EP2419799A1 - Procédé de préparation de données d'état de processus et/ou de données d'état de machine d'une machine-outil - Google Patents

Procédé de préparation de données d'état de processus et/ou de données d'état de machine d'une machine-outil

Info

Publication number
EP2419799A1
EP2419799A1 EP10715695A EP10715695A EP2419799A1 EP 2419799 A1 EP2419799 A1 EP 2419799A1 EP 10715695 A EP10715695 A EP 10715695A EP 10715695 A EP10715695 A EP 10715695A EP 2419799 A1 EP2419799 A1 EP 2419799A1
Authority
EP
European Patent Office
Prior art keywords
data
machine tool
machine
state data
events
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Withdrawn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
EP10715695A
Other languages
German (de)
English (en)
Inventor
Matthias Muenzberg
Guenther Landgraf
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.)
Robert Bosch GmbH
Original Assignee
Robert Bosch GmbH
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 Robert Bosch GmbH filed Critical Robert Bosch GmbH
Publication of EP2419799A1 publication Critical patent/EP2419799A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/406—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by monitoring or safety
    • G05B19/4065—Monitoring tool breakage, life or condition
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
    • G05B19/4185—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by the network communication
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/10—Plc systems
    • G05B2219/14—Plc safety
    • G05B2219/14055—Make log, journal, history file of state changes
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/20—Pc systems
    • G05B2219/24—Pc safety
    • G05B2219/24055—Trace, store a working, operation history
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31457—Factory remote control, monitoring through internet
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/35—Nc in input of data, input till input file format
    • G05B2219/35291—Record history, log, journal, audit of machine operation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the present invention relates to a method for processing process state data and / or machine state data of a machine tool according to claim 1, a control device according to claim 9 and a computer program product according to claim 10.
  • an algorithm is provided in the machine, which is designed to receive corresponding operating parameters of the machine as an input variable, and from this the information about the wear of an S component of the machine or the information about the quality of a product to be produced by the machine To ensure production quality of the machine.
  • this algorithm includes a fixed assignment of certain characteristics of the operating parameters to the information about, the wear of the component of the machine or the information about the quality of a product to be manufactured by the machine. However, this assignment only depicts those relationships of operating parameters that are known at the time of the creation of the algorithm.
  • process state data and / or S machine state data can be very time-consuming and, if these tasks are to be performed in a real-time system, this can be a significant burden on the data processing capacity of the respective real-time system.
  • the object of the present invention is to enable an improvement in the processing of process state data and / or machine state data.
  • the present invention provides a method for evaluating state data of a machine tool, the method comprising the steps of: 0 - providing the state data by an action recorder in the
  • Machine tool wherein the state data provided in real time Represent control commands or events and wherein the events represent a response to the control commands in the machine tool; Transmitting and storing the status data from the action recorder into a log memory of a data processing unit independent of the action recorder; and
  • Monitoring unit which is arranged in a spatially remote position of the data processing unit, wherein the monitoring unit is configured to condition data from different machine tools from a plurality of different logbook
  • the present invention provides a control apparatus adapted to perform or drive steps of one embodiment of the above-mentioned methods.
  • a control device can be understood as meaning an electrical device which processes sensor signals and outputs control signals in dependence thereon.
  • the control unit may have an interface, which may be formed in hardware and / or software.
  • the interfaces can be part of a so-called system -AS IC, for example, which contains a wide variety of functions of the control unit.
  • the interfaces are their own integrated circuits or at least partially consist of discrete components.
  • the interfaces may be software modules that are present, for example, on a microcontroller in addition to other software modules.
  • a computer program product with program code which is stored on a machine-readable carrier such as a semiconductor memory, a hard disk memory or an optical memory and is used to carry out the method according to one of the embodiments described above, when the program is executed on a control unit.
  • the present invention is based on the recognition that a state of a machine tool can be evaluated very well if first an action recorder is used which records in real time control commands and / or events that occur during operation of the machine tool. These control commands and / or events may then be transmitted to a log memory in a data processing unit that is independent of the action recorder or the machine tool.
