EP1375140B1 - Control system for rotary printing machines - Google Patents

Description

The invention relates to a controller for rotary printing machines in aggregate construction with decentralized drives according to the preamble of the first claim.
Each aggregate of a rotary printing machine with decentralized drives represents a definable building and functional unit with local (decentralized) control and own local (decentralized) drives, which are synchronized across aggregates by a master computer in cooperation with a central machine control.

The control of rotary printing machines generally runs hierarchically in at least two control levels: in the aggregate control and in the subordinate drive control.

For the decentralized control of the individual functions within an aggregate are in each Aggregate arranged two aggregate control units. With the first control unit become the major aggregate functions, safety and health protection features realized, the second control unit is used for redundant control and monitoring the protection and safety features by putting the first control unit to the right one Processing of protection and safety signals controlled. For both unit control units programmable controllers (PLC) are used.

For redundant control and monitoring of safety functions, various concepts are state of the art. EP 1031 420 A1 describes a monitoring system for safety-relevant processes on actuating and drive elements, which detects safety-relevant states decentrally at the place of origin by means of safety input devices and forwards them to additional decentralized safety monitoring controls which can be assigned to these actuating and drive elements.
From DE 19529430 it is known to expand the drive control by error analysis functions. This document describes a safety module belonging to the drive system which is used for fault detection and diagnosis for all functions belonging to the drive system (eg sensor failure, excessive motor current, collision considerations).

From DE 19727824 a controller for rotary printing machines in aggregate construction with a parent machine control and decentralized attachments in the aggregate known.

For the cyclic synchronous control characteristic of rotary printing machines Angular-dependent unit functions (printing circuit, sheet guiding) are angular processing units (electronic cam switches) part of the central machine control, the signals from separate centralized or decentralized rotary encoders to process binary switching functions.

Decentralized drives or individual drives and methods for their synchronization are in accordance Commonly known in the art (e.g., DE 19626287). Such a drive consists essentially of a motor with drive controller, one with the drive shaft connected high-resolution rotary encoder and a programmable electronic Drive control unit.

The drive control units are in turn PLCs, all of which are directly necessary for the drive Control functions, such. As ramp-up and braking ramps or position control of the drive shaft of the motor according to a given function (virtual master axis, following axis control) To run.

Aggregate control units and drive control units communicate via bus systems or networks and are subordinate to the central machine control and the master computer.
A disadvantage of this control architecture is the high cost of control units and rotary encoders.

Based on the prior art, the invention is based on the object, the control systems to save costs.

This object is achieved by a controller having the features of the first claim. Advantageous embodiments are disclosed in the subclaims.

The decentralized drives must meet high requirements with regard to speed constancy or position accuracy and therefore have powerful drive control units. The invention now uses the always present in the drive control units Spare capacity to the functions of the aggregate control, over the immediate Drive functions, in addition to implement in the drive control units and thus reduce the hardware costs and minimize signal delays.

Furthermore, the high accuracy of the decentralized rotary encoder in the decentralized drives offers the possibility to save the separate rotary encoder of the central machine control and to realize the clock control of the aggregates on the basis of the clock signals formed in the decentralized drive controls themselves.
The decentralized distribution of the angular processing functions, which are assigned directly to the individual, these functions exporting aggregates and their control units, the known advantages of distributed distributed control functions result: reduced wiring costs, clear structuring of the control functions, saving communication times, etc.

For the execution of machine and occupational safety functions are for the reasons of Functional reliability (redundancy) provided in each case two parallel-processing control units. By including the aggregate control in the drive control units is eliminated the installation of a second aggregate control unit only for redundant backup functions.

The following are examples of the embodiments of the invention shown.

Fig. 1

die Hierarchie bekannter Maschinensteuerungen und die erfindungsgemäße Hierarchie in einem Abschnitt einer Rotationsdruckmaschine

Fig.2

einen Ausschnitt einer Steuerung einer Rotationsdruckmaschine mit zwei dezentralen Antrieben

Fig.3

die Steuerung mit zwei dezentralen Antrieben mit separaten Signalein- und ausgangsmodulen,

Fig.4

die Steuerung mit 2 dezentralen Antrieben je Aggregat für die redundante Ausführung von Sicherheitsfunktionen.

Showing:

Fig. 1

the hierarchy of known machine controls and the hierarchy according to the invention in a section of a rotary printing machine

Fig.2

a section of a control of a rotary printing machine with two decentralized drives

Figure 3

the control with two decentralized drives with separate signal input and output modules,

Figure 4

the control with 2 decentralized drives per unit for the redundant execution of safety functions.

