DE102019122477A1 - Sensor device, sensor arrangement, sensor system and method for the transmission of signal states - Google Patents

Abstract

Existing industrial plants / production lines are usually equipped with different machines (3, 3 ', 3 ") which have different signal lamps (1, 1', 1"). The signal lamps (1, 1 ', 1 ") are used to monitor the status of the machines (3, 3', 3"), such as B. to signal their operating temperature or the like visually. The problem to be solved is to get the status signals of various machines (3, 3 ', 3 ") and signal lamps (1, 1', 1") with the least possible effort and possible without changing the industrial plant to optimize its control. For this purpose, a sensor device (2, 2 ') with light detectors (20, 200) is proposed, which detects the optical signals of the signal lamps (1, 1', 1 "), digitized, in Converts status data and feeds it via a radio interface (23) to an evaluation and / or analysis device (5), which can also have a connection to a cloud (4) and / or have an IIoT gateway.

Description

The invention is based on a sensor device for the transmission of signal states according to the preamble of independent claim 1.

Furthermore, the invention is based on a sensor arrangement having several such sensor devices and several signal lamps.

In addition, the invention is based on a sensor system having such a sensor arrangement and an evaluation and / or analysis device.

Furthermore, the invention is based on a method for transmitting signal states.

Such sensor devices, sensor arrangements, sensor systems and methods serve to transmit signal states and can be used, for example, to signal and / or evaluate the state of complex industrial plants, in particular a production plant.

State of the art

In the prior art, various devices and methods for signaling the state of a complex industrial plant, for example a production plant consisting of several machines, also using wireless signal transmission, are known.

The pamphlet DE 101 24 132 A1 shows a display column for displaying machine activity, in particular machine malfunctions, with a base element and at least one light element for visually perceiving the machine activity and possibly an acoustic element for acoustic perception of the machine activity, the display column being assigned at least one radio module which is connected to a receiver Connection.

The pamphlet EP 1 575 011 A1 discloses a signal column 1 which is able to generate signals outside the range of the usual optical and acoustic signals. For this purpose, a wireless transmission unit is provided for the transmission of data to a receiver, the transmission unit being arranged in an exchangeable module.

The pamphlet EP 2 209 099 A1 proposes a warning light device with at least two warning lights. This is characterized in that the display unit is designed as a signal column with at least one second interchangeable module comprising at least one second light-emitting element or module light-emitting element. Compared to a screen as a display unit according to the prior art, a display unit designed as a signal column is much less expensive to manufacture and can be integrated into a signal column system / network significantly more cost-effectively and better.

The disadvantage of the current state of the art is that many signal lamps that already exist on the market and are installed in industrial plants do not have a common network interface at all. Furthermore, many industrial plants have grown historically and have machines that can use different protocols accordingly. If some of the signal lamps already have radio modules, or at least a retrofit option for such radio modules, these radio modules are often not compatible either.

A later integration of an evaluation and analysis device in an already existing industrial plant, e.g. B. a production plant, so for example the integration of an additional industrial computer for cloud connection in an existing production line, is therefore often problematic in the current state of the art. Finally, for the reasons mentioned above, retrofitting the industrial systems is associated with undesirably high costs and, in the worst case, with undesirable downtimes of the industrial system.

Task

The object of the invention is to reduce the effort that is necessary to integrate an additional evaluation and analysis device into an existing industrial plant.

This object is achieved by the characteristics of the independent claims.

A sensor device is used to transmit signal states from machines in an industrial plant to an evaluation and / or analysis device.

The sensor device has at least one light detector. This is used to detect and convert at least one light signal from a signal lamp connected to one of the machines into at least one electrical signal.

The sensor device also has a microprocessor which is connected to the at least one light detector via at least one electrically conductive connection. This microprocessor initially serves to receive the at least one electrical signal from the detector via the at least one electrically conductive connection. The microprocessor is also used to process the at least one electrical signal in status data. In particular, the processor can be set up to convert a large number of such electrical signals into status data. For this purpose, the microprocessor can, for example, have a CPU (central processing unit = main processor) and a combined data and program memory. An executable program which is suitable for said processing of the at least one electrical signal into status data can be stored in the combined data and program memory. These status data describe the status of the machines belonging to the industrial plant and thus also the status of the industrial plant.