  • the data on the state of the machine tool is also an evaluation unit at your disposal when the machine tool is not in operation. For example, the data about the
  • the state of the machine tool (hereinafter also referred to as "state data”) can be read out by a monitoring unit via a data transmission unit which is constructed in a spatially remote position to the machine tool, in particular by the manufacturer of the machine tool
  • this monitoring unit should be designed to read out the status data of several machine tools (from corresponding logbook memories) in order to be able to carry out remote maintenance.
  • An important aspect of the invention can be seen in the fact that it is now possible to detect critical events such as a "crash” and / or a "critical event” (eg collet opens too slowly) in the machine tool.
  • this information is provided to a higher-level evaluation unit (ie the monitoring unit), since this is very valuable information about the state or completion of production of the machine. For example, in a machine that has had a crash when the spindle has traveled at high speed against the workpiece, it should be taken into account that the production quality is no longer guaranteed and the machine immediately fails for further part processing. If such events are known (eg by reading the logbook memory of the monitoring unit), by exporting specific test methods, such as a circularity test or a Vibration energy analysis, the central components of the machine are checked for their condition.
  • the present invention offers the advantage that it is now possible to check several machine tools by the central monitoring unit.
  • the status data of the machine tools stored in the logbook memory enable an operator of the monitoring unit to carry out a very precise analysis of the actions and events of the corresponding machine tool.
  • special knowledge about the mode of operation of the machine tool can be used by the central evaluation in a monitoring unit, so that even very rarely occurring error messages can be reacted quickly and correctly. For example, when certain state data occur, a service technician may be instructed to replace a particular component of the machine tool, whereas without the knowledge of that particular state data, the problem would first have to be found by the field service technician.
  • status data may be provided representing a desired movement of a tool to a predetermined machining position and / or providing in the providing step status data representing an actual movement of the work train to the predetermined one
  • Such an embodiment of the present invention offers the advantage that certain crashes or accidents can be clearly identified from the condition data and, responsive to this, a fast and correct remedy of such a problem is possible.
  • status data which represents times at which the control commands are issued by a control unit of the machine tool and / or reproduce the times at which the events occurred in response to the control commands.
  • Such an embodiment of the present invention offers the advantage that a continuous deterioration of a state of the machine tool on the basis of the cached points in time is possible. For example, a mispositioning of a tool that has occurred through a single event at a particular time or is progressively degrading. From this, conclusions can be drawn by evaluating the times of the corresponding events or control commands.
  • temporally successive state data can be buffered in a ring memory of the machine tool in the step of providing, wherein in the step of transmitting after occurrence of an event, a plurality of state data about the event immediately previous states from the ring buffer are transferred to the log memory ,
  • an evaluation and / or display of the status data in the data processing unit can also take place in the step of transferring and storing.
  • Such an embodiment of the present invention as offers the advantage that also an operator of the machine tool on site information about errors or critical events can be given, so that a first troubleshooting or error correction is supported on site.
  • An advantage of such an embodiment of the present invention is the possibility to enable a readjustment or readjustment of control parameters in a control unit of the machine tool in response to status data stored in the log memory. For example, a shift of a coordinate system for a holder of a workpiece can take place, if by a crash of a tool this holder the holder has been bent or slipped. By means of the corresponding parameterization, the effect of the error triggered by the critical event can thus be weakened.
  • step of transferring and storing further control commands from a control unit for the machine tool can be transmitted to the logbook memory and stored in the logbook memory.
  • Such an embodiment of the present invention offers the possibility of being able to reconstruct the causes of a critical event as comprehensively as possible on the basis of the control commands for the machine tool.
  • a monitoring unit which is set up in a machine tool monitoring area of a manufacturer of the machine tool.
  • a monitoring unit is used which is set up in a machine tool monitoring area of a manufacturer of the machine tool.
  • the status data are temporarily stored in the logbook memory over a period of at least one month, preferably over a period of at least three months, prior to the execution of a step of transferring and evaluating.
