DE102022102762A1 - Calculation of a service life characteristic of components operated in an automation system - Google Patents

Abstract

In one aspect, the invention relates to a method for calculating a service life parameter (B10) for a component (K) that is operated in an automation system (AA), with the following method steps: - Recording (S1) of data and in particular a failure signal (a ) the component (K) and detecting (S2) and storing (S3) a cycle counter value at the time the failure signal is detected and causing the cycle counter to be reset (S4) to the value "0";- Aggregating (S6) the detected data, in particular the cycle counter values of several components (K) of the same type and applying (S7) a statistical function (f) to the aggregated data to calculate (S8) a load situation-specific service life parameter (B10);- transmitting (S9) the calculated load situation-specific service life parameter (B10) to the component (K) for controlling (S91) the same and/or the automation system (AA).

Description

The present invention is in the field of automation technology and relates to the reliability of components installed in automation systems.

In today's systems in automation technology, a large number of different components are usually built into complex systems. Depending on the application, the error-free operation of such an automation system is of the highest priority, e.g. in laboratory technology or the pharmaceutical industry.

In order to ensure reliability in previous systems, it is known to determine service life characteristics during the release of components as part of endurance tests and to make these available to the customer (for example with the released component) as a guide value. These service life characteristics are therefore based on data from firmly defined test intervals and operation of the component under laboratory conditions.

A disadvantage of the solution outlined above is that the service life characteristics are determined under laboratory conditions and do not correspond to the real application situation/load situation in the automation system.

It is therefore an object of the present invention to provide more reliable information about the probable service life of a component in the real operating situation in the automation system. In addition, the service life parameters should be calculated on the basis of downtimes actually measured for the respective components. The safety of the system should be improved by a more reliable prediction of the service life parameters.

This object is achieved by the appended patent claims, in particular by a computer-implemented method for calculating a service life parameter, a component, a system and by a computer program. Advantageous embodiments of the invention can be found in the dependent claims and in the following description.

• - Erfassen von Daten und insbesondere eines Ausfallsignals der Komponente (repräsentiert ein Ausfall- und/oder Austauschereignis der Komponente) und Erfassen und Speichern eines Zykluszählerwertes eines Zykluszählers zum Zeitpunkt des Erfassens des Ausfallsignals und Veranlassen eines Zurücksetzens des Zykluszählers auf den Wert „0“ und optional: Erfassen eines Typs der Komponente. Der Zykluszähler muss nicht zwangsläufig unmittelbar auf der Komponente K implementiert sein. Vorzugsweise wird der Zykluszähler für jede zu überwachende Komponente lokal auf der Steuerung oder auf einem Edge Device betrieben.
• - Aggregieren der erfassten Daten, insbesondere des Zykluszählerwertes, von mehreren Komponenten vom selben Typ über eine Netzwerkverbindung bzw. ein Netzwerk (z.B. Feldbus) auf einer (lokalen oder zentralen) Recheneinheit; neben dem Zykluszählerwert können noch weitere Daten aggregiert werden, die auf der Komponente oder für die Komponente erfasst werden und die z.B. kennzeichnend oder indikativ für die Lastsituation und/oder für die Betriebsbedingungen der Komponente in der Automatisierungsanlage sind.
• - Anwenden einer statistischen Funktion auf die aggregierten Daten zur Berechnung einer lastsituationsspezifischen Lebensdauerkenngröße;
• - Übermitteln der berechneten lastsituationsspezifischen Lebensdauerkenngröße an eine Steuerung zur Steuerung derselben und/oder der Automatisierungsanlage.

According to a first aspect, the invention relates to a computer-implemented method for calculating a service life parameter or a service life parameter, in particular a static service life parameter, for a component that is operated in an automation system. The process includes the following process steps:

• - Capturing data and in particular a failure signal of the component (representing a failure and/or replacement event of the component) and capturing and storing a cycle counter value of a cycle counter at the time the failure signal is detected and causing the cycle counter to be reset to the value "0" and optionally : detecting a type of the component. The cycle counter does not necessarily have to be implemented directly on the K component. The cycle counter for each component to be monitored is preferably operated locally on the controller or on an edge device.
• - Aggregating the recorded data, in particular the cycle counter value, from a plurality of components of the same type via a network connection or a network (eg fieldbus) on a (local or central) computing unit; In addition to the cycle counter value, other data can also be aggregated, which is recorded on the component or for the component and which is, for example, characteristic or indicative of the load situation and/or of the operating conditions of the component in the automation system.
• - Applying a statistical function to the aggregated data to calculate a load situation specific lifetime parameter;
• - Transmission of the calculated load situation-specific service life parameter to a controller for controlling the same and / or the automation system.

With the increasing networking of components and machines or systems, according to the invention, data on the wear of components from real operation can flow into the dynamically and continuously updated calculation of the service life parameter and thus successively optimize the service life parameter. This results in a customer benefit, since the reliability of the operated components can be improved. In addition, information can be provided on site as to when which component needs to be replaced under the current operating conditions. In addition, further automatic measures can be initiated on the component and/or the system on the basis of the calculated service life parameter. How the values are aggregated and made available to the customer can be done in different ways.

