franz DÖRIG
Original assignee: Tecon Ag
Priority date: 2004-09-06
Filing date: 2005-07-01
Publication date: 2006-03-16
Also published as: EP1787174A1

Abstract

The invention relates to a method and a control/regulating unit for controlling/regulating machine sequences or processes by using standardized regulating and control units, particularly microcontrollers with a fixed operator interface. To this end, the invention provides that the operator uses a separate mobile hand-held unit configured as an application-specific man-machine interface (MMI). The microcontroller is adapted for exchanging date in both directions i.e. to and from the mobile hand-held unit. The data exchange can ensue via wire communication or wirelessly. The operator interface achieves a level of comfort that comes close to that of using a PC. With appropriate programming, not only can all inputs of the microcontroller be carried out comfortably but the most varied types of graphics can be displayed on the screen of the mobile hand-held unit thereby supporting the operation on-site or even remotely.

Description

Method for controlling / regulating machine sequences or processes as well as control / regulating device

Technical area

The invention relates to a method for controlling / regulating machine sequences or processes by means of standardized control and control devices, in particular micro-controllers with stationary user interface. The invention further relates to a control / regulating device for machine processes or processes by means of standardized control and control devices, in particular micro-controllers, with fixed operator interface.

State of the art

The control of machine operations or processes is a very wide area. This is solved today with two approaches. A first approach is the control of machine operations including the corresponding processes, e.g. Die casting and injection molding machines. Here, a very large amount of intervention in a larger number of components must be made. Only the machine manufacturer has process and machine knowledge, so that at least the important control components are produced by him. It was used a variety of computers and memories, PLC and medium and larger screens PC's and special control units.

A second approach is the control / regulation of individual parameters in less complex machine processes and processes. Particularly common are those applications in which a temperature with conventional sensors (eg, platinum sensors, thermocouple, NTC, etc.) are regulated or controlled. However, there is a large variety of other applications, such as pH, ORP, conductivity, eg of ultrapure water, oxygen (dissolved) - measurement, further for OeI and water bath controller, dosing controller, reactor controller, cascades Controllers, master-slave controllers, program controllers, temperature controllers, safety controllers, controllers for night operation, laboratory controllers, pressure and vacuum controllers, - -

Process controller, thermostat, microstat, etc. The common in all these applications are the highest control requirements, both in terms of control stability and control quality. In this second approach, entire series have been developed from the simplest to the most complex controllers. The controllers have established themselves in practice with great success, so that standards (for example DIN standards) have become established for them, especially for the external dimensions. These standard regulators are produced in large numbers, but have no direct reference to the actual application at the time of delivery. The concrete reference only arises through the installation at the user. An independent class of controllers, the so-called micro-controllers, has emerged, with smallest front dimensions of e.g. 96 x 96, 96 x 48, 48 x 96, 48 x 48, 48 x 24 mm. This means that with the smallest micro-controller, the maximum possible user interface on the front has a straight thumb size. This requires a miniaturization of the display panel of the user interface. So that the most important information, e.g. If the temperature display for a temperature controller is also readable from a certain distance, the display for letters, numbers and characters has been limited to only two displays with four digits each. Another absolutely central factor for micro-controllers is the manufacturing or selling price. This is unbeatably deep by manufacturing in huge quantities. In addition to the two displays mentioned above, the control panel also has buttons for entering or changing the parameters as up / down keys or + (plus) - (minus) keys and start / stop keys. The control panel is thus almost completely used. In order to be able to select and correct different modes of operation, the two displays are used and displayed in the restricted field characters in the manner of "hieroglyphics" whose meaning is found in a manual. It follows from the above that the operation of the micro-controller is uncomfortable, at least when a greater influence on different modes and not just a numerical value must be read.

The new invention has now been based on the object to facilitate the operation and to improve the ease of use without massively increase the production costs.

Presentation of the invention

The inventive method is characterized in that the control / regulation of the machine sequence and the process on a separate, designed as an application-specific man-machine interface (MMI) mobile handset is executed.