  • a control unit of the machine tool in the step of transferring and storing, is driven in response to a condition of the machine tool detected from the condition data such that a test method, in particular a circularity test or a vibration energy analysis, is performed to check at least one
  • Such an embodiment of the present invention offers the advantage that when a certain critical event occurs, a special test procedure can be performed to thoroughly inspect a component of the machine tool.
  • special test methods can be used, depending on the detected state of the machine tool a possible damage with great certainty or can rule out.
  • the respective test method can be used in particular if there is an urgent suspicion of the occurrence of a specific critical event from the condition data.
  • the present invention also provides a method of processing process state data and / or machine state data of a machine tool, the method comprising the steps of:
  • the present invention is further based on the recognition that an improvement in the performance of a control system for a machine tool can be achieved if data relating to a process state or a machine state need not be evaluated in real time. Rather, these machine state non-machine state data may be transferred to a data store that has a very large data storage capability (preferably greater data storage capability than (for example, ring) memory)
  • Real-time system and can conveniently record process state or machine state data over a longer period of, for example, several weeks or months.
  • the evaluation of the process state data or the machine state data can then take place in a data processing unit, which need not have a high computing capability.
  • data processing unit which need not have a high computing capability.
  • data relating to a process state may be understood as an event, a specific event, a critical event or an accident (crash) during the machining of a workpiece.
  • an error in the process control may occur in a production process that results in a drill or milling head entering the workpiece or a fixture of the workpiece such that an error occurs in the (manufacturing) process of the workpiece.
  • data relating to a machine state may be understood to mean an event in which vibrations of a component of the machine occur which exceed, respectively
  • Sensors are detected and may cause damage to the machine.
  • the present invention also has the advantage that the conditioning of process state data and / or machine state data can be prepared using a system architecture that does not require as much processing power as conventional systems. In this way, an optimization of the communication between a higher-level data processing system and a Control system of the machine tool done in which data must be transmitted or evaluated in real time. A quick evaluation of the data of the process state or the machine state is often not necessary if the process quality or the closure of the machine is to be monitored over a longer period of time.
  • the storage capacity is variable by the execution of the step of processing and / or that the execution of the step of processing a memory structure of the process state data and / or machine state data in the ring buffer is changeable.
  • the frequency of data transfer from the real-time system to the non-real-time data processing system may be adjusted, which is tuned to the processing capacity of the non-real-time data processing system.
  • the use of a ring memory also allows data to be stored and retrieved in real time up to a certain point in time.
  • setpoint and actual positions are stored during the last crash process and then transferred to the associated log file.
  • the action recorder is always the same size.
  • data entries of the operator or external devices are recorded in the NC server and written to the log file, e.g. the entry of a tool offset.
  • the actions recorder which take place via a machine operating panel, such as the switching over of the operating mode from automatic to manual and back again are recorded with the action recorder:
  • the method may be repeatedly executed, wherein the step of driving taking into account Process state data and / or machine state data relating to an event that were detected in a previous step of the detection.
  • a start of the step of processing may be performed cyclically after a certain period of time.
  • the step of processing may also occur on the basis of a recognition of repeatedly transmitted process state data and / or machine state data, a request by a user, a start of a higher-level system of the data processing unit, and / or one or more data of the process state data and / or machine state data take several predetermined values, or the data storage is filled to a certain level.
  • This embodiment of the invention offers the advantage of being able to start the data processing of the data from the data memory as a function of special events or requirements.
  • a transfer of process state data and / or machine state data stored in the data store to a data processing system component higher than the data processing unit on which real-time data processing is not performed offers the advantage that, for example, a data processing is possible on other units that are idle, for example, at certain times and whose data processing capabilities could be used effectively at those times.
  • the data processing system component can issue a warning about the process state and / or the machine state of the machine tool to a service technician if the process state data and / or the machine state data satisfy a predefined triggering criterion.
