EP1834224A1 - A method and a device for controlling an industrial process or production unit - Google Patents

A method and a device for controlling an industrial process or production unit

Info

Publication number
EP1834224A1
EP1834224A1 EP05820991A EP05820991A EP1834224A1 EP 1834224 A1 EP1834224 A1 EP 1834224A1 EP 05820991 A EP05820991 A EP 05820991A EP 05820991 A EP05820991 A EP 05820991A EP 1834224 A1 EP1834224 A1 EP 1834224A1
Authority
EP
European Patent Office
Prior art keywords
production unit
operator
machine
control
pressure
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP05820991A
Other languages
German (de)
French (fr)
Inventor
Tobias Hansson
Lennart HÄRDELL
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ABB Technology AG
Original Assignee
ABB Technology AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ABB Technology AG filed Critical ABB Technology AG
Publication of EP1834224A1 publication Critical patent/EP1834224A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05G—CONTROL DEVICES OR SYSTEMS INSOFAR AS CHARACTERISED BY MECHANICAL FEATURES ONLY
    • G05G1/00—Controlling members, e.g. knobs or handles; Assemblies or arrangements thereof; Indicating position of controlling members
    • G05G1/52—Controlling members specially adapted for actuation by other parts of the human body than hand or foot

Definitions

  • a method,-a system and an operating member for controlling a process and/or a production unit/machine A method,-a system and an operating member for controlling a process and/or a production unit/machine.
  • the present invention relates to a method and a device for controlling an industrial process or a production unit, such as a machine or the like.
  • the invention especially relates to a method and a control device that free the operator's hands and that are used especially as a wireless control of a rotating winding machine for winding transformer windings or the like.
  • control panels For control of processes or production units, normally various forms of control panels, handheld control members or the like are used.
  • An operator controls the plant/machine by pressing different control members/switches and monitors the plant by studying control lamps or symbols, on a display unit.
  • a critical factor in a winding machine is to maintain a high degree of utilization, that is, to try to maintain the machine in operation for as long periods as possible. The time during which a machine is rotating creates value.
  • the operator is able to deliver various control commands or control functions to the machine by pressing various surfaces on the foot pedal, for example to start/stop the winding machine and to increase or decrease the speed of rotation of the machine.
  • the foot pedal limits the freedom of movement of the operator to a relatively locked/fixed position in relation to the rotating winding machine. The operator is locked to the same position to deliver/carry out various commands. Certain operations, such as, for example, stretching and reversing, would be considerably facilitated if the operator could move around the winding concurrently with the machine being operated/controlled.
  • Another disadvantage of using a foot pedal is that the machine is inefficiently utilized, which results in a lower utilization of time of the machine and hence a lower productivity.
  • the object of the invention is to provide a method and a device which solve the above-mentioned problems and by means of which an industrial process or a production unit/machine may be controlled in a flexible and efficient way by an operator, but which at the same time permit the operator to have his hands free during the whole operation.
  • the operator is to be able to control the machine from the position in which he is at the moment.
  • the control device should be comfortable to use and should satisfy hygienic requirements.
  • a machine or a process is no longer controlled via a foot pedal, placed on the floor, but via a wireless control device worn by the operator and which reacts to impulses via the operator's mouth, that is, the operator blows or sucks in a nozzle made for the purpose.
  • a control device ac- cording to the invention significantly facilitates the control of the production unit, among other things because it frees both hands of the operator for other operations than the actual control of the machine.
  • the wireless control device permits the operator to be very flexible and permits him to move freely within the reach range of the transmitter, which leads to good ergonomics and improved productivity.
  • a wireless control provides a more efficient running with faster start-up, step-up/step-down and higher speed of rotation as well as full freedom of movement around the whole opera- ting range of the machine.
  • the invention also reduces the number and the length of the so-called micro-pauses during the course of the work.
  • Figure 1 shows a block diagram of a control device according to the invention and its connection to a winding machine for transformers .
  • Figure 2 shows a block diagram/functional diagram of the connection and function of the operating member.
  • Figure 3 shows in more detail the operating member and its nozzle through which the operator gives his control commands.
  • Figure 3 shows the transmitter unit of the control device, here integrated with an ear defender worn by the operator.
  • FIG. 1 thus shows a block diagram of a control device Ia,b according to the invention, how it is electrically connected and how it cooperates with, in this case, a winding machine for manufacturing transformer windings .
  • the winding machine per se comprises a vertically standing/rotating cylinder 2 powered by an electric motor, around which a copper wire 3 is wound.
  • the electrically powered cylinder 2 is controlled by an automatic control unit 4 that supplies the electric motor (not shown) with electric power and control and monitors the necessary functions in the production facility.
  • the control device comprises a transmitter part Ia and a receiver part Ib.
