EP1427499A2

EP1427499A2 - Control system for winches and other machines

Info

Publication number: EP1427499A2
Application number: EP02779406A
Authority: EP
Inventors: Rainer M. Puls; Oliver Puls
Original assignee: PULS Oliver; PULS Rainer M
Current assignee: Puls Rainer M En Puls Oliver
Priority date: 2001-09-21
Filing date: 2002-09-23
Publication date: 2004-06-16
Anticipated expiration: 2022-09-23
Also published as: CN1589170A; ATE378099T1; DE10146521A1; AU2002342746A1; EP1427499B1; WO2003026998A3; JP2005503629A; WO2003026998A2; CN100475299C; DE10146521B4; DE50211219D1; JP4727921B2

Abstract

The invention relates to a multi-axle control system for winches and other machines, especially in theatre studios and theatres, whereby two axle calculators provided on the winch/machine are respectively connected to a group calculator. The invention enables up to 200 axles, or more, to be simultaneously and synchronously controlled and monitored in a secure manner.

Description

Control system for winches and other machines

The invention relates to a multi-axis control system for winches and other machineries in stages, studios and theaters, in particular for synchronous travel and similar safety-relevant movement sequences.

Various multi-axis control systems of this type are known, with which cable winches and other machinery can be controlled and monitored in stages, studios and theaters. As a rule, these systems require a lot of cabling and are therefore complex and prone to failure. Regardless of the amount of cabling, the known systems often have little flexibility and in many cases compromises are made in terms of the safety requirements to be met in terms of the availability of the control system.

From DE 32 33 788 a control system for a stage machinery is known, through which the separation between upper machinery control and lower machinery control is to be overcome. For this purpose, a computer system is provided for the upper machinery and for the lower machinery for the control of individual and common movements of the trains or the floor parts. The two computing systems are connected to one another in order to synchronize movements of the drives of parts of the upper machine on the one hand and the lower machinery on the other hand.

Against this background, the aim of the invention is to provide a control system for cable winches and other machines in stages, studios and theaters which is on the one hand highly secure and on the other hand highly available, which can be implemented with little wiring and ensures a high degree of flexibility and security. This goal is achieved by a control system with the features specified in claim 1. Advantageous refinements result from the subclaims.

With a control system according to the invention, up to 200 cable winches and other machines (200 axes) can be moved synchronously, with safety class 5 according to DIN 19250 V VDE 0801 being achieved for safety-related computer controls.

In the following the invention is based on a

Exemplary embodiment explained in more detail with reference to the figures, in which:

Fig. 1 is a schematic diagram of the structure of a control system according to the invention; and

Fig. 2 is a schematic diagram of the control-relevant construction of a winch / machine within the control system according to the invention. -

As can be seen from FIG. 1, the control system according to the invention is divided into five areas, namely the axis level I, the central process computer level II, the operator and observer level III, the diagnosis and service level IV and remote maintenance level V. Levels I, II, III and IV are connected to each other via industrial bus systems, level V to level IV via a

Telecommunication line (for example a modem-modem connection) connected.

As can be seen from FIG. 2, the cable winches / machines M1, M2 .. Mn to be controlled or monitored are located in level I, a large number of which can be controlled and monitored with the control system according to the invention. In the following the construction according to the invention is described in detail with reference to the cable winch / machine M1 in FIG Machines M2 to Mn repeated accordingly or in a slightly modified form.

As shown in the winch / machine Ml, the winch / machine to be controlled and monitored has a motor M which is controlled via a first axis computer AR1 and a frequency converter FU (driver circuit). For this purpose, the first axis computer AR1 is connected to the frequency converter FU. The axis computer AR1 preferably works in real time and is equipped with a real-time industrial operating system. There is an absolute encoder AIWGl on a drive shaft of the cable winch / machine, which feeds its signal to the first axis computer AR1. Furthermore, the cable winch / machine is assigned a second axis computer AR2, which is connected to the first axis computer AR1 via an interface, for example a serial interface in accordance with RS-485, and which is preferably equipped with an on-site control panel. The second axis computer AR2 is also connected to the frequency converter FU and preferably works in real time, for which purpose it is also equipped with a real-time industrial operating system. A second absolute encoder AIWG2 is connected to the second axis computer AR2 and sits on an output shaft of the cable winch / machine. By comparing the actual values of the two absolute encoders AIWGl and AIWG2, the function of the absolute encoders can be checked on the one hand, and monitoring for gear breakage, shaft breakage, clutch breakage, etc. is possible, since one absolute encoder on the drive shaft and the other on the output shaft Cable winch / machine is arranged.