Furthermore, the sensor device has a wireless transmission interface connected to the microprocessor via a data line for wireless transmission of the status data to the evaluation and / or analysis device.

The aforementioned industrial plant can be, for example, a production plant, for example a production line, a machine park and / or a power plant, etc.

• Bei der Auswert- und/oder Analyseeinrichtung kann es sich um einen separaten Computer, insbesondere einen Industrierechner, handeln, der insbesondere dazu in der Lage ist, eine Netzwerkanbindung und insbesondere eine Cloudanbindung herzustellen. Die Auswert- und/oder Analyseeinrichtung kann dann beispielsweise Zustandsdaten an eine Cloud o. ä. übertragen und insbesondere auch selbst verarbeiten.

The possible applications of such a sensor device in connection with the said evaluation and / or analysis device are diverse. Some of these are presented below by way of example and not in a limiting manner in order to give an idea of their benefits:

• The evaluation and / or analysis device can be a separate computer, in particular an industrial computer, which is in particular able to establish a network connection and in particular a cloud connection. The evaluation and / or analysis device can then, for example, transmit status data to a cloud or the like and in particular also process it itself.

Alternatively or in addition, the status data can be collected, merged and evaluated at a central point on a dashboard or in a long-term analysis by a so-called “IIoT” (Industrial Internet of Things) gateway. Such an IIoT gateway is basically characterized by the fact that the data is at least partially on site, e.g. B. directly on the end device and / or within a factory or the like, can be processed, but the method still benefits from the advantages of the cloud.

The evaluation and / or analysis device can therefore have a computer, in particular with a cloud connection. The computer, e.g. B. a central computer, for example, can then also be used in a decentralized manner to take appropriate measures, e.g. B. when a certain material is running low or missing in an industrial plant, especially a production plant. Alternatively or additionally, the industrial plant can also be controlled via the cloud.

Measures to protect the industrial plant can also be initiated, taking into account additional external information, for example certain environmental conditions, e.g. B. Weather conditions o. Ä., Relate. These can then, for example, also be associated with a forecast, for example with a weather forecast, with the available information about the current state of the industrial plant also being taken into account in the analysis, of course. This means that preventive action can also be taken, i.e. before the industrial plant z. B. threatens to overheat and / or is exposed to too high humidity, whereby certain materials, such. B. plastics, no longer behave optimally, z. B. can no longer be processed optimally, a cooling process no longer takes place optimally, etc.

In addition, the evaluation and / or analysis device can also be used in an advantageous embodiment to manually or automatically trigger or take over separate control functions in a decentralized manner, e.g. B. to switch on a water cooling system as soon as a single machine signals overheating, or switch on an air conditioning system to e.g. B. to support and / or protect manufactured products during their cooling process, etc.

Advantageous embodiments of the invention are specified in the subclaims.

In an advantageous embodiment, the electrical signal which is transmitted from the light detector of the sensor device to its microprocessor can be, for example, a discrete signal which, in particular, can only assume two states (“on / off”). This simplifies the data transfer.

In another advantageous embodiment, this electrical signal can also be a discrete signal which can assume more than two states. In this way, at the same time as the binary status (“On / Off”), at least one additional piece of information, e.g. B. the color of the light signal are transmitted.

In a further advantageous embodiment, the electrical signal which is transmitted from the light detector to the microprocessor can also be a continuous signal. Then the microprocessor can output the signal e.g. B. in convert / digitize two or more states (e.g. "On / Off") by e.g. B. the over or

Falling below a threshold value registered. This variant is particularly advantageous because the microprocessor can be adapted particularly flexibly to different light detectors through its program, that is to say on the software side.

In a further advantageous embodiment, the electrical signal can also be a data signal, that is to say a coded bit sequence. This has the advantage that the signal is already converted into data in the light detector, as a result of which the entire computing power is optimized in a decentralized manner by automatically increasing with the number of signals to be detected and the number of light detectors.