The method includes method steps that can be executed on the component and those that can be executed on the processing unit. In a first embodiment of the invention, the computing unit can be implemented on the component be. Then the procedure is performed locally and entirely on the component. In a second embodiment of the invention, the computing unit is not implemented on the component, but in a higher-level controller (e.g. as an embedded system on an edge device) or a PLC or on a server, e.g. a cloud server, which has a network connection, among other things the component is in data exchange. In the second embodiment of the invention, the method is executed in a distributed manner: on the one hand locally on the component and on the other hand on the remote computing unit (which, as mentioned above, can be implemented on a higher-level controller).

In principle, this is independent of whether a digital processing unit is implemented on the component, which is designed to execute a load algorithm for calculating the load value.

In a further embodiment of the invention, the digital processing unit may be formed not on the component but on a remote device (e.g.: server).

The service life parameter is a value (service life parameter) over the remaining service life of the component or indicates a remaining service life and/or a need to replace the component in the automation system. The service life parameter can be a statistical value (e.g. a B-10 value), which is in particular a statistical expected value of the number of cycles at which a preconfigurable percentage of the components (e.g. 10% of the components) exceed the limit values defined for the test ( switching time, leakage switching pressure ...) have exceeded under defined conditions. Conversely, this is also the probability that the 100% remaining percentage (i.e. in the example above: 90%) of the test specimens will achieve the specified service life B10. The preconfigurable percentage can be in a range between 5% and 20% and in particular can be 10%. The service life parameter can be used in a downstream method for a predictive maintenance process for the automatic replacement of components and/or to automatically carry out improvement measures.

A component is a part in an automation system or in a machine and can be, for example, a valve or an actuator, such as a cylinder, a tensioner, or a drive axle. The component can be an electrical and/or a pneumatic component, each in a linear or rotary design.

The cycle counter value represents the operational cycles performed during the healthy operation of the component. The cycle counter value is recorded by a cycle counter, which functions as a sensor for recording the number of operating cycles that have been carried out correctly. The cycle counter is usually operated on a controller or on an edge device for each component to be monitored. The detected cycle count is then transmitted from the cycle counter to the computing unit via the network. When the computing unit is implemented on the component, the cycle count is communicated to the component for further processing. Alternatively, the cycle counter can also be implemented directly on the component.

The statistical function can be an averaging function. The statistical function can compare the calculated mean value with an expected value in order to determine a modified mean value as a service life parameter specific to the load situation.

The data recorded on the component can relate to the dynamics (acceleration, speed, jerk), the supply pressure, the installation position or installation situation (vertical, horizontal) and/or an environmental category (i.e. an abstract category in which a cylinder is operated; e.g. in Cowsheds have a high concentration of ammonia in the air, so cylinders corrode more quickly). The recorded data are characteristic of a load situation and/or an operating condition of the component and are encoded in a load situation data record and are taken into account when calculating the service life parameter. In principle, these parameters can be configured statically and/or transferred to the system from measured variables at runtime.

Since stresses on components can be very different and depend on the orientation of a cylinder, the pressure, the environmental conditions, etc., the parameters for acquiring the measurement data that characterize a load situation and/or an operating condition can be configured in a configuration phase.

• - Dieser Verbau-Datensatz kann als Attribut in der Lebensdauerkenngröße annotiert sein. Der Verbau-Datensatz muss in einer Engineering-Phase des Systems in der jeweiligen Komponente oder entlang des Kommunikationswegs des Zykluszählers hinterlegt sein, sodass die Lebensdauerkenngröße mit diesen Meta-Informationen erweitert werden kann. Die Codierung kann in beliebigen Formaten möglich sein. Ein Beispiel hierfür ist JSON.
• - Pneumatische Wirkkette: Ventil, Zylinder bzw. pneumatischer Antrieb, Vakuumsauger;
• - Wie sind die Komponenten verbaut: Einbaulage: horizontal oder vertikal;
• - Zykluszeit, mit der die Komponenten betrieben werden;
• - Bewegte Masse;
• - Ausgeübte Kraft der Komponente;
• - Chemische Umgebungseinflüsse: Staub, Schmiermittel, Luftfeuchtigkeit, Temperatur → Klassifikation der Verbauposition der Komponente: Lebensmittelindustrie, Pharma, Schwerindustrie, Reinraum, Agriculture, Automobil-Rohbau, Automobil-Montage, etc.

In a preferred embodiment of the invention, at least the following parameters are recorded to characterize the load situation and/or the current operating condition of the component:

• - This shoring data record can be annotated as an attribute in the service life parameter. The shoring data record must be stored in an engineering phase of the system in the respective component or along the communication path of the cycle counter so that the service life parameter can be expanded with this meta information. The coding can be in any format. An example of this is JSON.
• - Pneumatic action chain: valve, cylinder or pneumatic drive, vacuum suction cup;
• - How are the components installed: Installation position: horizontal or vertical;
• - cycle time with which the components are operated;
• - moving mass;
• - Applied force of the component;
• - Chemical environmental influences: dust, lubricants, humidity, temperature → classification of the installation position of the component: food industry, pharmaceuticals, heavy industry, clean room, agriculture, car body construction, car assembly, etc.

These parameters can be recorded using suitable sensors. However, these parameters do not necessarily have to be recorded using sensors. They can also be read as data from a memory. However, the sensors can serve as an aid to avoid static configuration of pressure or humidity. The storage can take place on the valve terminal in the fieldbus node, on the controller, an edge device and/or in the on-premise/cloud installation. Regardless of where the storage takes place, it must be ensured that the life metric is linked to the correct information on operating conditions.