  • the step of processing may be based on a replaceable and / or modifiable processing algorithm. This allows the
  • Fig. 1 is a block diagram of a system architecture with an exemplary
  • a control apparatus for a machine on which embodiments of the present invention can be carried out
  • Fig. 2 is a block diagram of an embodiment of an action recorder
  • Fig. 3 is a block diagram of a system for providing data
  • FIG. 1 shows a block diagram of a system architecture with an exemplary data processing unit (Remote Condition Monitoring System) 10 for a machine on which exemplary embodiments of the present invention can be performed.
  • the machine includes components 20, which may include, for example, a bearing, a drive motor, sensors, controls and / or other components.
  • Controls NC, PLC, Motion, RC, (7), actuators (drive, possibly also with integrated PLC or motion) and intelligent sensor systems (possibly also with own evaluation unit) can be found on the real-time level.
  • the units 30 can communicate via an interface 40 with a function interface SO for encapsulating the actual functionality, in which operating parameters (for example vibrations, control signals or other detectable physical variables such as the variables mentioned above) are supplied to this functional interface 50 via the interface 40.
  • the functional interface 50 as well as the unit from a third party supplier 33 can also be supplied with measurement data by a machine tool 35.
  • the functional interface 50 has an interface 60 to a database 70, in which setup data, characteristic data, graphics data, raw data or other data can be stored.
  • the database 70 may be, for example, an SQL database (for example from Microsoft or Oracle), which contains, among many other data for the individual methods, setup data, characteristic data, graphics data, raw data and the like.
  • the functional interface 50 comprises an algorithm execution unit 80 in which, for example, the algorithm or the replacement algorithm is executed on individual, a group of several or all operating parameters received via the interface 40.
  • the algorithm execution unit 80 can also be designed as an interface for integrating DHs (created, for example, using the simulation tool Mathlab), ie for integrating algorithms that were created and tested with Matlab and then transferred to C # code.
  • the data output by the executed algorithm can then be transmitted via the interface 60 and stored in the Database 70 are stored.
  • the control unit 10 can be configured as a generic data server 85 which includes the interface 40, the functional interface 50, the interface 60, the database 80 and the algorithm execution unit 80.
  • the functional interface 50 can have an interface 90 to other data processing units or computers, which can be realized, for example, as a web server 100 (for example in Microsoft ASP .net technology and further graphic components) and a web client 110 (which can be used, for example, as AJAX (ie Java script) executed in the browser), which may be designed according to the Microsoft .NET standard.
  • a web server 100 for example in Microsoft ASP .net technology and further graphic components
  • a web client 110 which can be used, for example, as AJAX (ie Java script) executed in the browser
  • AJAX ie Java script
  • a definition file 120 for the database 70 can now be provided, which among other things will achieve a change in a visualization, an evaluation and a measurement data structure in the control device and is loaded into the algorithm execution unit 80 as a replacement algorithm.
  • the measurement data file is used to describe the surface characteristics (type of display, color selection, specification of the values to be displayed), to describe the tables required for the evaluation method within the database and to describe the structure of the measured data file, with the help of the measured data from the real-time part is transmitted to the Remote Condition Monitoring System.
  • the description of the measured data file structure allows easy parsing and interpreting of the data supplied in the measurement files.
  • other parameters provided, such as the sampling time with which the recording in
  • This definition file 120 may be obtained, for example, using a measurement data file 130 that is sent to a dedicated location (the Remote Condition Monitoring System) by measuring operating parameters (including header signaling information) of one or more machines 35.
  • This definition file 120 can be loaded into the Algorithmenauschtungstechnik 80 and a change in data processing and storage of processed data in the database 70 or a change in the output of the modified data via the web server 100 or the web client 1 10 effect.
  • OPC-UA OPC-Unified Architecture, OPC originally: OLE for Process Control
  • GDS generic database server 85
  • SCP interface 40 which has proved its worth for the devices 30.
  • An OPC UA can be used between the GDS 85 and the Web server 100 or the MES systems, for example, in the first step, SQL function accesses which are encapsulated via the function interface 50.
  • the communication between the web server 100 and the web client 110 can take place, for example, via the protocol HTTPS.
  • distributed systems can be used, such as a web server with multiple GDSen (via a communication via UA) or a central GDS (for example, Oracle-DB) is fed by several smaller decentralized GDSen.