The control / regulating device according to the invention is characterized in that a separate mobile handset designed as an application-specific human-machine interface (MMI) is provided for more comfortable operation, wherein the mobile hand-held device is programmed for data exchange in both directions and the microcomputer is programmed. Controller has appropriate adaptations.

The new invention solves the task in a surprising way. In practice, it is possible for the mobile handset latest mobile telephones, e.g. the so-called mobile phone or analog industrial-grade devices, which are available because of the enormous mass production at low prices. The mobile handset must first be programmed in an application-specific manner and the microcontroller must be adapted. Programming is a one-time job for every application. Commercially available components can be used to adapt the microcontroller so that the user receives a cost-effective solution for this as well.

A particular aspect of the new invention is that an equally inexpensive controller was created for an extremely low-cost controller, which were previously possible in many respects only with user interfaces with PC and screens. According to the new invention, the stationary user interface is left in an aboslutem miniature format again created in a slightly enlarged format, however, user-friendly. The application-specific embodiment allows a number of particularly advantageous solutions, for which reference is made to claims 2 to 4 and 6 to 14.

A particularly important aspect is that the stationary operator interface of the control and regulating device or microcontroller designed as a segment LED display re-displays the given information on the mobile handset in the user language and enters and / or commands corresponding control commands on the MMI handset be changed. In the mobile hand-held device, the information reduced to code characters on the stationary user interface is converted into the language of the user by appropriate programming, so that he does not have to resort to every major intervention in the manual. The mobile handset can be used with corresponding, eg wireless data transmission, as a remote control device. When activating the mobile handset can the fixed operator interfaces are locked in relation to inputs. Conversely, it is possible to block the mobile operator interface on the fixed operator surface. Apart from the size of the user interface, the new solution in terms of user-friendliness comes close to a PLC or PC solution, but which costs many times. For this purpose, the user interface of the mobile handset is designed so that the process flow and associated parameters can be configured on a mini screen or retrieved and changed as a configuration menu. The data exchange between the fixed microcontroller and the mobile handset can be done via a wire connection or wirelessly.

On the mobile handset, a screen display is arranged for selecting and displaying various modes, with the word display being in the operator language. The mobile handset is programmed so that on the screen of the mobile handset, a mode display and a selectable parameter display can be called, which can be changed and set via a keyboard. For this purpose, the user interface of the mobile handset on a screen with a display field for selectable modes and a parameterization field for the input and modification of parameters and a keyboard for corresponding inputs or control commands. Thus, the new solution allows ease of use, which in many aspects offers advantages compared to a PLC with screen. Because the handset is mobile, the machine or the process can be remotely operated, especially when connected wirelessly. In particular, the handset can be placed directly on a site to be tested in a facility and the intervention e.g. for service, to be done on site.

The control / regulating device has a microprocessor-controlled regulating and control device with a standard housing, and the mobile handset can be designed as a commercially available mobile phone or PDA or smartphone with appropriate programming. Both parts together result in an unexpected low price, because each of the components are mass-produced commercial parts. Prerequisite is only the user-specific program parts and corresponding electronic components for data exchange. The data exchange between the control unit and the mobile handset takes place in both directions, eg via radio, IR, IrDA, Wireless USB, WLAN B / G or Bluetooth signals. All important information, such as software version, date of manufacture, control and control parameters, configuration parameters are interchangeable and can be displayed on the screen and also changed on site. The data exchange can be as mentioned with - -

commercially available mobile phones (SMS, EMS & MMS formats), PDA, or Smartphone via radio, IR, IrDA, Bluetooth, WirelessUSB or WLAN B / G done. The data exchange is based on additional electronics, which are either integrated on the motherboard, plugged into a special additional module on the motherboard or plugged as an external module in an additional module in the standard housing. Because these are also extremely low-cost trading components, the final price is only slightly larger. Specifically, the data exchange between the electronic controller to a Bluetooth transmitter / receiver via the standard USB interface / plug in the housing with a standard USB <-> Bluetooth adapter is formed.