The load situation is characterized by at least the following parameters; Working pressure, moving mass, shoring situation and/or shoring position or shoring location and/or humidity. However, the load situation can also be encoded as an abstract classification, such as "cowshed", which is used to classify the cycle value. It is important that this information is used to clearly assign the cycle value to a load situation.

The data recorded on the component or for the component (i.e. e.g. on another unit) is transmitted to the computing unit for calculating the load situation-specific service life parameter. Data is transmitted to the computing unit via appropriate interfaces and the network, in particular a bus system, for example. Typical bus systems are: Profinet, EtherCAT, EthernetlP.

• - Komponente 1: erfasster Zykluszählerwert, also ausgeführte Betriebszyklen bis zum Ausfall: n1;
• - Komponenten 2: erfasster Zykluszählerwert: n2;
• - Komponenten i: erfasster Zykluszählerwert: ni;

wobei die Komponenten 1, 2 und i alle vom gleichen Typ sind (erste Bedingung) und dieselbe oder eine ähnliche Lastsituation haben (zweite Bedingung), um vergleichbar zu sein.The aggregation of the data that was recorded for a set of components can, for example, be processed in an abstract form using the following scheme:

• - Component 1: recorded cycle counter value, i.e. operating cycles executed until failure: n1;
• - Components 2: captured cycle counter value: n2;
• - components i: cycle counter value captured: ni;

where components 1, 2 and i are all of the same type (first condition) and have the same or similar load situation (second condition) to be comparable.

1. 1. Mittelwert bilden aus n1, n2, ni und dann folgende Berechnungsformel anwenden:
2. 2. Lastsituationsspezifische Lebensdauerkenngröße := gebildeter Mittelwert.

In a preferred embodiment of the invention, the load is taken into account in the calculation. In this case, the load situation must also be queried and saved on the component. In an alternative embodiment of the invention only the cycle counter values are collected from all components of the same type and the load is averaged:

1. 1. Calculate the mean value from n1, n2, ni and then apply the following calculation formula:
2. 2. Service life parameter specific to the load situation := formed mean value.

In a preferred embodiment of the invention, the service life parameter is aggregated in a central infrastructure (on-premise at the customer or centrally at the manufacturer (Festo)). In this case, a plausibility check of the reported load scenarios and associated cycle values must take place. This has the technical advantage that an implausible shift in the calculated service life parameter, which would induce consequential errors, and/or malicious manipulation can be avoided, which would cause excessive maintenance costs and/or downtimes for the customer

In a further preferred embodiment of the invention, the service life parameter is aggregated decentrally and/or locally, e.g. on the component or on a (e.g. mobile) device uniquely assigned to the component.

The control may relate to issuing a warning message. The control can also include the triggering of an automatic replacement of the component when the remaining operating time is about to expire according to the calculated load situation-specific service life parameter. The output can take place locally on the component or on a higher-level controller. The output can be provided in different formats: optical, acoustic and/or as a tactile signal (vibration signal).

• - Bereitstellen einer vorläufigen Lebensdauerkenngröße, die unter Laborbedingungen und/oder mit fest vordefinierten Prüfintervallen ermittelt wurde; die vorläufige Lebensdauerkenngröße wird üblicherweise noch vor Inbetriebnahme bereitgestellt;
• - Ersetzen der bereitgestellten vorläufigen Lebensdauerkenngröße durch die berechnete lastsituationsspezifische Lebensdauerkenngröße auf der Komponente, falls Abweichungen zwischen der bereitgestellten vorläufigen Lebensdauerkenngröße und der berechneten lastsituationsspezifischen Lebensdauerkenngröße erfasst werden.

In a further preferred embodiment of the invention, the method comprises the following method step:

• - Provision of a provisional service life parameter, which was determined under laboratory conditions and/or with fixed, predefined test intervals; the provisional service life parameter is usually made available before commissioning;
• - Replacing the provisional service life parameter provided by the calculated load situation-specific service life parameter on the component if discrepancies between the provided provisional service life parameter and the calculated load situation-specific service life parameter are detected.

In a preferred embodiment of the invention, however, the provisional service life parameter is not overwritten; instead, the calculated load situation-specific service life parameter is stored separately. This has the advantage that the transparency of the method can be increased and the different instances of the service life parameter always remain traceable. It has proven to be particularly advantageous that the respective service life parameter is always stored with a time stamp.

According to a further preferred embodiment of the invention, a warning message is issued before the load situation-specific service life parameter expires. The warning message can be output either on the component itself, on a higher-level controller (e.g. PLC), on a device in the automation system and/or on a computer (e.g. only temporarily) connected to the component (e.g. mobile end device that is connected via data technology coupling clearly assigned to the component or on which the component is clearly identifiable).

• - Erfassen von Messdaten mittels Sensoren, die indikativ für eine Lastsituation der Komponente sind;
• - Initiieren oder Auslösen eines Übermittelns der erfassten Messdaten an die Recheneinheit.

According to a further preferred embodiment of the invention, the method comprises the following method steps to be carried out on the component:

• - Acquisition of measurement data by means of sensors that are indicative of a load situation of the component;
• - Initiating or triggering a transmission of the recorded measurement data to the processing unit.