The first and second axis computers AR1 and AR2 have direct access to the frequency converter FU or an upstream contactor and to a braking device for switching off and safely stopping the winch / machine.

Furthermore, one or more safety sensors S for determining overload, underload, overspeed, There are winding errors, reaching end positions, etc., the output signals of which are fed to both the first and the second axis computer AR1 or AR2.

Two group computers GR1 and GR2 are provided in level II, which control and monitor synchronous group trips of several winches / machines. Both group computers preferably work in real time and are therefore equipped with a real-time industrial operating system. The first group computer GR1 is connected to the first axis computers AR1 of level I via a bus B1, preferably an optical waveguide bus. Bus Bl is preferably designed as a Simolink bus or an equidistant professional bus.

The fiber optic bus Bl allows simple, space-saving ring-shaped instead of star-shaped cabling and ensures low susceptibility to incident interference. In addition, the Simolink bus, like the equidistant professional bus, is a deterministic bus in which the cycle time of the computer programs is always constant and is not briefly or irregularly influenced by occasionally arithmetic-intensive procedures. Combined with the high transmission rate of 11 Mbit / s regardless of the cable length, this design means that the control, regulation and monitoring of the drives is significantly better than that of controls that do not use deterministic buses and whose transmission rate is less than 11 Mbit / s and where the cable routes influence the signal transmission.

Thanks to the safe and fast signal transmission of the Simolink fiber-optic bus Bl mentioned above, the drives in Level I can be controlled very quickly and to the highest degree synchronously, which on the one hand brings significant improvements with regard to the noise behavior that is important in theaters and in the event of an error or Disturbance a very fast and synchronous The rope winches / machines can be shut down. The "moving apart" of synchronous and coupled drives can be significantly reduced. This is particularly important in the theater, since large and heavy decorative parts often have to be lifted and moved by several winches / machines. Actors, artists and stage workers work under these decoration parts and the "pulling apart" of the drives too much can lead to a decoration tearing apart or tipping over or a drive being overloaded and ropes torn etc.

The first group computer GR1 sends commands corresponding to the protocol used to the first axis computers AR1 via bus B1 and receives signals from the axis computers. The commands sent from the first group computer GR1 convert the respective first axis computer AR1 into the control signals to the frequency converter FU, i.e. the motors of the side winches / machines

The signals received from the absolute encoders AIWGl and AIWG2 and the safety sensors S (overload, underload, slack rope, emergency end, overspeed, winding errors, tracking errors (positional deviation), bus errors etc.) are used to monitor and control the synchronous travel of the drives and at least for this purpose partially transferred from the axis computers to the group computer.

In the event of an error, the group computer GRl shuts down the synchronous drives, with the shutdown also taking place synchronously.

The respective first axis computer ARl of each winch / machine also monitors the function of the individual winch / machine directly on the drive and also switches itself off to the group computer GRl with a time delay in the event of a fault. If the group computer GR1 fails, the faulty drive is additionally switched off by the first axis computer ARl. However, in the case of synchronous traversing movements of several axes, if an error occurs on one axis, as a rule synchronous stopping of all drives, i.e. not only the faulty one is required, the stopping by the first axis computer AR1 is delayed compared to the stopping by the group computer GRl.

In the event of malfunctions, both the first axis computer AR1 and the first group computer GR1 react. In the event of a drive failure, the group computer GR1 determines whether another cable winch / machine is being moved in synchronism with the faulty cable winch / machine. If this is the case, the group computer GR1 determines the way in which the synchronous winches / machines have to be braked and / or stopped. In the best case scenario, all cable winches / machines moving synchronously in a group are braked synchronously (but quickly).