On the screen of the mobile handset of the control or control process is graphically displayed and / or stored in the mobile handset. Further, the mobile handset has an interface for an evaluation unit (e.g., PC, laptop, etc.) with the possibility of paper-based documentation e.g. to create measurement reports. A memory stick as a storage medium or a USB <-> Bluetooth adapter can be connected to the standardized controller and control unit.

Brief description of the invention

The invention will now be explained with reference to some embodiments with further details. Show it:

Figure 1 a schematically shows a micro-controller with additional Bluetooth adapter / memory (memory stick); Figure 1 b shows two alternatives to Figure 1 a with special additional module, either mounted on the motherboard or an external module can be inserted into the housing; Figure 1 c shows an example of the new invention with a mobile handset to a corresponding converted standard micro-controller; FIG. 2 is a flow chart for the sequences of operations; Figure 3a micro-controller of the prior art with four different standard dimensions; Figures 3b to 3d three different standard housing with the appropriate dimensions in mm; FIGS. 4a and 4b show examples of the additional electronic equipment of a standard microcontroller; FIG. 5 shows an application example for a sterilization apparatus; Figure 6 shows another example of the temperature control of a plastic extruder; Figure 7 shows the user interface of a microcontroller of the prior art; FIG. 8 shows the possibility of specifying the model for the microcontroller; Figure 9a is a small excerpt from the user manual for a micro-controller according to the prior art, based on the symbol language; FIG. 9b shows another example from the operator manual for the meaning of the inputs of the language of the operator according to the prior art.

Ways and execution of the invention

FIG. 1a shows the housing contours of a microcontroller 1 with an operator interface shown only diagrammatically on the front side 2 of the housing 3. The user interface of the front side 2 of the microcontroller according to the prior art is shown in FIG. In the prior art, data exchange takes place via an RS-232/422/485 interface on the rear of the device. According to the embodiment of the new invention, the USB connector 4 (USB versions: 1 .0; 1 .1; 2.0) is mounted on the front side 2. At any time, the customer can easily exchange measurement data, software version, control and control parameters, device settings / configurations with another platform (PC, laptop, notebook, mobile phone, PDA, Smartform, etc.) , The data can be exchanged via a data cable or just with a standard USB memory stick. The controller can also function as a data logger, and the measured data can be further processed later on an evaluation unit. Thus, the requirements of the FDA 21 CFR Part 1 1 (Auditor Features, Audit Trail, Electornic Signing, etc.) can be met in an elegant way. The necessary USB plug (4) is installed in the housing or soldered to the board so that the USB memory stick (5) can be simply plugged in or removed from the front of the controller by the customer. So that the high IP protection of the front of the micro-controller can be maintained without memory stick 5, a protective cap (6) is inserted into the opening when the plug is not in use. The micro-controller is characterized in that on the front side, for example, an IP 65 protected plug is attached. The protection must be removed so that a USB memory (memory stick) can be inserted. All important information, such as software version, manufacturing date, control and control parameters, measurement and configuration data with standard platforms (PC, laptop, notebook, PDA, mobile phone, smartphone, etc.) via this USB memory Stick exchanged. The data exchange via a commercially available USB memory (memory stick) can also be used with PC, laptop, notebook, mobile phone, PDA, smartphone, host computer, etc., USB versions 1 .0; 1 .1; 2.0 done.

In the microprocessor-controlled control and control devices in the mold housings, customers often require archiving of the control measurement and control parameters on commercially available platforms such as PCs, laptops, notebooks, smartphones, cell phones, PDAs, etc., for example the fulfillment of the FDA 21 CFR Part 1 1 demands. Once all the important exchange data have been saved on the USB memory stick, the customer can remove the memory stick and then plug the stick into the evaluation station (the various platforms) where the data is read in to evaluate it later , edit, archive, etc. to be able to. In this way, new software-up-dates can take place, or even the important data, such as control parameters, configuration and measurement data for a service department over the mobile network, Internet, etc. are made available.