The recorded measurement data thus characterize the respective application situation or the respective operating conditions with which the components in the system or machine are operated, i.e. also with which load they are operated, among other things. The measurement data are therefore also indicative of a wear condition of the component. The amount of measurement data (in particular which parameters are recorded here) can be defined in a configuration phase.

In a further preferred embodiment of the invention, a classification of the acquired data is carried out before the aggregation, in order to form classes of components with a matching load situation and/or operating condition on the basis of the acquired measurement data, and the aggregation is carried out in the classes formed. This can improve the informative value of the result, in particular of the calculated load situation-specific service life parameter.

According to a further preferred embodiment of the invention, the (in particular on or for the component) recorded data and/or the calculated data, in particular the load situation-specific service life parameter, and/or recorded measurement data and/or possibly the classification of the components into classes of components saved with the corresponding load situation. This has the advantage that these values can be used for further and later analyses. The storage preferably takes place on the computing unit, which can be implemented on a control of the automation system that is superordinate to the component.

In a further preferred embodiment of the invention, a stress value is automatically calculated from the recorded measurement data using a stress algorithm.

Preferably, the load algorithm calculates the load value from an energy index, which represents the energy consumed by the component, and from the executed movement task of the component, which is encoded in a movement parameter, and from the time interval used for this.

1. 1. Klassifikation der Beanspruchung: Hier können Verfahren wie k-Means verwendet werden, die Cluster-Zentren ausbilden. Die Achsen des Cluster-Raums werden durch die definierten Beanspruchungsparameter (Druck, Ort, Dynamik, etc.) aufgespannt.
2. 2. Soll ein neuer Zykluszählerwert zu einem Beanspruchungsszenario bzw. einer im ersten Schritt gebildeten Klasse zugeordnet werden, wird der nächste Abstand zu einem Cluster-Zentrum gewählt und für dieses Cluster der Zykluszähler in den entsprechenden Lebensdauerkenngrößen-Wert aggregiert.

The loading algorithm can preferably be two-stage:

1. 1. Classification of stress: Methods such as k-means that form cluster centers can be used here. The axes of the cluster space are spanned by the defined stress parameters (pressure, location, dynamics, etc.).
2. 2. If a new cycle counter value is to be assigned to a stress scenario or to a class formed in the first step, the nearest distance to a cluster center is selected and the Cycle counter aggregated into the corresponding life metric value.

Preferably, a k-means algorithm can be used to classify the stress. K-Means is a vector quantization technique that is also used for cluster analysis. K-Means groups different sensor values (e.g. sensor1 = pressure; sensor2 = humidity) into clusters. The space spanned by the various sensors is n-dimensional, where n is the number of different sensors (in terms of sensor types; in the example above: sensor type1: pressure gauge; sensor type2=humidity sensor). Each cluster in this n-dimensional space then corresponds to a stress scenario or load scenario for which the load situation-specific service life parameter is determined.

• - Versorgungsdruckmesser und/oder
• - Durchflussmesser und
• - Zeitgeber.

In a further preferred embodiment of the invention, the sensors for acquiring the measurement data for a pneumatic component are selected from the group consisting of:

• - Supply pressure gauge and/or
• - flow meter and
• - Timer.

• - Strommesser,
• - Spannungsmesser und/oder
• - Zeitgeber.

For an electrical component, the sensors for recording the measurement data are selected from the group consisting of:

• - current meter,
• - voltmeter and/or
• - Timer.

• - der bewegten Masse,
• - Beschleunigung,
• - Ruck,
• - Temperatur,
• - Einbaulage und/oder
• - Schaltspiel pro Zeiteinheit.

Alternatively, further sensors can be designed to detect:

• - the moving mass,
• - acceleration,
• - Shock,
• - temperature,
• - installation position and/or
• - Switching cycle per time unit.

Alternatively or cumulatively, the parameters mentioned above can be defined by means of configuration in an engineering phase.

• - Einer Ausfalleinheit, die ausgebildet ist, ein Ausfallsignal zu erfassen, das ein Ausfallereignis der Komponente repräsentiert;
• - Einer Schnittstelle zu einem Zykluszähler, der ausgebildet ist, die Betriebszyklen für die Komponente zu zählen; der Zykluszähler kann auf einer Steuerung oder einem Edge Device implementiert sein;
• - Einem Speicher zur Speicherung der erfassten Daten; und
• - Einem Netzwerk zum Datenaustausch (zwischen den Bauteilen der Komponente und ggf. auch zu externen Bauteilen), insbesondere mit einer Datenverbindung zu einer Recheneinheit.

In a further aspect, the invention relates to a component that is operated in an automation system and for which a service life parameter is to be calculated, with:

• - A failure unit, which is designed to detect a failure signal that represents a failure event of the component;
• - An interface to a cycle counter, which is designed to count the operating cycles for the component; the cycle counter can be implemented on a controller or an edge device;
• - A memory for storing the collected data; and
• - A network for data exchange (between the components of the component and possibly also to external components), in particular with a data connection to a computing unit.

1. 1. Ventile haben einen internen Flash mit Zykluszeit und eine Ventil-ID. Wenn sich die Ventil-ID ändert, so kann das als Indiz genommen werden, dass das Ventil defekt war und getauscht wurde (Ausfallsignal).
2. 2. Weiterhin kann eine Erkennung eines defekten Ventils durchgeführt werden, indem:
   • - Das Ventil angesteuert wird und
   • - keine Reaktion an Endlagenschaltern gesehen wird oder
   • - Die Spulenstrom-Auswertung eine Anomalie aufzeigt.