The transmission of the signal from the light detector to the microprocessor can take place particularly advantageously by means of a so-called “interrupt”. Such an interrupt is usually characterized by the fact that the microprocessor interrupts its previously planned program sequence at a connection provided for this purpose by means of an interrupt signal applied to it and first jumps to a separate program part provided for this purpose, namely an ISR (Interrupt Service Routine), to address it to be processed with priority. In the present case, the light detector can request the microprocessor in such an ISR to receive the electrical signal at any time. The microprocessor then continues its planned program sequence at the previously interrupted point.

In a preferred embodiment, the sensor device is able to use each light detector to determine two signal states, namely “on” and “off”. This is particularly advantageous when a light detector is attached to each light source.

In an advantageous embodiment, the sensor device can provide an associated light detector for each light signal to be detected, in particular for each light source of the signal lamp. This light detector is able to detect the light intensity of the light signal in question.

This is particularly advantageous because it enables fast and inexpensive digitization. Furthermore, this results in a particularly low susceptibility to errors. Finally, each light detector is then set up to detect only the intensity of the light signal from the light source on which it is arranged.

In another advantageous embodiment, the sensor device provides a color-selective light detector for detecting several mutually differently colored light signals, which is therefore suitable for detecting not only the intensity, but also the color of the respective light signal. This has the advantage that detectors are saved, as a result of which costs and installation space can be saved.

In a particularly preferred embodiment, this color-selective light detector can be connected to all differently colored light sources of a signal lamp via one light line, e.g. B. an optical fiber, in particular a fiber optic cable, be connected. Thus, the sensor device provides a light guide for several of the light signals to be detected, which guides the light signal to the light detector. As a result, the light sensor can be positioned flexibly, which advantageously simplifies the construction of the sensor arrangement and its assembly.

Alternatively or in addition, the color-selective light detector can be arranged in the vicinity of one of the light sources of the signal lamp and connected to the other light sources of this signal lamp via light lines, e.g. B. fiber optic cables, in particular fiber optic cables, be connected. This advantageously saves a light guide compared to the aforementioned variant. For a number n of light signals to be detected, only n-1 light guides are then ultimately required. If the signal lamp has more than two light sources, i.e. the number of light signals is n> 2, in this case too the light detector is connected to several differently colored light sources of the signal lamp via one optical waveguide each.

In a particularly advantageous embodiment, the light detector can be a photovoltaic cell, in particular a solar cell. As a result, the energy required for processing the light signal can be obtained from the light signal at the same time. Alternatively, the photovoltaic cell, in particular the solar cell, can also be used exclusively for the purpose of generating electrical energy and in addition to the said light detector.

A sensor arrangement can have several of these sensor devices and several signal lamps, each with several different colored light sources. One of the sensor devices can then be arranged on each signal lamp. In particular, the attachment of the sensor device to the associated signal lamp is particularly advantageous because it allows the position of the light detectors relative to the light sources to be optimally determined and for the time being is immutable. In this way, the incidence of scattered light can also be effectively and reliably prevented.

A sensor system can have such a sensor arrangement and also an evaluation and analysis device. As already mentioned, each sensor device has an interface for wireless transmission methods, in particular a radio interface. The evaluation and analysis device has a further wireless transmission interface, in particular a radio interface. The wireless transmission interface of the sensor device and the further wireless transmission interface of the evaluation and analysis device are in radio communication with one another. It can thus process the said light signals from the signal lamp on which it is arranged to form status data and transmit this status data via this wireless transmission interface via the radio link to the further wireless transmission interface of the evaluation and / or analysis device.

Furthermore, the evaluation and / or analysis device can be set up to transmit status data to a cloud. Alternatively or additionally, it can be set up to process the status data itself and to collect it decentrally in the form of an IIoT gateway and evaluate it at a central point on a dashboard or in the form of a long-term analysis.

• Eine Maschine kann zu einer Industrieanlage, beispielsweise zu einem Maschinenpark, einer Fertigungsstraße, etc. gehören. Weiterhin kann sie verschiedene Zustände besitzen, z. B. Auslastung, Temperatur, Energieverbrauch, ablaufendes Wartungsintervalle, etc. sowie weitere individuelle maschinenspezifische Parameter.