FIG. 1b shows two variants of FIG. 1a. The necessary additional electronics can either be integrated on the motherboard (7) or plugged into a special additional module on the motherboard or plugged as an external module (3) in an additional module in the standard housing. The data exchange can also take place here with the commercially available mobile phones (SMS, EMS & MMS formats) or PDAs via radio, IrDA, Bluetooth or WLAN B / G. The operation is characterized in that the data exchange takes place in both directions via radio, IrDA, Bluetooth signals. All important information such as software version, manufacturing date, control and control parameters can also be exchanged here, displayed on the screen 10 of the mobile handset 9 or also changed on site. It can completely leave the input option on the micro-controller or locked, which is usually done there via the input UP / Down buttons and is displayed via seven segment LEDs.

The connection to the standard controller is via radio, IrDA or Bluetooth to the PDA or mobile phone with any operating system. The transmitter / receiver can be integrated in the controller or installed or plugged in as a module. Advantages: the customer or the service department, development, marketing, sales of the manufacturer, dealer, programmed worldwide, in all world languages can directly retrieve the data of the controller, make changes, download new software versions, set and verify process parameters, manufacturer information (Serial number, date of manufacture, SW version, etc.), documenting the data - o -

a commercial printer, transferring the data to a Microsoft Office document, storing the data on a database / server, using the data for the in-house Q system.

All applications are possible where e.g. a temperature with the usual sensors (platinum sensors, thermocouple, NTC, etc.) should be regulated. Furthermore, applications for pH, redox, conductivity, - ultrapure water, dissolved oxygen (ge triggers) -, regulators, oil and water bath controller, dosing controller, reactor controller, cascade controller, master / slave Controllers, program controllers, temperature controllers, safety controllers, regulators for night operation, laboratory controllers, pressure and vacuum controllers, general-purpose process controllers, thermostats, microstat.

The microprocessor controlled controllers in the standard housings with LED and LCD displays have from time to time to download new software versions from customers or service personnel or other important parameters, such as those shown in FIG. Date of manufacture, control or control parameters can be displayed or changed. Since the displays are only equipped with numeric LED displays or even very small LCD displays, this requirement can be met via a standard mobile phone (with SMS, EMS or MMS) or a PDA via radio, IrDA, Bluethooth or WLAN B / G ,

FIG. 1 c shows a further embodiment of the above-mentioned control applications. The necessary additional electronics can also be integrated here either on the main board (7) or plugged into a special additional module (8) on the motherboard or plugged as an external module in an additional module in the standard housing (USB connector (4); USB < -> Bluetooth adapter (5)). The interface, electronic controller to Bluetooth transmitter / receiver can be done via the standard USB interface (version 1 .0 to 2.0) with a standard USB <-> Bluetooth adapter.

Operation is via a mobile phone or PDA 9. It is of great advantage if the mobile handset 9 has a mini-screen 10 and the necessary input keys 1 1 and a cursor. On the right in FIG. 1 c is an example of a user interface for the mobile handset. With the cursor as well as a key MODE all representable or programmable schemes and tables can be called up on the screen. The important point here is that on the screen surface of the mobile handset due to appropriate programming all text parts appear in clear text in the user language. The - y -

Manual is thus, as far as the operation of the mobile handset 9, no longer needed. At the operator interface, all required keys, e.g. for the mode selection, Out-Off 1 3 and for entering and changing parameter values or the raising and lowering of the same via corresponding keys 14. Again, the operation is characterized in that the data exchange in both directions via radio , IR, IrDA, Wireless USB Wi-Fi B / G or Bluetooth signals. All important information such as software version, manufacturing date, control and control parameters, configuration parameters can be exchanged, displayed on the screens or even changed on site.

The customer or service personnel must be able to download new software versions or other important parameters, such Date of manufacture, controller or control configuration parameters can be displayed or changed. Since the displays are only equipped with numerical LED displays or very small LCD displays, this requirement can be met with a mobile handheld device.