The failure unit is an electronic module that is designed to detect the failure signal that represents a failure event of the component. Two different embodiments can be provided for the automatic detection of defective valves (in the case of a pneumatic component type):

1. 1. Valves have an internal flash with cycle time and valve ID. If the valve ID changes, this can be taken as an indication that the valve was defective and was replaced (failure signal).
2. 2. Furthermore, a defective valve can be detected by:
   • - The valve is controlled and
   • - no reaction is seen at limit switches or
   • - The coil current evaluation shows an anomaly.

According to a preferred embodiment of the invention, the component includes a set of sensors to acquire measurement data. Measurement data or data can be read in cumulatively from other modules via corresponding interfaces (data interfaces) on the component in order to supplement the measurement data. The measurement data recorded are indicative of a load situation of the component and/or of a current operating condition with which the component in the system is being operated.

According to a further preferred embodiment of the invention, the component comprises a digital processing unit, in particular for executing the loading algorithm.

The solution to the problem was described above using the method. Features, advantages or alternative embodiments mentioned here are also to be transferred to the other claimed objects and the opposite. In other words, the subject claims (which are directed, for example, to a component, a system or a computer program) can also be developed with the features that are described or claimed in connection with the method. The corresponding functional features of the method are formed by corresponding physical modules, in particular by hardware modules or microprocessor modules, of the system or product and vice versa.

• - Eine Komponente, wie vorstehend beschrieben;
• - Eine Recheneinheit, die dazu bestimmt ist, die erfassten Daten, insbesondere die Zykluszählerwerte, von mehreren Komponenten vom selben Typ zu aggregieren und die weiter dazu bestimmt ist, eine statistische Funktion auf die aggregierten Daten zur Berechnung einer lastsituationsspezifischen Lebensdauerkenngröße anzuwenden;
• - Zumindest ein Netzwerk zum Datenaustausch und insbesondere zum Übermitteln der berechneten lastsituationsspezifischen Lebensdauerkenngröße an die Komponente zur Steuerung der Komponente und/oder der Automatisierungsanlage mit der Komponente.

In a further aspect, the invention relates to a system for calculating a service life parameter for a component that is operated in an automation system. The system includes:

• - A component as described above;
• - A computing unit which is intended to aggregate the acquired data, in particular the cycle counter values, from a plurality of components of the same type and which is further intended to apply a statistical function to the aggregated data in order to calculate a load situation-specific service life parameter;
• - At least one network for data exchange and in particular for transmitting the calculated load situation-specific service life parameter to the component for controlling the component and/or the automation system with the component.

The computing unit can be formed locally on the component, in particular on a component functioning as a master, with the master component taking over control tasks for all other components that are operated in slave status. The processing unit can alternatively or cumulatively be designed as a separate instance on another device (e.g. control unit) or an external unit.

In a preferred embodiment of the invention, the system comprises a digital processing unit for executing a loading algorithm intended for dynamic calculation of a loading value. The load value encodes the current load situation of the component.

In a further aspect, the invention relates to a computer program, comprising instructions which, when the computer program is executed by a computer, cause the latter to execute the method described above.

In the following detailed description of the figures, exemplary embodiments, which are not to be understood as limiting, are discussed with their features and further advantages on the basis of the drawing.

character list

• 1 shows an overview of the structure of a system for calculating a service life parameter for a component that is operated in an automation system according to a preferred embodiment of the invention;
• 2 shows a schematic representation of a component according to a preferred embodiment of the invention;
• 3 shows a further schematic representation of a system according to a preferred embodiment of the invention;
• 4 Fig. 12 is a flow chart showing several optional steps, each indicated with dashed lines;
• 5a shows an exemplary embodiment of a pneumatic component with a set of sensors and
• 5b an exemplary embodiment of an electrical component with a set of sensors;
• 6 FIG. 12 is a schematic overview of two embodiments for calculating the service life parameter, one with and one without taking into account a provisional service life parameter.

Detailed description of the invention

1 shows a schematic overview of a system for calculating a service life parameter B10 for a component K that is operated in an automation system AA. The service life parameter B10 represents and encodes the remaining service life of the component K and thus a need for replacement or a period of time until replacement is necessary. It is essential that the calculated service life parameter B10 is not only provided on the basis of standardized laboratory tests, as was previously the case in the prior art, but is adaptively adapted to the respective operating and/or load situation of the component K in the automation system AA and takes this into account. In a particularly preferred embodiment of the invention, the load situation and/or the operating situation (eg installed situation, vertical/horizontal) of the component is taken into account when calculating the service life parameter B10.

As in 1 shown schematically, the component K can be an actuator, such as a pneumatic cylinder, an electrical actuator, a tensioner and/or another module of an automation system AA. The different types of components K can be divided or classified into classes. Different components of a type (e.g. all cylinders of the same design) are then grouped together in a class that is clearly assigned to a type. In principle, several components K can be combined or interconnected to form a superordinate module, such as a valve assembly V or a valve terminal VI. The components and/or modules mentioned are in data exchange with higher-level entities via a network (e.g. fieldbus system) NW, for example with an edge device that can function as a computing unit RE and can be intended for controlling parts of the automation system AA, with a Cloud-based server, with an engineering tool and/or with an on-premise IT data tool, which can also act as a computing unit RE.