  • the transmitter part Ia in turn, consists of an operating member 8, provided with a nozzle 9, and a signal-processing module 10, a transmitter 11 and an aerial 12a.
  • the receiver part Ib is connected to the control unit 4 of the production facility and is provided with an aerial 12b for receiving radio waves.
  • the transmitter 11 transmits signals in a wireless manner, preferably with the aid of radio waves with a carrier fre- quency of, for example, 433 MHz, to a receiver part Ib.
  • the transmission may also be made with the aid of IR light, ultrasound, laser, etc.
  • the reach of the transmitter 11 should be between 25 and 200 m depending on the production equipment, the surrounding environment, the supplied power, etc.
  • FIG. 2 shows the various functional blocks of the trans- mitter part Ia.
  • the transmitter part Ia comprises both a signal-processing unit 10, placed in the operating member 8, and a transmitter 11, for example provided with a key set 13 and an aerial 12a.
  • the operating member 8 is provided with a nozzle 9 and comprises two sensors, a pressure transducer 14, which may be of a piezoelectric type, and a touch- or contact-sensing transducer 15, which may preferably be of a capacitive type but which may also consist of a microswitch, a conducting rubber membrane or the like. Both transducers 14, 15 are built together and enclosed in the operating member 8.
  • the pressure transducer 14 detects the air pressure that the operator 7 through his mouth applies in the operating member
  • the nozzle 8 by way of the nozzle 9.
  • three different levels are detected, an overpressure, a negative pressure, but also a normal pressure. This corresponds to the states the operator 7 achieves by blowing, sucking, or doing neither, in the nozzle 9 of the operating member 8.
  • the contact-sensing transducer 15 is placed in/at the nozzle
  • the transducer 15 detects accordingly and prevents the machine from starting; alternatively, if the machine is already running, a stop is triggered.
  • the signal from the pressure transducer 14 is amplified in an instrumentation amplifier 16 and the resultant signal is supplied to a first and a second comparator 17, 18.
  • the first comparator 17 compares the signal from the pressure transducer 14 with a signal level that is preset by means of a first potentiometer 19, and delivers an output signal to the transmitter 11 when the signal level exceeds a preset value. This indicates that an overpressure has been detected in the nozzle/the pressure transducer 8, 14.
  • the second comparator 18 compares the signal from the pressure transducer 14 with a value that is preset by means of a second potentiometer 20, and delivers an output signal to the transmitter 11 when the signal level falls below the preset value. This indicates that a negative pressure has been detected in the nozzle/the pressure transducer 8, 14.
  • a key set 13 is connected to the transmitter.
  • an additional number of commands may be given by the operator 7 and be transferred to the machine and which do not require that the operator 7 should have free hands.
  • these commands may con- trol functions such as raising or lowering the rotating cylinder 2, opening or closing a cavity that exists between the rotating cylinder and the floor level, changing the direction of rotation of the cylinder 2, and controlling the brake system (on/off) etc.
  • the contact-sensing transducer 15 (the presence transducer)
  • said transducer delivers a signal that is transmitted to the transmitter 11.
  • the signal thus implies that "the presence of the operator is detected” and is transmitted from the transmitter 11 to the receiver Ib that decodes the signals and adapts them to the automatic control unit 4 of the process/the machine and allows the process/machine to be released so that it can start working.
  • FIG 3 shows in more detail the operating member and its nozzle via which the operator delivers control commands by blowing, sucking or just touching with his mouth/lip.
  • the operating member 8 comprises a housing 21 which together with an upper housing section 22 forms a cavity in a mounted position.
  • the cavity forms a closed pressure chamber 23 that communicates with the nozzle 9 via a channel 24.
  • the pressure transducer 14 is arranged so as to detect the difference between the pressure that arises in the chamber 23 when the operator 7 blows/sucks and the external atmospheric pressure that exists outside the operating member, and this via an additional channel 25.
  • the presence-sensing transducer 15 comprises a thin metal plate 26 or foil, which is here placed on the upper housing section 22 of the operating member 8 near the nozzle 9.
  • the plate 26 is connected to electronics and is able to detect the presence of the mouth/lip of the operator 7.
  • a signal-processing unit 10 comprising, inter alia, an instrument amplifier 16 and comparators 17, 18 is arranged in the operating member 8 and cables 27 leading to the transmitter 11 are placed inside a flexible arm 28.
  • the operating member 8 is also provided with an edge 29 that makes it easier for the operator 7 to hold the unit in the right way in his mouth.
  • Figure 4 shows how the operating member 8 according to the invention is applied to a headset/ear defender 30.
  • the operating member 8 is here mounted on a flexible arm 28, the other end of which is fixedly or detachably connected to one of the ear muffs 31.
  • the transmitter part 11 may be integra- ted into one of the muffs or be a loose unit and connected via a cable and can then be attached to the operator's clothes, be placed in a pocket, etc.
  • the transmitter 11 is connected to an aerial 12a that is mounted on the muff 31.
  • the position of the operating member/the nozzle 8, 9 may be easily adjusted and be set so as to fit and be comfortable for use by the operator 7.
  • the pressure transducer 14 to sense the air pressure that is applied in the nozzle 9, in a stepless o o manner, and on the basis of such a signal the machine, for example, controls the speed in a stepless manner. By varying the intensity of blowing the nozzle 9, the operator 7 is thus allowed to control the speed of the machine in a step- less manner.