  • An integrated into the device 10 configuration means for configuring the data analysis unit (or Algorithmenausschreibung unit 80) with respect to the analysis to be performed and the configuration of the device 10 with respect to the manner of further processing the result of data analysis by means of one of the interfaces or by means of the long-term data storage can be provided.
  • the XML file for example, in the definition file 120
  • the simulation tool Matlab is preferably used (for example for simulation and for creating a dll).
  • any variables can be recorded cyclically or only on change, and the temporal behavior can be analyzed in more detail in the form of a diagram.
  • Fig. 2 shows a block diagram of the integration of an action recorder.
  • a real-time system 200 (which is executed for example in a machine such as a milling machine, a drill or another of the machine tool) and a Data processing system 210 used, which may be, for example, a PC, which must be able to perform no real-time data processing.
  • Functions for controlling the operation of the machine such as an NC program 215 or a PLC program 220, may be executed on the real-time system 200.
  • an action recorder MTX acr (essentially for recording events) of all types (this may be user inputs, or other external systems' instructions) 225, such as an NC server 230, a record preparation 235, or an interpolator 240.
  • the results (only those of the record preparation 235 or [selected] selected by the machine manufacturer) of the interpolar 240 may be stored in a circular buffer 250.
  • Events, special events, critical events or crashes 255 recorded by the controller of the MTX acr 225 are stored in a log memory 260.
  • the data is stored on the one hand by the Firmware of the controller generated at specific points (Appl he can configure this).
  • log memory 260 can have a very large data storage capacity and thus store the events or accidents (crashes) 255 occurring over a very long period of time.
  • additional data 265 eg, target and actual positions in different ones may be stored in this log memory 260
  • Coordinate systems are stored from the ring memory 250 (for example, in a crash).
  • the logbook memory 260 is conveniently arranged in the data processing system 210 (for example, a PC) that no real-time data processing must be able to execute.
  • a unit 270 for performing a visualization and configuration function may be provided which outputs configuration data 275 and parameterizes the recording functions within the control firmware. For example, it determines whether changes to the tool data entered via the user interface are written to the logbook or not.
  • the configuration data 275 can also be displayed to a user 280.
  • data may be transmitted to a generic data server 85, which may be connected, for example via an interface 90 shown in FIG. 1, to a web server 100 and further to a web client 1 10 is connected. Above the web client 110, the results obtained can be displayed graphically or visually.
  • the logbook memory 260 can be read out by the database server 85 in such a way that certain events can be detected and, in response to these events, service personnel for the maintenance of the machine on which the real-time system 200 is running are sent. For example, an accident can be a tool of
  • Machine tool are detected on which the real-time system 200 is running.
  • corresponding events or accidents 255 are communicated to the logbook memory 260, which can recognize the machine / tool crash from the transmitted data and send out via the generic database server 85 a service technician to the machine on which the real-time system 200 is running , In this way, the maintenance of the machine including the real-time system 200 is significantly improved.
  • An important aspect of the present invention is the use of a so-called action recorder.
  • This is an integrated and fully configurable maintenance information system as well as a machine / operational data acquisition system.
  • the task of the action recorder can be seen in that it records, stores and also processes data changes brought about by the operator, operator actions via the machine operating panel and / or other control or machine-internal events for a later evaluation.
  • the action recorder can be used for certain applications such as improved fault diagnosis, as a crash recorder, for preventive maintenance, as condition monitoring and / or for machine and operating data acquisition.
  • the Action Recorder can record special types of events. For example, "normal” events (eg selection of NC Program, change zero offset, error messages, ...) are recorded or an automatic capture of all relevant events. Furthermore, special events can also be used, ie for example
  • Mode change, channel state change, etc. are recorded, which implement or enable a systematic detection of operator actions (in particular for the reconstruction of crashes).
  • action recorder MTX acr critical events, e.g. if a tool is not being clamped or workpiece clamping is taking too long, etc., recording of critical machining / machine conditions (particularly to prevent machine downtime) can be detected.