2 shows a preferred embodiment of a component K, which is mixed with other components (in 2 for the sake of clarity not shown or only indicated) is operated in an automation system AA. In this embodiment, the component K contains a failure unit AE which is intended to detect a failure event of the component. As soon as the component K fails due to an error or for other reasons and/or can no longer be operated correctly, this is recorded as a failure event and stored by the failure unit AE as a failure signal a. In addition, the component K includes an interface to a cycle counter Z. The cycle counter Z is preferably designed as an electronic module and can be provided as a software and/or hardware module. The cycle counter Z is intended to count the operating cycles of the component. The cycle counter Z thus counts the operating cycles of the component K during error-free operation and until failure. The component K also includes a memory K2 for storing the data recorded locally or on a remote entity, for example, and in particular for storing the failure signal a of the failure unit AE and the cycle counter value of the cycle counter Z at the point in time at which the failure event was recorded. The failure signal a and the corresponding cycle counter value are stored in the memory K2 in an associated manner. This has the advantage that the cycle counter value up to the failure event can be recorded with a simple look-up access. As a rule, a failure event entails replacing component K in order to be able to ensure the safety and error-free functionality of the automation installation AA. This allows the cycle counter value to be recorded until the component K is replaced. The component K also has a network NW, such as a field bus system or the like. The network NW is intended in particular to provide a data connection to a computing unit RE.

The data recorded on the component K or for the components K and in particular the cycle counter value, which is associated with the failure signal a in terms of time, is fed back or transmitted to the processing unit RE via the network NW.

The computing unit RE is designed to collect or aggregate different data sets from different components K in order to use a statistical function f based on the aggregated data to calculate a load situation-specific service life parameter B10. In an advantageous simple embodiment of the invention, the statistical function f is an averaging.

The arithmetic unit RE is preferably implemented on an electronic entity that is superordinate to the respective components K. The computing unit RE can be implemented, for example, on an edge device and/or on a controller (PLC). In this embodiment of the invention, the processing unit RE is not implemented locally on the component K, but separately on an external entity, for example on a control unit of the automation system AA. Correspondingly, the network NW also includes a data interface to the respective external electronic entity on which the computing unit RE is implemented, in particular for exchanging the failure signal a and the cycle counter value and optionally other measurement data recorded by the sensors.

In a further advantageous embodiment of the invention, the computing unit RE is implemented locally and directly on a component K functioning as a master. In this embodiment, the components K can be operated as a master or as a slave. In addition to their conventional component functionality, as masters they also act as controllers for all slave components. The slave components are distinguished by the fact that they have no control functionality and are only designed to provide the functionality of the respective component. Usually only one component is selected as the master component for a set of components. The master component is in data exchange with all slave components.

Optionally and in alternative embodiments, component K can also have other components. this is in 2 represented by the dotted components. Thus, the component K can include a number of sensors sens, which are designed to acquire different measurement data of the component K in each case. The kind or type of measurement data can be configured in a configuration phase. In the configuration phase, it is possible in particular to configure which sensor types or which measurement data types are to be recorded. In principle, the sensors sens are intended to record those measurement data on the component K that characterize a load situation of the components K. For example, a supply pressure meter, a flow meter and/or a timer can be provided for a pneumatic component. For example, an ammeter (or a voltmeter) and a timer may be provided for an electrical component. In advantageous developments, additional sensors can also be provided in order to record, for example, the moving mass, acceleration, jerk, temperature, installation position and/or other parameters that characterize the respective load situation of component K.

In a further advantageous embodiment, the component can optionally (and therefore in 2 shown dotted) a digital processing unit VE can be implemented, which is intended to execute a loading algorithm. The loading algorithm is usually identified in the figures with the reference symbol S16. The load algorithm is designed to calculate a load value from the recorded measurement data, which encodes the respective load situation of component K. The load situation represents a stress scenario of component K. For a cylinder (as an electrical component type), at least the following parameters are relevant for calculating the load situation: the installation position, the mass being moved, the dynamics of the system with speed, acceleration and/or jerk.

For a valve (as another, namely pneumatic component type), at least the following parameters are relevant for calculating the load situation: temperature, switching cycles per unit of time, pressure from supply units.

3 shows in a schematic representation and according to a preferred embodiment of the invention the different components of a system for calculating a service life parameter B10 for a component K, which is operated together with other components in an automation system AA. The automation system AA includes a number of components K, a computing unit RE and a network NW. In an advantageous development of the invention, the system can still optionally (and therefore in 3 shown dotted) include a digital processing unit VE, which is intended for executing the loading algorithm.

4 is an interaction diagram between the components of the above-mentioned system, in particular between the component K and the computing unit RE and optionally with the digital processing unit VE. In step S1, data is recorded on the component K or for the component. In particular, a failure signal a of component K is detected, which represents a failure, an error or some other failure event. The failure signal is preferably detected on the K component. In step S2, the cycle counter value of the cycle counter Z at the time of detection (therefore in 4 parallel ie shown at the same time) of the selection signal a detected and subsequently stored in step S3. In step S4, the cycle counter is reset to the value "ZERO" either directly if the cycle counter is implemented on the component K or indirectly by causing or initiating the reset by sending a reset signal to the cycle counter if it is not implemented directly on the component.