Landscapes

  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Automation & Control Theory (AREA)
  • Preliminary Treatment Of Fibers (AREA)
  • General Factory Administration (AREA)
  • Selective Calling Equipment (AREA)

Abstract

The invention relates to a method for controlling a process and/or a production unit. The invention is achieved by the operator controlling the production unit by blowing or sucking a specially designed control device. The invention also relates to a system and an operating member for controlling a process and/or a production unit.

Description

A method,-a system and an operating member for controlling a process and/or a production unit/machine.
Technical field
The present invention relates to a method and a device for controlling an industrial process or a production unit, such as a machine or the like. The invention especially relates to a method and a control device that free the operator's hands and that are used especially as a wireless control of a rotating winding machine for winding transformer windings or the like.
Background of the invention and prior art
For control of processes or production units, normally various forms of control panels, handheld control members or the like are used. An operator controls the plant/machine by pressing different control members/switches and monitors the plant by studying control lamps or symbols, on a display unit.
For example, when manufacturing large transformers and when winding the transformer windings thereof, it is necessary, and also a requirement, that the operator's two hands be free and can be used for supporting or controlling the winding operation. A critical factor in a winding machine is to maintain a high degree of utilization, that is, to try to maintain the machine in operation for as long periods as possible. The time during which a machine is rotating creates value.
For the above reason there is used today a type of foot pedal when manufacturing transformer windings. By means of the foot pedal, the operator is able to deliver various control commands or control functions to the machine by pressing various surfaces on the foot pedal, for example to start/stop the winding machine and to increase or decrease the speed of rotation of the machine. However, the foot pedal limits the freedom of movement of the operator to a relatively locked/fixed position in relation to the rotating winding machine. The operator is locked to the same position to deliver/carry out various commands. Certain operations, such as, for example, stretching and reversing, would be considerably facilitated if the operator could move around the winding concurrently with the machine being operated/controlled.
In addition, such a foot pedal leads to an unnatural working position, since the operator in practice remains standing on one leg when he controls the winding machine, for example by pulsed pressing or kicking on the pedal. This mode of operation entails a physical static load since the operator has to balance his body, and this often results in strain injuries to the neck and the back.
Another disadvantage of using a foot pedal is that the machine is inefficiently utilized, which results in a lower utilization of time of the machine and hence a lower productivity.
To reach a good cost effectiveness and improved ergonomics, and thus reduce personnel injuries, it becomes increasingly more important to make use of a different and better technique.
Objects and most important characteristics of the invention
The object of the invention is to provide a method and a device which solve the above-mentioned problems and by means of which an industrial process or a production unit/machine may be controlled in a flexible and efficient way by an operator, but which at the same time permit the operator to have his hands free during the whole operation. By means of the invention, the operator is to be able to control the machine from the position in which he is at the moment. In addition, the control device should be comfortable to use and should satisfy hygienic requirements. The above object and other objects are achieved according to the invention by a method according to claim 1, by a system according to claim 4, and by an operating member according to claim 9.
According to the invention, a machine or a process is no longer controlled via a foot pedal, placed on the floor, but via a wireless control device worn by the operator and which reacts to impulses via the operator's mouth, that is, the operator blows or sucks in a nozzle made for the purpose.