  • the Action Recorder allows the recording of accidents (i.e., crashes), among which the detection of crashes including related data can be counted.
  • the action recorder can also record freely definable types of events (ie, free definable event types (machine / operating data), which relate for example to manufactured parts, a machine temperature, a hydraulic pressure, an air consumption per part, etc. Also free for them definable events can be stored with any additional data.
  • free definable event types ie, free definable event types (machine / operating data)
  • machine / operating data which relate for example to manufactured parts, a machine temperature, a hydraulic pressure, an air consumption per part, etc.
  • definable events can be stored with any additional data.
  • Action recorder status messages for example, MTX acr has been turned on, crash trigger detected, ...) - Control error or warning (Serious system error, inte ⁇ olator error, %)
  • Control message (control information, or messages issued from the NC program)
  • a configuration of the relevant event can take place in the NC control, whereby a recording of these events takes place automatically.
  • the task of the action recorder is that further status data can be recorded immediately after the occurrence of a special event, in particular for the reconstruction of the causes of crashes.
  • a change mode automated follow-on block, block search, ...) or a channel state change (channel running, ready for next block, IPO paused, etc.) can be considered as special events.
  • Other state data to be recorded by the action recorder may include, for example, the following:
  • the commissioning of the action recorder the user can define by configuration the additional data to be recorded, the recording is then carried out automatically.
  • the PLC control can also capture relevant PLC-side special events including additional data using a function block.
  • critical event recording the task of the Action Recorder may be seen as including the recording of all Critical Events with additional state data for detecting critical machining and machine conditions to prevent machine failures.
  • Critical events can be, for example, the following:
  • further status data such as e.g. a PLC trace of specific PLC or NC variables can be recorded by the Action Recorder.
  • the recording of the relevant critical events takes place on the PLC by means of a function block, to which further status data can be given if necessary.
  • the action recorder can then record the associated data, such as on the NC side SolWIst positions of the last 10 s from the ring memory for all relevant (driven) axes of the machine tool and thereby record data, as well as record when a special event would.
  • the action recorder could record any other associated data that the PLC records.
  • the axes to be recorded in the ring buffer can be defined by configuration.
  • NC-side events which are to be interpreted as a crash and for which a crash recording is to take place, can be specified. Reading out the Ring memory then automatically in the event of a crash. Crashes that are detected by the PLC can be communicated to the action recorder by setting a specific crash signal.
  • the recording of any data in the Action Recorder can provide further advantages in the evaluation of machine or process conditions.
  • acquisition and recording of any data, including additional data can be done in the Action Recorder.
  • the following data may fall under any data (Free Definable Event Types (Machine / Operating Events)): - shift change or
  • associated data can be recorded and recorded, such as - air consumption per shift
  • the freely definable events are to be recorded on the PLC side under a function block, whereby here as well further data can be given to the function block for transmission in the logbook.
  • the action recorder MTX acr collects all relevant events, from simple state information to crashes. This information can then be used in the higher-level remote condition system to assess the machine condition or quality of the machine.
  • machine events user-specific inputs or messages can be considered as events, for example. Special events may be errors or BA switching.
  • a critical event could be, for example, the jamming of a tool clamping system.
  • a crash can then be detected if the tool is controlled uncontrollably in the workpiece or a bracket.
  • the Action Recorder gets told via SD data what he should record.
  • the storage period can include a position setpoint and actual value for approx. The last 10 s and approx. Every 100 ms).
  • PLC-FB PLC: Programmable Logic Controller
  • FB Function Block One Piece of PLC-Program
  • the PLC-FB offers several functionalities, for example it can offer the possibility to write NC-data into the logbook 260. It can also attach an additional file or allow a language-independent implementation if required by means of IDs. In the same way, events can be written to the logbook on the NC by the NC program.
  • the data management can be done on the PC part.
  • a visualization can be done in a container, for example, to list the events in chronological order. If a GDS is present, for example, the data is cyclically loaded by the GDS (for example by means of a file transfer).
  • the data can also be prepared and stored in DB 70. Statistical evaluations with corresponding graphics can be planned, eg to determine how long the machine stands still for certain reasons.