In step S5, the data recorded on or for the component K and in particular the recorded cycle counter value are transmitted to the arithmetic unit RE. This is done via the network NW.

In an optional step S51, whose optional character in 4 shown in dashed lines, the components K can be classified according to their load situation or operating condition. Components with the same or similar load situation and/or operating conditions are grouped or classified into a class. This has the advantage that the recorded data (cycle counter values) can also be classified according to the load situation/operating condition of its components, so that the aggregation or aggregation takes place in step S6 in the classes formed. In this way, a more reliable statement can be made about the service life parameter.

In step S7, a statistical function f is applied to the aggregated data in order to calculate the load situation-specific service life parameter B10 in step S8.

In step S9, the calculated service life parameter B10 specific to the load situation is transmitted back to the component K via the network NW for the purpose of control. Based on the transmitted load situation-specific service life parameter B10 can be initiated in step S91 a modified control of the component K and / or the automation system AA.

As in 4 characterized by the boxes shown in dashed lines, a number of further method steps can also be carried out. In this context, it should be emphasized that the sequence of the method steps can be varied. In particular, the numbering of the reference symbols for the individual method steps is not indicative of a chronological sequence of the same. For example, method step S10 for providing a provisional service life parameter LDK can be carried out not only after the steps described above, but also at an earlier point in time, for example even before method step S1.

The optional step S10 thus relates to the provision of a provisional service life parameter LDK. The provisional service life parameter LDK was determined under laboratory conditions or with fixed, predefined test intervals. The provisional service life parameter LDK is therefore not adapted to the respective load situation or not to the respective operating conditions (e.g. installation situation) of component K in the automation system AA or it is not calculated on the basis of the current load situation and the current operating conditions. The initially saved provisional service life parameter LDK comes from endurance tests at the manufacturer of the components and can be made available to the system as a starting value. Starting from this value, the statistical processing unit implemented in the calculation unit RE makes gradual changes. This means that the statistical calculation must be low-pass filtered to avoid jumps in the B10 value and to embody a gradual behavior. Jumps in the B10 value could mean that customers suddenly have to replace a larger number of components or that components that were declared as worn are then declared as good parts again. This is advantageously avoided by the low-pass filtering.

In contrast to this, however, the service life parameter B10 specific to the load situation is calculated taking into account the respective load situation and/or the current operating conditions of the respective component K. Instead of using the unspecific provisional service life parameter LDK for the process control on the respective component K, the dynamically adapted and specifically calculated load situation-specific service life parameter B10 can advantageously be used in step S11. The provisional service life parameter LDK can be replaced by the load situation-specific service life parameter B10.

In a preferred embodiment, however, both service life parameters B10, LDK are stored in order to enable later evaluation and, in particular, calibration of the calculation of the load situation-specific service life parameter B10.

The load situation-specific service life parameter B10 predicts the remaining service life of component K until failure based on statistical data. In a preparation phase, a period of time can be configured before the end of the remaining lifetime (e.g. one day, 1 hour, 10 minutes, 10 seconds before the end of the remaining lifetime of the component K), in which a warning message is output on the component K in step S12. The warning message can be issued in different formats and can be acoustic, visual and/or haptic, for example.

In a preferred embodiment, in step S14, measurement data can be recorded by means of the sensors sens, which are indicative of a load situation of component K, such as the supply pressure and/or the flow rate in the case of a pneumatic component or such as current/voltage, moving mass, acceleration, Jerk in an electrical component.

In step S15, the recorded measurement data are prepared for transmission to the processing unit RE. The data transfer can then be initiated.

In a preferred embodiment, all input data, intermediate results and final results are stored in a memory in step S13. The data to be stored can be the data recorded in step S1, i.e. in particular the failure signal a and the cycle counter value, the measurement data recorded in step S14, the calculated service life parameter B10 specific to the load situation, the classification carried out in step S51 and /or the provisional service life parameter LDK.

In a further advantageous embodiment, a load algorithm can be executed in step S16 in order to use the measurement data recorded in step S14 to calculate a load value which represents the respective current load situation and/or the current operating conditions of component K, as they are in the automation system AA is operated.

The loading algorithm can have an energy index as an input variable, which represents the energy consumed by the component. A motion coding that encodes the motion task performed by the component K can serve as a further input variable. The time interval used for the movement task can serve as a further input variable. The load value is output as the result or output variable.

As in 4 indicated, the loading algorithm can be executed on the digital processing unit VE. The digital processing unit VE can either be implemented directly and locally on the component K and/or the digital processing unit VE can be implemented on a separate entity and be in data exchange with the component K via the network NW.

5a and 5b show exemplary designs of a component with the respective sensors sens. 5a shows a pneumatic component K _p with a supply pressure gauge, a flow meter and a timer as sensors sens and 5b shows an electrical component K _e with an ammeter, a voltmeter and a timer as sensors sens. In more complex developments of the invention, further sensors can be implemented in order to detect and characterize the load situation and/or the operating conditions of the respective component K in order to take them into account when calculating the load situation-specific service life parameter B10.