Through these impulses in the nozzle, the operator can start or stop the winding machine and increase or reduce the speed of the winding machine. If the operator releases the nozzle with his mouth, the machine will stop. A control device ac- cording to the invention significantly facilitates the control of the production unit, among other things because it frees both hands of the operator for other operations than the actual control of the machine. The wireless control device permits the operator to be very flexible and permits him to move freely within the reach range of the transmitter, which leads to good ergonomics and improved productivity. A wireless control provides a more efficient running with faster start-up, step-up/step-down and higher speed of rotation as well as full freedom of movement around the whole opera- ting range of the machine. The invention also reduces the number and the length of the so-called micro-pauses during the course of the work.
Brief description of the accompanying drawings
The invention will be described in greater detail below with reference to the accompanying figures.
Figure 1 shows a block diagram of a control device according to the invention and its connection to a winding machine for transformers .
Figure 2 shows a block diagram/functional diagram of the connection and function of the operating member. Figure 3 shows in more detail the operating member and its nozzle through which the operator gives his control commands.
Figure 3 shows the transmitter unit of the control device, here integrated with an ear defender worn by the operator.
Description of preferred embodiments of the invention
Figure 1 thus shows a block diagram of a control device Ia,b according to the invention, how it is electrically connected and how it cooperates with, in this case, a winding machine for manufacturing transformer windings . The winding machine per se comprises a vertically standing/rotating cylinder 2 powered by an electric motor, around which a copper wire 3 is wound. The electrically powered cylinder 2 is controlled by an automatic control unit 4 that supplies the electric motor (not shown) with electric power and control and monitors the necessary functions in the production facility. When manufacture of a new transformer winding is to be started, the end of a copper wire 3 from a drum 5 with copper wire, placed in an uncoiling unit 6, is attached to the cylinder 2 which is then set in rotation by the operator 7 via the control device Ia, b.
The control device comprises a transmitter part Ia and a receiver part Ib. The transmitter part Ia, in turn, consists of an operating member 8, provided with a nozzle 9, and a signal-processing module 10, a transmitter 11 and an aerial 12a. The receiver part Ib is connected to the control unit 4 of the production facility and is provided with an aerial 12b for receiving radio waves.
The transmitter 11 transmits signals in a wireless manner, preferably with the aid of radio waves with a carrier fre- quency of, for example, 433 MHz, to a receiver part Ib. The transmission may also be made with the aid of IR light, ultrasound, laser, etc. The reach of the transmitter 11 should be between 25 and 200 m depending on the production equipment, the surrounding environment, the supplied power, etc.
Figure 2 shows the various functional blocks of the trans- mitter part Ia. The transmitter part Ia comprises both a signal-processing unit 10, placed in the operating member 8, and a transmitter 11, for example provided with a key set 13 and an aerial 12a. The operating member 8 is provided with a nozzle 9 and comprises two sensors, a pressure transducer 14, which may be of a piezoelectric type, and a touch- or contact-sensing transducer 15, which may preferably be of a capacitive type but which may also consist of a microswitch, a conducting rubber membrane or the like. Both transducers 14, 15 are built together and enclosed in the operating member 8.
The pressure transducer 14 detects the air pressure that the operator 7 through his mouth applies in the operating member
8 by way of the nozzle 9. Preferably, three different levels are detected, an overpressure, a negative pressure, but also a normal pressure. This corresponds to the states the operator 7 achieves by blowing, sucking, or doing neither, in the nozzle 9 of the operating member 8.
The contact-sensing transducer 15 is placed in/at the nozzle
9 in such a way that it senses the presence of the operator 7 in that the operator's mouth, lip or teeth come into contact with or touch the transducer 15. If there is no presence, the transducer 15 detects accordingly and prevents the machine from starting; alternatively, if the machine is already running, a stop is triggered.