With the data of the controller changes can be made, new software versions can be downloaded, process parameters set and checked, also manufacturer information (series number, date of manufacture, SW version, etc.), retrieved, data printed on a standard printer, data in a Microsoft Office document, data is stored on a database or a server and used for the in-house Q system.

FIG. 2 shows a flow chart for the stepwise operations. For each mode, both the symbolic display 100 (as hieroglyphics) and the display in the colloquial language 101 are represented. With the mobile handset, the same representation can be retrieved in any section or period, provided that the corresponding parts have been programmed for it.

FIGS. 3 a to 3d show examples of standardized micro-controllers, in the top of FIG. 3 a as a photographic image, in FIGS. 3 b to 3 c three different magnitudes with dimensions in mm.

Figures 4a and 4b show an example of the electronic equipment of the microcontroller. The controller data / parameters are stored in the volatile / non-volatile memory (21) (RAM, EEPROM) and are transmitted via the internal data bus 22 via a commercial USB converter IC 23 (version 1 .0 or 2.0) to the USB Bus plug 24 forwarded. The plug can be soldered directly into the print 25 or be connected via cable 26, ribbon 27 to the printed circuit. The USB connector is connected from the front side 2 or on any other side 29 of the housing via a corresponding opening 30 with the printed circuit board. The plug can be mounted vertically 31 or horizontally 32 to the housing surface. The standard connectors can be used in either single 34 or multiple 35 versions. It is important that the connector quality is very high regarding the number of mating cycles (especially thick gold coating). Thus, the usual high degree of protection, such as IP 64, can be obtained, the plug must be covered when not in use with a waterproof and dustproof cap 36. The protective cap can be connected to the housing by means of a chain 37 or cord 38 or can be enclosed in a multiple version of the packaging.

The connection to the standard controller is via radio, IrDA or Bluetooth to the PDA or mobile phone with any operating system. The transmitter / receiver can be integrated in the controller or installed or plugged in as a module. The interface to the internal controller electronics can be made via a standard USB interface (version: 1 .0 to 2.0). A standard USB <-> Bluetooth adapter can thus be used. Manufacturer information (serial number, date of manufacture, 'SW version, etc.) can be documented using a commercially available printer. Furthermore, this data can be further processed or stored in software databases, Microsoft Office documents (database, server, etc.). This information can then be used e.g. be taken over by the internal company Q system (process proofs, etc.).

The data exchange takes place via a necessary additional electronics, which are either integrated on the main board 41, plugged into the motherboard in a special additional module 42 or plugged into the standard housing as an external module 47 in an additional module, USB plug 44; USB <-> Bluetooth adapter 5. The data exchange between the electronic controller and the Bluetooth transmitter / receiver can be made via the standard USB interface / plug in the housing (version 1 .0 to 2.0) with a commercially available USB <-> Bluetooth adapter , _ _

FIG. 5 shows an application example for the temperature control for a sterilizer (top) as well as a control / regulation of the ramps. The picture is just one example of the fact that two or more controllers can be operated via the mobile handset.

FIG. 6 shows a further application example for the temperature control / regulation in a plastics extruder.

FIG. 7 shows the user interface 15 in the case of a microcontroller with the smallest dimensions. It has only one field 1 6 for numbers, letters and symbol displays. The key 1 7 is for the increase and the key 1 8 for the reduction of the numerical values. The desired mode is selected with the MODE button 19. With the switch 20, the indicator can be switched on or off. The letters a, b, etc. are LEDs for status indications of the process.

Figure 8 shows a sticker as it is glued directly to the micro-controller on a side wall. The sticker contains all information about the specific controller, such as manufacturing data, exact type of the device, serial number and the device configuration. In the installed state of the micro-controller, the adhesive is no longer accessible. The new invention now allows the corresponding information to be programmed into the mobile handset and displayed at any time. At the same time, the specific software version can be displayed on the screen, so that in the case of service work or for the programming of new software they are easily accessible.