6 shows an advantageous development of the invention for calibrating the calculation of the load situation-specific service life parameter B10. For this purpose, the cycle counter value of the cycle counter Z of a component and the assigned failure signal a of the failure unit AE are transmitted to the arithmetic unit RE in order to calculate and output the service life parameter B10 specific to the load situation. Furthermore, the provisional service life parameter LDK is also transmitted to the computing unit RE in order to compare the two service life parameters B10, LDK for deviations. The calculation of the lifespan parameter B10 specific to the load situation can then be calibrated on the basis of the deviations. This calibration process is in 6 denoted by the reference KAL. The two service life parameters B10, LDK can be stored in a memory MEM.

Finally, it should be pointed out that the description of the invention and the exemplary embodiments are not to be understood as restrictive with regard to a specific physical realization of the invention. All of the features explained and shown in connection with individual embodiments of the invention can be provided in different combinations in the object according to the invention in order to realize their advantageous effects at the same time. The order of the process steps can be varied.

The scope of protection of the present invention is given by the following claims and is not limited by the features explained in the description or shown in the figures.

It is particularly obvious to a person skilled in the art that the invention can be applied not only to pneumatic or electrical components, but also to other components or devices that are operated in an automation system. Furthermore, the parts of the component and/or of the system can be distributed over a number of physical products.

Claims (15)

Computer-implemented method for calculating a service life parameter (B10) for a component (K) that is operated in an automation system (AA), with the following method steps: - Acquisition (S1) of data and in particular a failure signal (a) of the component (K) and acquisition (S2) and storage (S3) of a cycle counter value at the time of the acquisition of the failure signal and causing a reset (S4) of the cycle counter to the value " 0"; - Aggregating (S6) the recorded data, in particular the cycle counter values of several components (K) of the same type and applying (S7) a statistical function (f) to the aggregated data to calculate (S8) a load situation-specific service life parameter (B10); - Transmission (S9) of the calculated load situation-specific service life parameter (B10) to the component (K) for controlling (S91) the same and/or the automation system (AA). procedure after claim 1 , in which the method comprises the following method step: - On the component (K): providing (S10) a provisional service life parameter (LDK), which was determined under laboratory conditions and/or with fixed, predefined test intervals; - On the component (K): Replacement (S11) of the provisional service life parameter (LDK) provided by the calculated load situation-specific service life parameter (B10), if deviation Deviations between the provided provisional service life parameter (LDK) and the calculated load situation-specific service life parameter (B10) are recorded. Method according to one of the preceding claims, in which a warning message is output (S12) on the component (K) before the end of the load situation-specific service life parameter (B10). Method according to one of the preceding claims, in which the method comprises the following method steps, which are carried out on the component: - Acquisition (S14) of measurement data by means of sensors (sens), which are indicative of a load situation and/or an operating condition of the component (K); - Initiating a transmission (S15) of the recorded measurement data to the computing unit (RE). Method according to the immediately preceding claim, in which the data collected is classified (S51) on the computing unit (RE) before the aggregation (S6) in order to identify classes of components (K) with matching values based on the measurement data collected in step (S14). To form load situation and / or matching operating condition and in which the aggregation (S6) takes place in the classes formed. Method according to one of the preceding claims, in which the recorded data and / or the calculated data, in particular the load situation-specific service life parameter (B10), the measurement data recorded in step (S14) and / or a classification (S51) is stored (S13), in particular is stored on the computing unit (RE). Method according to any of the foregoing Claims 4 until 6 , in which a current load value is automatically calculated on the computing unit (RE) and/or a digital processing unit (VE) from the recorded (S14) measurement data using a load algorithm (S16). procedure after claim 7 , in which the load algorithm (S16) calculates the load value from an energy index that represents the energy consumed by the component (K) and a motion code that encodes the movement task performed by the component (K) and the time interval consumed for this purpose . Procedure according to one of Claims 5 until 8th , in which for a pneumatic component the sensors (sens) for acquiring (S14) the measurement data are selected from the group consisting of: supply pressure meter and/or flow meter and timer and in which the sensors for acquiring the measurement data are selected for an electrical component from the group consisting of: ammeter, voltmeter and/or timer. Component (K) that is operated in an automation system (AA) and for which a service life parameter (B10) is to be calculated, with: - A failure unit (AE), which is designed to detect a failure signal (a); - An interface to a cycle counter (Z), which is designed to count the operating cycles of the component (K); - A memory (K2) for storing the locally recorded data; and - A network (NW) with a data connection to a computing unit (RE). component after claim 10 , which includes a set of sensors (sens) to collect measurement data. component after claim 10 or 11 , which comprises a digital processing unit (VE), in particular for executing a loading algorithm (S16). System for calculating a service life parameter (B10) for a component (K), which is operated in an automation system (AA), with: - A component (K) according to one of Claims 10 until 12 ; - A computing unit (RE), which is intended to aggregate the recorded data, in particular the cycle counter values, from several components of the same type and which is further intended to apply a statistical function to the aggregated data to calculate a load situation-specific service life parameter (B10) apply; - At least one network (NW) for data exchange and in particular for transmitting the calculated load situation-specific service life parameter (B10) to the component (K) for controlling the component (K) and/or the automation system (AA). A system according to the immediately preceding claim, comprising: - A digital processing unit (VE) for executing a loading algorithm (S16). Computer program, comprising instructions which, when the computer program is executed by a computer, cause the latter to run Ver carry out driving according to one of the preceding method claims.

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