The signal from the pressure transducer 14 is amplified in an instrumentation amplifier 16 and the resultant signal is supplied to a first and a second comparator 17, 18. The first comparator 17 compares the signal from the pressure transducer 14 with a signal level that is preset by means of a first potentiometer 19, and delivers an output signal to the transmitter 11 when the signal level exceeds a preset value. This indicates that an overpressure has been detected in the nozzle/the pressure transducer 8, 14. The second comparator 18 compares the signal from the pressure transducer 14 with a value that is preset by means of a second potentiometer 20, and delivers an output signal to the transmitter 11 when the signal level falls below the preset value. This indicates that a negative pressure has been detected in the nozzle/the pressure transducer 8, 14.
A key set 13 is connected to the transmitter. By means of this key set 13, an additional number of commands may be given by the operator 7 and be transferred to the machine and which do not require that the operator 7 should have free hands. As regards winding machines, these commands may con- trol functions such as raising or lowering the rotating cylinder 2, opening or closing a cavity that exists between the rotating cylinder and the floor level, changing the direction of rotation of the cylinder 2, and controlling the brake system (on/off) etc.
When the operator's 7 mouth/lip touches the contact-sensing transducer 15 (the presence transducer) , said transducer delivers a signal that is transmitted to the transmitter 11. The signal thus implies that "the presence of the operator is detected" and is transmitted from the transmitter 11 to the receiver Ib that decodes the signals and adapts them to the automatic control unit 4 of the process/the machine and allows the process/machine to be released so that it can start working.
Figure 3 shows in more detail the operating member and its nozzle via which the operator delivers control commands by blowing, sucking or just touching with his mouth/lip. The operating member 8 comprises a housing 21 which together with an upper housing section 22 forms a cavity in a mounted position. The cavity forms a closed pressure chamber 23 that communicates with the nozzle 9 via a channel 24. The pressure transducer 14 is arranged so as to detect the difference between the pressure that arises in the chamber 23 when the operator 7 blows/sucks and the external atmospheric pressure that exists outside the operating member, and this via an additional channel 25.
The presence-sensing transducer 15 comprises a thin metal plate 26 or foil, which is here placed on the upper housing section 22 of the operating member 8 near the nozzle 9. The plate 26 is connected to electronics and is able to detect the presence of the mouth/lip of the operator 7.
A signal-processing unit 10 comprising, inter alia, an instrument amplifier 16 and comparators 17, 18 is arranged in the operating member 8 and cables 27 leading to the transmitter 11 are placed inside a flexible arm 28.
The operating member 8 is also provided with an edge 29 that makes it easier for the operator 7 to hold the unit in the right way in his mouth.
Figure 4 shows how the operating member 8 according to the invention is applied to a headset/ear defender 30. The operating member 8 is here mounted on a flexible arm 28, the other end of which is fixedly or detachably connected to one of the ear muffs 31. The transmitter part 11 may be integra- ted into one of the muffs or be a loose unit and connected via a cable and can then be attached to the operator's clothes, be placed in a pocket, etc. The transmitter 11 is connected to an aerial 12a that is mounted on the muff 31. The position of the operating member/the nozzle 8, 9 may be easily adjusted and be set so as to fit and be comfortable for use by the operator 7.
The invention has been described above with reference to a few different preferred embodiments. The invention is not, of course, limited to these embodiments only but other variants of embodiments may be embraced by the scope of protection of the accompanying claims. Thus, it is fully conceivable for the pressure transducer 14 to sense the air pressure that is applied in the nozzle 9, in a stepless o o manner, and on the basis of such a signal the machine, for example, controls the speed in a stepless manner. By varying the intensity of blowing the nozzle 9, the operator 7 is thus allowed to control the speed of the machine in a step- less manner.