In the following, a method for transmitting signal states, e.g. B. with a sensor device and in particular a sensor arrangement, in particular a sensor system of the aforementioned type, described:

• A machine can be part of an industrial plant, for example a machine park, a production line, etc. Furthermore, it can have different states, e.g. B. utilization, temperature, energy consumption, expiring maintenance intervals, etc. as well as other individual machine-specific parameters.

A signal lamp is connected to each of these machines. This signals at least one state of the machine by means of at least one light signal. Different machines can use different protocols to transmit their states to the signal lamps connected to them. The signal lamps connected to the respective machines are adapted to the respective protocol in order to visually signal the states of the machines to which they are connected. Many industrial plants have grown historically in this way.

In order to monitor the state of such industrial plants with a uniform sensor arrangement and to be able to continue to use this sensor arrangement universally, the light signals of the light sources of the said signal lamps, which already exist in the industrial plant, are now read out by means of light detectors. For this purpose, at least the intensity of the respective light signal is detected.

The respective light signal is converted into at least one electrical signal by the associated light detector and then transmitted to a microprocessor, for example by means of the aforementioned interrupt.

The microprocessor can now use its program to obtain status data therefrom and transmit it to an evaluation and / or analysis device via a wireless transmission interface.

Such a sensor arrangement and such a method are particularly advantageous because the status signals of many different industrial systems can be standardized as a result. The said sensor system can therefore be integrated and put into operation in a large number of different industrial plants without further ado and with extremely little effort, without disadvantageously interrupting the operation of the industrial plants.

Figure list

• 1a eine Signallampe mit einer Sensorvorrichtung mit mehreren Lichtdetektoren;
• 1b eine Signallampe mit einer modifizierten Sensorvorrichtung mit einem Lichtdetektor und mehreren Lichtwellenleitern;
• 2 eine Industrieanlage mit mehreren Maschinen und einem intergierten Sensorsystem.

An embodiment of the invention is shown in the drawings and is explained in more detail below. Show it:

• 1a a signal lamp with a sensor device with a plurality of light detectors;
• 1b a signal lamp with a modified sensor device with a light detector and several optical fibers;
• 2 an industrial plant with several machines and an integrated sensor system.

The figures contain partially simplified, schematic representations. In some cases, identical reference symbols are used for identical, but possibly not identical elements. Different views of the same elements could be scaled differently.

The 1 shows a signal lamp, the four different colored
Light sources 10 , 10 ' , 10 " , 10 ''' owns. At every
Light source 10 , 10 ' , 10 " , 10 ''' is a light detector 20th a sensor device 2 arranged. At the light detector 20th it is a pure brightness detector, i.e. the intensity of the light signal the respective light source 10 , 10 ' , 10 " , 10 ''' on which it is arranged measures. These four light detectors 20th can therefore be similar to each other.

Of course, the number of light sources is chosen as an example. A different number of light sources could also be used in other designs as required 10 , 10 ' , 10 " , 10 ''' and detectors 20th be provided, e.g. B. one, two, three, five, six seven or eight, or any other natural number.

The light detectors 20th receive the respective light signal from that light source 10 , 10 ' , 10 " , 10 ''' where they are arranged and convert it into an electrical signal. This electrical signal is generated via electrically conductive connections 21st , 21 ' , 21 " , 21 ''' to a microprocessor 22nd the sensor device 2 transfer.

The microprocessor 22nd has a combined working and program memory in which a microprocessor 22nd executable program is stored. This program is used to convert the electrical signals into status data.

The sensor device also has 2 a radio interface 23 for wireless transmission of status data. This radio interface 23 is for this purpose via a data line 231 to the microprocessor 22nd connected.

• ART: „Betriebstemperatur“; ZUSTAND: „Überhitzt‟/ „In Ordnung“
• ART: „Luftfeuchtigkeit“; ZUSTAND: „Im akzeptablen Bereich“/ „Kritisch“
• ART: „Wartungsintervall“; ZUSTAND: „Abgelaufen“/ „noch nicht abgelaufen“, etc.