If, due to failure of the first group computer GRl, it is not possible for the first group computer GRl to shut down the winches / machines, the winches / machines running synchronously are nevertheless stopped. For this purpose, a second group computer GR2 is available in level II to protect the synchronous control system, which also monitors the synchronous group movements.

The second group computer GR2 is connected via a second bus B2, preferably an optical fiber bus, to the second axis computers AR2 of the winches / machines. A high transmission rate of 12 Mbit / s is also available here. For the second bus B2, what has been said above about the first bus B1 also applies.

The second axis computer AR2 of each winch receives all the above information about the condition of the cable winch / machine via the second absolute encoder AIWG2 and the safety sensors S. The second axis computer AR2 transmits this information to the other via bus B2 Group computer GR2 further. This means that the information about the condition of the cable winch / machine is available twice in level II: once in the group computer GR1 and once in the group computer GR2

In order to additionally monitor one another, the two group computers GR1 and GR2 synchronize and compare their information either via a group computer GRV connection or via a shared memory area.

If malfunctions occur, each system can react on its own by using the primary connection (group computer GRl O first axis computer ARl) or the second redundant connection (group computer GR2 O second axis computer AR2) to the winch / machine and its shutdown / Shutdown mechanisms FU / A is affected.

In addition, the faulty drive is also switched off directly on the winch / machine via the respective AR2 axis computer. This shutdown takes place just like the time delayed by the first axis computer AR1 for the shutdown by the group computers GR1 and GR2, in order to ensure synchronous shutdown and to prevent the drives from "moving apart", for example by prematurely applying the brake of a single drive.

There are two mutually independent and monitoring group computers GRl and GR2 with real-time operating systems for controlling and monitoring synchronous runs, two fast, safe but separate and therefore diverse bus systems Bl and B2, two independent separate and decentralized axis computers ARl and AR2 on the winch / Machine several different and independent switch-off mechanisms (double brakes, switch disconnector, locks of the controller releases) double safety sensors S (limit switches, load measurement, etc.) read into independent systems and double, separate and independent systems If absolute absolute encoders AIWGl and AIWG2 are read in, the system as a whole is redundant, diversified and mutually monitored and accordingly designed to be safe. If one of the control systems reacts differently from the other, this is also recognized and reported.

In the event that either the first group computer GR1 or the second group computer GR2 are not ready for use, it is possible to drive the winch / machine either with the first group computer GR1 or with the second group computer GR2 in the event of a fault. This ensures maximum availability for the system even if one computer fails. If both group computers fail, an additional on-site operation of each drive is possible via the second AR2 axis computer, since the second axis computer is equipped with an operating panel.

The control system for

Cable winches / machines with the first group computer GRl and the second group computer GR2 reach security level AK5 according to DIN 19250 / V VDE 0801. If one of the two group computers fails, the control of the cable winches / machines via the remaining group computer alone reaches security level AK4.

It is therefore possible to implement an emergency control or a backup solution with the existing components, which allows the system to continue operating even if a computer system fails. No additional components are required. This reduces costs for the operator and, by reducing the number of parts, the probability of the system failing.

The connection to one or more control panels BP in level III is made via an (Ethernet) bus B3, likewise preferably using fiber optic technology, so that the Connection between levels II and III is insensitive to interference and can be realized with a high transmission rate.

In level IV, a service and diagnostic computer SDR is provided, which is also connected via the (Ethernet) bus B3 to the computers in level II and the control panels BP in level III.

In level V, a remote maintenance computer FWR is provided, which is connected to the computer SDR via a telecommunication connection B4, for example a connection via modem MD1 and MD2. This means that the group computers of level II can be accessed directly via the additional remote maintenance connection B4 to level V between levels IV and V. The information, parameters and settings of level II are thus available for remote maintenance in level V.

The service and diagnostic computer SDR is preferably connected to the cable winches / machines via a further bus 5 or alternatively via the existing bus lines B1, B2 and B3, preferably directly to the axis computers AR1 and AR2 and the frequency converters of the cable winches / machines and likewise also with additional peripheral drives. This enables direct access to all these components and the information and parameter settings available there, in particular the settings of the absolute encoders via remote maintenance.