Claims

1. A method for controlling a process and/or a production unit/machine, characterized in that - the operator controls the process/production unit by applying an air pressure, blowing or sucking, in a specially designed control device.
2. A method according to claim 1, characterized by - detecting the applied air pressure,
- determining a control signal related to the pressure level in question,
- transmitting said control signal to control equipment for a process or a production unit/machine, for control thereof.
3. A method according to claim 1 or 2, characterized in that
- said transmission of the control signal takes place in a wireless manner.
.
4. A system for controlling a process and/or a production unit/machine, characterized in that
- means are arranged such that the operator is able to control the process/production unit by blowing or sucking a specially designed control member.
5. A system according to claim 4, characterized in that
- means are arranged for detecting the applied air pressure,
- means are arranged for determining a control signal related to the pressure level in question, - means are arranged for transmitting this control signal to control equipment for a process or a production unit/machine, for control thereof.
6. A system according to claim 4 or 5, characterized in that - means are arranged for wireless transmission of the control signal .
7. A system according to one or more of claims 4-6, characterized in that - a control device is arranged for detecting one of several possible and predetermined pressure levels that are applied in the operating member.
8. A system according to one or more of claims 4-6, characterized in that
- a control device is arranged for detecting an overpressure, a negative pressure and a normal pressure and, based thereon, controlling the process/the production unit.
9. An operating member for controlling a process and/or a production unit/machine, characterized in that
- a pressure transducer is arranged to detect an overpressure or a negative pressure, and based on the detected pressure, generate a signal by which the process/production unit can be controlled.
10. An operating member according to claim 9, characterized in that - a presence transducer is arranged to detect the presence of an operator's mouth/lip.
EP05820991A 2004-12-31 2005-12-30 A method and a device for controlling an industrial process or production unit Withdrawn EP1834224A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE0403228A SE0403228D0 (en) 2004-12-31 2004-12-31 Method and apparatus for controlling an industrial process or production unit
PCT/SE2005/002068 WO2006071196A1 (en) 2004-12-31 2005-12-30 A method and a device for controlling an industrial process or production unit

Publications (1)

Publication Number Publication Date
EP1834224A1 true EP1834224A1 (en) 2007-09-19

Family

ID=34132477

Family Applications (1)

Application Number Title Priority Date Filing Date
EP05820991A Withdrawn EP1834224A1 (en) 2004-12-31 2005-12-30 A method and a device for controlling an industrial process or production unit

Country Status (4)

Country Link
EP (1) EP1834224A1 (en)
CN (1) CN100589061C (en)
SE (1) SE0403228D0 (en)
WO (1) WO2006071196A1 (en)

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2397136A8 (en) * 1976-07-28 1979-02-02 Thevenot Louis Operating mechanism for tetraplegia invalids - comprises electrical contacts operated by invalid in breathing or tongue action
CH660554A5 (en) * 1983-04-12 1987-05-15 Clayton Found Res DEVICE FOR DRIVING AN ELECTRICALLY OPERATED APPARATUS.
CN1003146B (en) * 1986-03-11 1989-01-25 上海师范大学 Multi-layer winding contact type autotransformer and manufacturing method thereof
US4840634A (en) * 1987-06-10 1989-06-20 Clayton Foundation For Research Calibration controller for controlling electrically operated machines

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO2006071196A1 *

Also Published As

Publication number Publication date
CN100589061C (en) 2010-02-10
WO2006071196A1 (en) 2006-07-06
SE0403228D0 (en) 2004-12-31
CN101095092A (en) 2007-12-26

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