  • the advantage of this solution is also that the changes in operating parameters of the automation components connected to the administration system 210 can be logged over a longer period of time by means of the long-term data memory 260.
  • buffers can be provided for data volumes of up to 10 terabytes.
  • the data processing unit 210 or in the generic database server 85 is during or after the Data buffering (even after years) makes it possible to examine the data logged by means of the interface with arbitrary methods / algorithms (possibly optimized several times in succession) in order to derive insights regarding the state of the automation system component.
  • the results generated by the data analysis means can then be used both in the
  • the means 225 thus serves as an interface for exchanging data between two systems which can use different communication protocols.
  • the means 225 (ie the MTX action recorder integrated in the real-time part of the MTX as firmware) also has the function of a control entity, which components connected to the device, such as programmable logic controllers (PLC), numerical controls (NC, CNC), drive controllers and motors, monitored with respect to their operating state, their operating state analyzed and the parent system 210, 85 communicates this operating state.
  • PLC programmable logic controllers
  • NC numerical controls
  • drive controllers and motors monitored with respect to their operating state, their operating state analyzed and the parent system 210, 85 communicates this operating state.
  • the long-term data memory 260 could also serve as a data buffer for the data analysis unit 210, with the analysis results or intermediate analysis results in the
  • Long-term data storage 260 can be stored and read out again by means of the data analysis unit 270 from the long-term data storage and further processed.
  • the data from the long-term data memory 260 can be retrieved from this higher-level system 85 by means of a superordinate system that can be connected to the first interface. It would also be conceivable to make the data storage retrievable by an automation system component connected to the second interface.
  • Fig. 3 shows a block diagram of a system for providing data.
  • the real-time part of the MTX acr (the MTX acr-Kemservice) (310), whose main task is to record events, is used within the MTX 320 CNC control core (part of the control firmware)
  • the MTX acr core service 310 has an interface to a mount directory 325 and another interface to the SCP 330.
  • a human-machine interface PC 335 runs an MTX acr panel service 340 of the data from the mount directory 325 and the SCP 330.
  • the MTX acr panel service 340 provides data to an archive directory 345 and data to an XML directory 350.
  • a visualization function 355 From the XML directory 350, data is sent to a visualization function 355 and data to a database 70 of a generic database server 80 (Remote Condition Monitoring System) to also be used in the data from the database 70 to a visualization functionality 360.
  • the gen er see database server 85 offers a functionality of a remote control monitoring 365th
  • the user-configurable MTX acr core service displays all configured events with an exact time stamp and stores them in the logbook. Furthermore, data can also be written to the logbook from the PLC as well as from the NC. The data is then stored on the mount and processed further from there by the MTX acr panel service. The data are sorted in chronological order from the various subsystems (NC server, PLC program, NC program, etc.) and enriched with texts. Furthermore, at this point a graphical distribution (Style) is optionally available for later display within the user interface or in the RCM system.
  • Machine status data possible. Due to the realizable long-term recording, data can be used to accurately analyze the cause of problems with machines Optimization of products (eg components of a machine tool) and to optimize process flows available. Certain changes of parameters in the test methods can be related to the events and further future actions derived therefrom. In the simplest case, for example, to avoid incorrect operation of the machine or during programming that lead to a crash.
  • preprocessing unit for data may be included.
  • MES Manufacturing Execution System
  • the actual processing of the data in the sense of a control station or process control continues, for example, with the MES.
  • the configuration of a processing operation may include the following steps:
  • a start event is defined.
  • the processing can be started cyclically at specific time intervals or at defined times depending on this start event. In addition, it can be defined under which circumstances the processing should be started, for example:
  • a measuring point assumes a certain value (for example change of operating mode);
  • the memory for example the logbook memory 260
  • a certain size for example memory 90% filled with data
  • measurement data can be grouped. It can be determined where in the GDS 85 evaluation results should be stored (database, file system) and whether, or to which addressee, a notification regarding existing calculation results should be sent. It is also possible to define the memory size (eg n data bytes in a ring buffer). Furthermore, it can be defined whether a reference to the data base used for the calculation should be stored together with the prepared data. For example, it can be referred to where the input data for the calculation came from and how they are to be assigned to the result. There is also information on how many input values were used for the calculation, the period from which these input values originate and whether they are still stored in the data memory or already deleted. In addition, it can be defined whether and how the data structure for the prepared measured values is integrated in the measurement point browser.