FIG. 9a shows a small extract from the user manual for a prior art microcontroller, based on the symbol language.

FIG. 9b shows another example from the operator manual for the meaning of the inputs of the language of the operator according to the prior art.

Claims

claims

1. A method for controlling / regulating machine sequences or processes by means of standardized control and control devices, in particular microcontrollers with fixed operator interface, characterized in that the operator in a separate, than application-specific human-

Machine interface (MMI) trained mobile handset operated.

2. The method according to claim 1, characterized in that formed as a segment LED display fixed user interface of the control and regulating device displayed on the mobile handset in the user language and corresponding control commands entered and / or changed the MMI handset.

3. The method according to claim 1 or 2, characterized in that upon activation of the mobile handset, the stationary user interface is locked with respect to inputs and / or the mobile user interface can be locked on the stationary user interface.

4. The method according to any one of claims 1 to 3, characterized in that the mobile handset, the process flow and associated parameters can be configured on a mini-screen or retrieved as a configuration menu and changed.

5. Control / regulating device for machine processes or processes by means of standardized control and control devices, in particular micro-controllers with stationary user interface, characterized in that provided for a more comfortable operation a separate, as an application-specific human-machine interface (MMI) trained mobile handset is, wherein the mobile handset is programmed for a data exchange in both directions and the micro-controller has corresponding adaptations. - IO

6. Control / regulating device according to claim 5, characterized in that a wire connection or a wireless connection is provided for the data exchange.

7. Control / regulating device according to claim 5 or 6, characterized in that the mobile handset, a screen display is arranged for the selection and display of various modes, wherein the display is in the user language.

8. Control / regulating device according to one of claims 5 to 7, characterized in that on the screen of the mobile handset, a mode display and a selectable parameter display can be called, which is variable via a keyboard or adjustable.

9. Control / regulating device according to one of claims 5 to 8, characterized in that the user interface of the mobile handset has a screen with a display panel of different modes and a parameter setting for the input and modification of parameters and a keyboard for corresponding inputs or control commands ,

10. Control / regulating device according to one of claims 5 to 9, characterized in that it comprises a microprocessor-controlled controller and control unit with a standard housing and the mobile handset is designed as a commercially available mobile phone or PDA or smartphone with appropriate programming.

11. Control / regulating device according to one of claims 5 to 10, characterized in that the data exchange between the control and control device and the mobile handset in both directions via radio, IR, IrDA, WirelessUSB, WLAN B / G or Bluetooth Signals takes place, wherein all important information, such as software version, date of manufacture, control and control parameters, configuration parameters are aus¬ exchanged and displayed on the screen or can be changed on site. _

12. Control / regulating device according to one of claims 5 to 11, characterized in that the data exchange with commercially available mobile phones (SMS, EMS & MMS formats), PDA, or smartphone via radio, IR, IrDA, Bluetooth, wireless USB or WLAN B / G takes place.

13. Control VRegelgerät according to one of claims 5 to 12, characterized in that the data exchange takes place via a necessary additional electronics, which are either integrated on the motherboard, plugged into a special additional module on the motherboard or as an external module in an additional module in the standard - Housing is inserted.

14. Control / regulating device according to claim 13, characterized in that the data exchange between the electronic controller to a Bluetooth transmitter / receiver via the standard USB interface / plug in the housing with a standard USB <-> Bluetooth adapter takes place.

15. Control / regulating device according to one of claims 5 to 13, characterized in that on the screen of the mobile handset of the control or control flow graphically displayed and / or stored in the mobile handset.

16. Control / regulation device according to claim 15, characterized in that the mobile handset has an interface for an evaluation unit (for example PC, laptop, etc.) with the possibility of paper-based documentation, e.g. for measurement reports.

17. Control / regulating device according to one of claims 5 to 16, characterized in that a memory stick as a storage medium or a USB <-> Bluetooth adapter can be connected to the standardized control and control device.