A further increase in safety can be achieved in that, in cooperation with a control system according to the invention, the double brakes of the cable winches / machines are mounted on the output shaft and no longer on the drive shaft.

The arrangement of an absolute encoder AIWGl on the drive shaft and an absolute encoder AIWG2 on the output shaft makes it possible to break in between or failure of a gearbox, a coupling, a welded connection, a shaft / hub connection, a screw connection, any other frictional or positive connection etc. and then safely stop the winches / machines by activating and applying the brakes on the drive.

In addition, this arrangement of the brake allows the safety factor 2 prescribed for all mechanical drive components according to DIN for stage technology e.g. for gears, shafts, clutches etc. against permanent breakage can be omitted, since these are now behind the brake. The cable winches / machines are at least 30% smaller and less expensive and, thanks to the use of smaller component sizes, they are also quieter.

The overall advantages of the control system according to the invention are as follows:

two mutually independent and mutually monitoring group computers with real-time operating systems (e.g. Siemens RMOS) for controlling and monitoring synchronous drives,

two diverse optical fiber bus systems with a speed of over 11 Mbit / s,

Use of the deterministic Simolink fiber-optic bus

two independent and decentralized axis computers on the winch / machine,

Several different, independent switching systems controlled by independent systems (double brakes, switch disconnectors, blocking of controller releases) double safety sensors that are read into independent systems (limit switches, load measurement, slack rope, winding errors etc.)

double different absolute encoders read into independent systems and attached to both the input shaft and the output shaft

Accessibility and service and maintenance options via ISDN, modem or Internet to all components of the control system including the absolute encoder and frequency converter

High availability of the system even if one group computer fails due to the possibility of being able to drive all drives with synchronous movements even via the respective redundant second group computer (this without the need for additional components.)

If both group computers fail, the drives can still be operated using the respective local controls on the winches / machines

Claims

P A T E NTAN S P RÜ C H E

Control system for winches and other machines, especially in stages, studios, and theaters

a. Two axis computers (ARl, AR2) each for controlling and monitoring one of several cable winches / machines (Ml, M2, ... Mn), which are assigned to a first control level (I),

i. which are both connected to a control circuit (FU) for an electric motor of the winch / machine and

ii. of which a first axis computer (ARl) is connected to a first absolute value encoder (AIWGl), which is arranged on the cable winch / machine, and

iii. of which a second axis computer (AR2) is connected to a second absolute encoder (AIWG2), which is arranged on the cable winch / machine; and

b. two group computers (GR1, GR2) assigned to a second control level (II),

i. of which a first group computer (GRl) is connected to the first axis computers (ARl) via a first bus (B1) and

ii. of which a second group computer (GR2) is connected to the second axis computers (AR2) via a second bus (B2) independently of the first bus (B1), and iii. which are connected to one another via a group computer connection (GRV) or a common memory or memory area for exchanging information independently of the first and second bus (B1, B2).

2. Control system according to claim 1, characterized in that the first bus (Bl) is designed as an optical waveguide bus.

3. Control system according to claim 1 or 2, characterized in that the first bus (B1) is designed as a deterministic bus, preferably as a Simolink bus or an equidistant professional bus.

4. Control system according to one of the preceding claims, characterized in that the second bus

(B2) is designed as an optical waveguide bus.

5. Control system according to one of the preceding claims, characterized in that the second bus

(B2) is designed as a deterministic bus, preferably as a Simolink bus or an equidistant professional bus.

6. Control system according to one of the preceding claims, characterized in that one or more control panels (BP) are provided which are assigned to a third control level (III) and which are connected to the first and second group computers (GR1, GR2) via a third bus (B3) are connected.

7. Control system according to claim 6, characterized in that the third bus (B3) is designed as an optical fiber bus, wireless bus or mixed bus.

8. Control system according to claim 6 or 7, characterized in that the third bus (B3) is designed as an Ethernet bus.

9. Control system according to one of the preceding claims 6 to 8, characterized in that a service and diagnostic computer (SDR) is provided, which is assigned to a fourth control level (IV) and via the third bus (B3) with the first and the second group computer (GRl, GR2) and is connected to the control panels.