  • the manner of the data processing can be defined, for example by selecting a suitable algorithm, for example for calculating an average value, for calculating minimum or maximum values or for performing a Fourier transformation.
  • Certain inputs and / or outputs of an automation system component connected to the GDS can be specifically linked to an algorithm so that different algorithms for different operating parameters of the automation component are used. It is also possible to validate the correct interconnection as part of the processing, for example with regard to the data types and the amount of data, such as the minimum number of input values.
  • a device-integrated configuration means for configuring the data analysis unit with respect to the analysis to be performed and the configuration of the device with respect to the manner of further processing the result of the data analysis provided by means of one of the interfaces or by means of the long-term data memory.
  • FIG. 4 shows a flow chart of an embodiment of the present invention as a method 400 for evaluating status data of a
  • a machine tool comprising a first step of providing 410 the state data through an action recorder 225 in the machine tool, the state data representing control commands or events 255 provided in real time, the events 255 representing a response to the control commands in the machine tool. Furthermore, the method 400 has a step of transmitting 420 and storing the status data from the action recorder 225 into a log memory 260 of a data processing unit 210 that is independent of the action recorder 225. The method 400 also has a step of retrieving 430 and evaluating the data recorded in the logbook.
  • Memory 260 stored state data from a monitoring unit 85, which is arranged in a remote location from the data processing unit 210, wherein the monitoring unit 85 is configured to retrieve state data from different machine tools from a plurality of logbooks 260 and evaluate.
  • Interface to the control unit or sensor / actuator 50 Function interface for encapsulating the algorithm execution unit 60 Interface to the database 70 Database
  • Algorithm execution unit 90 Interface to a Web server 100 Web server 110 Web client 120 Definition file for describing the surface characteristics, for
  • Additional data eg axis positions during a crash
  • NC control MTX NC core with recording part of the
  • Non-real-time part of a control unit (NC, PLC, Motion, RC, ...) 340 MTX acr panel service

Abstract

La présente invention concerne un procédé (400) d'évaluation de données d'état d'une machine-outil, le procédé (400) présentant une première étape de fourniture (410) des données d'état par un enregistreur d'action (225) dans la machine-outil, les données d'état représentant des ordres de commande fournis en temps réel ou des événements (255), les événements (255) représentant une réaction de la machine-outil aux ordres de commande. En outre, le procédé (400) présente une étape de transfert (420) et de conservation en mémoire des données d'état provenant de l'enregistreur d'action (225) dans une mémoire (260) d'historique d'une unité (210) de traitement de données indépendante de l'enregistreur d'action (225). Le procédé (400) présente également une étape d'appel (430) et d'évaluation des données d'état conservées en mémoire dans la mémoire (260) d'historique par une unité de surveillance (85) qui est disposée en une position située à distance spatiale de l'unité (210) de traitement de données, l'unité de surveillance (85) étant configurée pour appeler et évaluer les données d'état de différentes machines-outils provenant de plusieurs mémoires (260) d'historique.
EP10715695A 2009-04-17 2010-04-15 Procédé de préparation de données d'état de processus et/ou de données d'état de machine d'une machine-outil Withdrawn EP2419799A1 (fr)

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DE102009017562 2009-04-17
DE102009024101A DE102009024101A1 (de) 2009-04-17 2009-06-06 Verfahren zum Aufbereiten von Prozesszustandsdaten und/oder Maschinenzustandsdaten einer Werkzeugmaschine
PCT/EP2010/002303 WO2010118863A1 (fr) 2009-04-17 2010-04-15 Procédé de préparation de données d'état de processus et/ou de données d'état de machine d'une machine-outil

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