In Fig. 1a is a portion of a known controller of a rotary printing press, the two printing units DW1, DW2, each with two decentralized drives 5, shown. The higher-level host computer 1 is via a known bus system 2, each with two aggregate control units 4 connected in the individual printing machine units. The aggregate controllers 4.1.4.2 of an aggregate are coupled to each other with bus lines 3. The bus systems 2 and 3 may differ from each other, but also one form a common bus system. The respective first unit control unit 4.1 is for example with two subordinate drive control units 6.1,6.2 of two decentralized drives 5.1.5.2 in this printing unit (e.g., a drive for the sheet-guiding cylinders and a separate drive for the plate, rubber and / or one or more of the The inking cylinder). By fully integrating the functions of the state of the art the technology drives the higher-level aggregate controls 4 in the drive control units 6, the previously provided for the aggregate control PLC are no longer needed. This eliminates a control level, so that the signal paths and response times significantly be shortened (Fig. 1b).

Each drive control unit 6 comprises a PLC for the unit-specific drive control (eg for run-up and braking ramps), a drive controller, a power electronics unit and inputs and outputs for the control signals. The PLC of the drive control points the signal and bus inputs and outputs E, A required for communication (FIG. 2).

The drive control units 6 are each assigned a drive motor 8. Integrated in the engine 8 or on the shaft 8 driven by the motor, a rotary encoder 9 is arranged, which transmits the position information about the driven assembly of the drive control.

In the drive control unit 6, the rotational angle signals are first in a known manner used for position control of the drive motor 8. The used on decentralized drives However, rotary encoders 9 already have the very high resolution of rotary encoders for the central timing and synchronization of the printing press units. The subject invention Therefore, includes the state of the art of a separate Angular processing unit 7 (electronic cam controller) within the central Machine control needed for the aggregate control in the individual units To make clock signals directly on site from the decentralized drive control. Is to only one program module for freely programmable angle processing in the drive control units 6 record. By expanding the functional scope of the drive control units 6 with a module for angle signal processing 7, the rotation angle-dependent Control signals (clock signals) for the clock control of the aggregate functions be provided directly from the drive control of the respective unit. Thus, there is no additional hardware for central angle detection and processing necessary.

Another application of the inventive concept leads to the integration of otherwise in the im Host computer 1 implemented synchronization functions of drives within a Aggregates and / or aggregate across the drive control units 6 to be synchronized Drive motors 8 and aggregates DW1, DW2, so that the drive control units 6.11,6.12,6.21 form a drive control system. The required high-resolution Rotary encoder 9 are already present in the decentralized drives 5. The too synchronizing drive control units 6 are via the bus system 2, which the synchronization signals transmits, among themselves and connected to the host computer 1, the only sub-functions according to the control task (for example, specification of the virtual Leading axis). In addition to a discharge of the central machine control are shorter Transmission paths, thereby shorter reaction times and thus an improved control behavior and ultimately to achieve an improvement in the synchronicity of the drives.

To perform additional distributed aggregate control functions by the drive controllers 6, it is advantageous to provide the signals necessary for monitoring and control by the shortest route to capture or spend at the place of their origin. This can be done by separate, locally arranged input and output modules 10,11, the via a bus system 3, which transmits the status and control signals, to these signals processing drive control units 6 are connected (Fig. 3). In this way is one simple extension of the functionality of the drive control units 6 by coupling several input and output modules 10,11 according to the number of executed aggregate control functions possible.

A further extension of the functional scope of the drive control units 6 with control functions, which are not immediate drive functions, constitute the safety functions, such. B. the monitoring and execution of health and safety functions. The safety-relevant states must be read in at two independent inputs and processed independently of each other in independent safety modules. To ensure the required redundancy double safety contacts on the circuit breakers for triggering the safety-related signals, separate signal inputs and 2 independent, security signals processing security modules in separate control units for the parallel processing of security signals are required. The safety-relevant process is already triggered if a triggering of a safety contact is detected in just one module - either in the safety module or in the redundant safety monitoring module. In this way it can be ensured that in the event of a fault in the safety signal processing, the redundant function module triggers the safety function via the second safety contact. In addition, the signal states of the safety contacts and the output signals of both safety modules are monitored by the safety monitoring module for equality and in case of inequality a fault message is output.
In a rotary printing press with two drives 5.11,5.12 per printing unit DW1 (eg transfer unit and pressure cylinder each driven separately) per aggregate two drive control units 6.11,6.12 are present, each having one of the safety modules 13,13. S To realize the redundant safety functions. However, even with only one decentralized drive per unit, the redundant safety signal processing can be secured by two decentralized control units 6.11, 6, 21 of different units DW1, DW2 operating in parallel during the safety signal processing (FIG. 4). Each safety module 13, 13. S is assigned one or more safety signal input modules 10.S by means of safety bus lines 3.S.
The respective safety signal input module 10.S reads the states of the emergency stop buttons, limit switches, temperature sensors or similar. 12 and transmits them via a safety-related bus system 3.S to the responsible safety module 13 in a drive control unit 6. Parallel to the first safety signal, the redundant safety signal is passed to a second, independent of the first input safety signal input ES in a second safety signal input module 10.S and in Security monitoring module 13.S processed. As soon as at least one of the two safety contacts 12 triggers, the safety function provided for the respective fault is thus activated by the corresponding signal outputs A being activated by one of the two or by both safety modules 13, 13. The respective first safety contacts 12 and the first safety module 13 are checked for proper functioning by the second safety monitoring module 13.S by comparison with the protective contact input states ES and the output signals A formed by the safety module. Should deviations in the signal states ES or in the safety signal processing between the redundant working Function modules occur by only one safety contact 12 is triggered or one of the two buses 3.S fails or a security module 13, 13.S work incorrectly, the output of an error message to the host computer 1 and / or the compulsory transfer of the printing press in a secure Status.