10. Control system according to claim 9, characterized in that the service and diagnostic computer (SDR) is additionally or alternatively connected via a fifth bus (B5) to the cable winches / machines (Ml, M2, ... Mn).

11. Control system according to claim 9 or 10, characterized in that a remote maintenance computer (FWR) is provided, which is assigned to a fifth control level (V) and which via a

Telecommunications connection (B4, MD1, MD2) with the service and diagnostic computer (SDR) is connected.

12. Control system according to one of the preceding claims, characterized in that the first and the second axis computer (AR1, AR2) are equipped with a real-time operating system.

13. Control system according to one of the preceding claims, characterized in that the first and the second group computer (GR1, GR2) are equipped with a real-time operating system.

14. Control system according to one of the preceding claims, characterized in that safety sensors (S) on winches / machines are provided, the output signals of which are fed to the first and the second axis computer (AR1, AR2).

15. Control system according to one of the preceding claims, characterized in that the first and the second axis computer (AR1, AR2) evaluates the signals received by the safety sensors (S) and at least partially forward them to the first and the second group computer (GR2).

16. Control system according to one of the preceding claims, characterized in that the first absolute encoder (AWIG1) is arranged on a drive shaft of the winch / machine and that the second absolute encoder (AIWG2) is arranged on an output shaft of the winch / machine.

17. Control system according to one of the preceding claims, characterized in that the second axis computer (AR2) is equipped with an operating panel for controlling the cable winch / machine by hand.

18. Control system according to one of the preceding claims, characterized in that the first group computer (GRl) is designed to control and monitor the first axis computer (ARl), that the second group computer (GRl) is designed to control the second axis computer ( ARl) to control and monitor, and that both group computers (GRl, GR2) are designed to monitor each other and to exchange information about the winches / machines and the axis computer for comparison.

19. Control system according to claim 18, characterized in that the control and monitoring of the axis computer (ARl, AR2) by the group computer (GRl, GR2) takes place in such a way that the cable winches / machines either by the first group computer (GRl) in Connection to the first axis computers (AR1) or solely from the second group computer (GR2) in connection with the second axis computers (AR2) takes place when the other group computer fails.

20. Control system according to claim 18, characterized in that the first or the second axis computer (AR1, AR2) are designed to delay the shutdown / shutdown of the cable winch / machine in order to trigger the in the event of a malfunction

Triggering shutdown / shutdown by the group computer (GRl, GR2).

21. Method for controlling several cable winches and other machines, in particular in stages, studios and theaters, characterized in that a first axis computer (ARl) receives the output signals of a first absolute value encoder (AIWGl) which is connected to one of the cable winches / machines ( Ml, M2, ... Mn) is arranged, and in each case a second axis computer (AR2) receives the output signals of a second absolute encoder (AIWG2) which is connected to the same cable winch / machine (Ml, M2,

... Mn) is arranged that a first group computer (GRl) controls and monitors the first axis computer (ARl), that a second group computer (GRl) controls the second axis computer (ARl) and monitors that the first and second group computers ( GRl, GR2) monitor each other and exchange information for comparison, the connections between the first and second axis computers (ARl, AR2) on the one hand and the first and second group computers (GRl, GR2) on the other via a separate bus (B1, B2) , preferably an optical waveguide bus, and the connection between the two group computers (GR1, GR2) takes place via a group computer connection (GRV) or a common memory or memory area.

22. A method for controlling several cable winches and other machines, in particular in stages, studios and theaters according to claim 18, characterized in that the control and monitoring of the axis computer (ARl, AR2) by the group computer (GRl, GR2) takes place in this way that the cable winches / machines either take place solely from the first group computer (GR1) in connection with the first axis computers (AR1) or solely from the second group computer (GR2) in connection with the second axis computers (AR2) if the other group computer fails ,

23. A method for controlling several cable winches and other machines in stages, studios and theaters according to claim 21 or 22, characterized in that the first or the second axis computer (ARl, AR2) in the event of a malfunction the shutdown / shutdown of the cable winch / machine in time delayed to trigger the

Trigger shutdown / shutdown by the group computer (GRl, GR2).