The 1b shows the signal lamp 1 with a slightly modified sensor device compared to the previous illustration 2 ' . The difference is that the modified sensor device only has a single, but also color-sensitive light detector 200 owns. This is via fiber optics 210 , 210 ' , 210 " , 210 ''' with the different colored light sources 10 , 10 ' , 10 " , 10 ''' connected. The light detector analyzes the color and the intensity (brightness) 200 the type and status of the signal, e.g. in the following form:

• TYPE: "Operating Temperature"; CONDITION: "Overheated" / "OK"
• TYPE: "Humidity"; CONDITION: "In the acceptable range" / "Critical"
• ART: "Maintenance Interval"; CONDITION: "Expired" / "Not yet expired", etc.

Via a single electrically conductive connection 21 '''' transmits the color-sensitive light detector 200 this information to the microprocessor 22nd , which in turn processes these into status data and sends them to the radio interface 23 transmits. Should have two light sources at the same time 10 , 10 ' , 10 " , 10 ''' light up, the color-sensitive light detector can measure this simultaneously and transmit it either simultaneously by means of a correspondingly more complex electrical signal or sequentially via the single electrically conductive connection. In another version, instead of a single 21 '''' several electrically conductive connections can also be provided.

The 2 shows an industrial plant with three different
machinery 3 , 3 ' , 3 " . To each of the machines 3 , 3 ' , 3 " is a different signal lamp 1 , 1' , 1'' connected. The machines 3 , 3 ' , 3 " use to control their respective signal lamp 1 , 1' , 1'' different protocols.

At every signal lamp 1 , 1' , 1'' is a sensor device 2 attached. Here, as in 1a shown at any light source 10 , 10 ' , 10 " , 10 ''' a light detector 20th arranged to measure the intensity of the light signal. As an alternative to this, the modified sensor device could of course also be used 2 ' from the 1b be used.

Any sensor device 2 converts, as described above, the light signals of the respective signal lamp 1 , 1' , 1" , in status data and transmits this via your radio interface 23 to an evaluation and analysis device 5 which for this purpose a further radio interface 53 having.

The evaluation and analysis device has an IIoT ("Industrial Internet of Things") gate and a connection to a cloud 4th .

The evaluation and analysis device 5 the status information of the machines can be decentralized and / or in connection with other information from the cloud 4th evaluate and analyze. This analysis can be used to optimize the control of the industrial plant.

Even if various aspects or features of the invention are each shown in combination in the figures, it is clear to the person skilled in the art - unless otherwise stated - that the combinations shown and discussed are not the only possible ones. In particular, corresponding units or feature complexes from different exemplary embodiments can be exchanged with one another.

List of reference symbols

1, 1 ', 1' '

different signal lamps

10, 10 ', 10 ", 10' ''

different colored light sources of a signal lamp

2, 2 '

Sensor device, modified sensor device

20th

Light detector (intensity measurement)

200

color-sensitive light detector (intensity and color measurement)

21, 21 ', 21' ', 21' '', 21 '' ''

electrically conductive connections (conductor tracks)

210, 210 ', 210 ", 210' ''

optical fiber

22nd

microprocessor

23

wireless transmission interface / radio interface of the sensor device

231

Data line

3, 3 ', 3 "

machinery

4th

Cloud

5

Evaluation and / or analysis device

53

wireless transmission interface / radio interface of the evaluation and / or analysis device

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• DE 10124132 A1 [0007]
• EP 1575011 A1 [0008]
• EP 2209099 A1 [0009]

Claims (14)