A further embodiment of the subject invention is to increase the signal transmission speed between the central machine control, the drive control units and the signal input and output modules directed by the signal transmission by optical means, e.g. by means of optical fibers, takes place. This is associated with an advantageous Insensitivity of the bus systems 2,3 with respect to EMC interference.

The control structure according to the invention is also with those in peripheral auxiliary drives existing drive control units that are not directly to the printing press units include, if they have the required power reserves - comparable to the decentralized drive control units 6 present in the printing units DW1, DW2 feature.

reference numeral

1

master computer

2

bus system

3

bus lines

3. S

safety bus

4

Physical control

5

decentralized drive

6

Drive control unit

7

electronic cam switch

8th

drive motor

9

Rotary encoder

10

Signal input module

10.S

Safety Signal Input Module

11

Signal output module

12

Security / protection Contact

13

security module

13.S

Safety monitoring module

A

signal outputs

DW1

Printing unit 1

DW2

Printing unit 2

e

signal inputs

IT

Safety Signal input

Claims (8)

1. Control for rotary printing machines in unit mode of construction

   with a superordinate machine control, decentral unit controls (4) and decentral drive control units (6) subordinate thereto,

   with decentral drives in the units (DW1, DW2), consisting of at least one drive motor (8), a rotational angle transmitter (9), an electronic drive control unit (6) and signal inputs and signal outputs (E, A),

   with a control computer (1) and

   with bus systems (2) or networks interconnecting the control components and drive control units (6),

   characterised in that the decentral unit controls (4) are integrated in the drive control units (6) and for that purpose unit control function modules, which execute decentral unit control functions in co-operation with other control components, are implemented in the capacity reserves, which are not needed for drive control functions, of the drive control units (6).
2. Control according to claim 1, characterised in that function modules processing position-dependent signals of the rotational angle transmitter (9) integrated in the decentral drive (5) and forming therefrom control signals dependent on rotational angle are implemented in the drive control units (6) and take over the cyclic control, which is dependent on the rotation of angle, of the units (DW1, DW2).
3. Control according to claim 1, characterised in that function modules for synchronising several decentral drives (5) are implemented in the drive control units (6) and form a drive regulating system.
4. Control according to claim 1, characterised in that function modules for synchronising several units (DW1, DW2) by means of control computer (1) are implemented in the drive control units (6) and the function modules are for that purpose connected by way of a bus system (2), which also transmits synchronisation signals, with the control computer (1) executing the central machine control functions.
5. Control according to one of claims 1 to 4, characterised in that separate signal input and signal output modules (10, 11), which are coupled with the drive control units (6) by means of the bus system (6), are arranged in front of the drive control units (6).
6. Control according to claim 1 or 5, characterised in that

   function modules for redundant execution of safety functions are implemented in each two drive control units disposed in a unit (6.11, 6.12) or in two different units (6.11, 6.21), wherein the respective first function module (13) processes the safety signals and triggers the intended safety function and the respective second function module (13.S) checks the respective first function module (13) for correct signal processing and in the case of disturbance triggers the safety function instead of the first function module (13),

   safety signal input modules (10.S) are arranged in front of the function modules (13, 1 3.S), which process the safety signals, in the drive control units (6) separately therefrom,

   the safety signal input modules (10.S) are connected by means of safety bus lines (3.S) with the safety signal inputs (E.S) of the drive control units (6.11, 6.12, 6.21) and

   the safety signals to be processed in accordance with the implemented safety functions are led in parallel on the safety signal inputs (E.S) of the respective first drive control unit (6.11) and second drive control unit (6.12, 6.21).
7. Control according to one of claims 1 to 6, characterised in that the signal transmission is carried out optically in the bus systems (2, 3).
8. Control according to one of claims 1 to 7, characterised in that the decentral drives (5) are auxiliary drives of peripheral units.

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