Sensor device (2, 2 ') for transmitting signal states of at least one machine (3, 3', 3 ") of an industrial plant to an evaluation and / or analysis device (5), the sensor device (2, 2 ') having the following: - At least one light detector (20, 200) for detecting and converting at least one light signal of at least one signal lamp (1, 1 ', 1 ") connected to one of the machines (3, 3', 3") into at least one electrical signal; - A microprocessor (22) connected to the at least one light detector 20, 200) for receiving the at least one electrical signal and via at least one electrically conductive connection (21, 21 ', 21 ", 21' '', 21 '' '') for processing this electrical signal into status data; - A wireless transmission interface (23) connected to the microprocessor (22) via a data line (231) for wireless transmission of the status data to the evaluation and / or analysis device (5). Sensor device (2, 2 ') for the transmission of signal states according to Claim 1 , wherein the sensor device (2, 2 ') is set up to determine at least two signal states per light signal by means of a light detector (20, 200), namely “on” and “off”. Sensor device (2) for transmitting signal states according to one of the preceding claims, wherein the sensor device (2, 2 ') provides an associated light detector (20) for each light signal to be detected, which light detector is set up to detect the light intensity of the light signal in question. Sensor device (2 ') according to one of the Claims 1 to 2 , wherein the sensor device (2 ') provides a light detector (200) for the detection of several mutually differently colored light signals, which light detector is set up to detect both the color and the intensity of the respective light signal. Sensor device according to Claim 4 wherein the sensor device provides an optical waveguide (210, 210 ', 210 ", 210"') each for the multiple light signals to be detected, which optical waveguide feeds the respective light signal to the light detector (200). Sensor device according to one of the preceding claims, wherein the respective light detector (20, 200) is a photovoltaic cell. A sensor arrangement comprising a plurality of sensor devices (2, 2 ') according to FIG Claim 1 and several signal lamps (1) each with several mutually differently colored light sources (10, 10 ', 10 ", 10"'), one of the sensor devices (2, 2 ') being arranged on each signal lamp (1). Sensor arrangement according to Claim 7 , wherein each sensor device (2) has several light detectors (20), with an associated light detector (20) being arranged at the light sources (10) of each signal lamp (1), which is set up to transmit the light signal from the associated light source (10) to detect its intensity. Sensor arrangement according to Claim 7 Each sensor device (2 ') has exactly one light detector (200), so that on each signal lamp (1) the sensor device (2') has exactly one light detector (200) for detecting all light sources (10, 10 ', 10 ", 10 "') of this signal lamp (1) is attached, the sensor device (2') each having a separate light line (210, 210 ', 210", 210th for each of these light sources (10, 10', 10 ", 10 '") ''') and is set up to transmit the light signal of the respective light source (10, 10', 10 ", 10 '") to the light detector (200) via the respective light line (210, 210', 210 ", 210"') ), wherein the light detector (200) is designed as a color sensor and is thus set up to distinguish several differently colored light signals by their color and to detect their state by their intensity. Sensor system, comprising a sensor arrangement according to one of the Claims 7 to 9 , the sensor arrangement additionally having an evaluation and / or analysis device (5) with a further wireless transmission interface (53) for receiving the radio signals from the wireless transmission interfaces (23) of the sensor devices (2, 2 '), each sensor device (2, 2 ') is set up to process the said light signals of the signal lamp (1, 1', 1 ") on which it is arranged to form status data and to transfer this status data via its wireless transmission interface (23) to the further wireless transmission interface (53) of the Transferring evaluation and / or analysis device (5). Sensor system according to Claim 10 , wherein the evaluation and / or analysis device (5) is set up to transmit the status data to a cloud (4) and / or to process the status data in a decentralized manner and to transfer them in the form of a so-called "IIoT" (Industrial Internet of Things) -Gateways and evaluate them at a central point on a dashboard or in the form of a long-term analysis. Method for the transmission of signal states, comprising the following steps: a) signaling at least one state of at least one machine (3, 3 ', 3 ") by means of a signal lamp (2, 2') by at least one light signal; b) detecting the light intensity of the at least one light signal by means of at least one light detector (20, 200) ; c) converting the at least one light signal into at least one electrical signal by the light detector (20, 200); d) transmitting the at least one electrical signal to a microprocessor (22); e) obtaining status data from the at least one electrical signal by the Microprocessor (22) by means of a program stored in its combined program / data memory; f) transmission of the status data via a wireless transmission interface (23) to an evaluation and / or analysis device (5). Procedure according to Claim 12 , wherein in step b.) the detection of the light signal also takes place in a color-selective manner; Method according to one of the Claims 12 to 13 , wherein step d.) is carried out by means of an interrupt.

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