JP4727921B2 - Control system for winches and other machines - Google Patents

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

  The present invention relates to a multi-axis control system for winches and other machines in the stage, practice field and theater, and more particularly to a multi-axis control system for synchronous operation and similar safety-related operation processing.

  Various multi-axis control systems of the type that can control and monitor winches and other machinery within the stage, practice field and theater are known. In general, such systems require sophisticated cabling operations, and as a result, are expensive and susceptible to failure. However, regardless of cabling work, known systems are often less flexible and many compromises are made in the availability of the control system in relation to the safety requirements to be met.

The prior art document discloses a stage machinery control system to overcome the separation between the upper machinery control and the lower machinery control cam. In this case, the upper machinery and the lower machinery each have a computer system for controlling the individual and common movements of the elevator or floor section. The two computer systems are connected together to synchronize the operation of the driving device of the upper machine component on one side and the lower machinery on the other side (see, for example, Patent Document 1).
German Patent No. 3233788

  In such a situation, the object of the present invention is to provide maximum reliability, secondly high availability, high flexibility and so that the object of the present invention can be achieved by reducing cabling work. It is to develop a control system for winches and other machines in the stage, practice field and theater that guarantees safety.

  This object is achieved by a control system having the features given in claim 1. Advantageous embodiments arise from the dependent claims.

  With the control system according to the present invention, up to 200 winches and other machines (200 axes) can be operated synchronously, with regard to safety requirements, DIN 19250 V VDE for safety-related computer control 0801 class 5 is met.

  The present invention is described below with reference to exemplary embodiments and drawings.

  As can be seen in FIG. 1, the control system according to the present invention is subdivided into five areas: axis level I, central processor computer level II, operation and observation level III, diagnostic and service level IV, and remote maintenance level V. Is done. Levels I, II, III and IV are connected together via an industrial bus system, and level V is connected to level IV via a remote communication line (eg, a modem for a modem connection).

  As FIG. 2 shows, Level I includes winches / machines M1, M2 ... Mn that are controlled and monitored, many of which can be controlled and monitored by the control system according to the present invention. . The following description details the structure according to the invention with respect to the winch / machine M1 of FIG. 2, but the structure according to the invention is repeated according to the machines M2-Mn or with a slight modification of the form of the machines M2-Mn. .

  As shown for winch / machine M1, the winch / machine to be controlled and monitored has a motor M controlled via a first axis computer AR1 and a frequency converter FU (driver circuit). The first axis computer AR1 is connected to the frequency converter FU for controlling the motor M. Preferably, the axis computer AR1 operates in real time and is equipped with a real time industrial operating system. Mounted on the winch / machine input drive shaft is an absolute value transducer AIWG1, which provides its signal to the first axis computer AR1. The winch / machine is also arranged with a second axis computer AR2, which is connected to the first axis computer AR1 via an interface, for example a serial interface to RS-485, and preferably a local control panel Equipped with. The second axis computer AR2 is also connected to the frequency converter FU, preferably operating in real time, and therefore also equipped with a real time industrial operating system. Connected to the second axis computer AR2 is a second absolute value transducer AIWG2 located on the output shaft of the winch / machine. By comparing the RMS values of two absolute value transducers AIWG1 and AIWG2, the function of the absolute value transducer can be inspected first, allowing monitoring of gear failure, shaft failure, clutch failure, etc. . This is because one absolute value transducer is located on the input shaft of the winch / machine and the other is located on the output shaft.

  The first and second axis computers AR1 and AR2 have direct access to the frequency converter FU or upstream contactor and direct access to the braking device for winch / machine disconnection and safe stop.

  In addition, one or more safety sensors S are provided to detect overloads, light loads, overspeeds, winding faults, end position arrivals, etc. Supplied to both second axis computers AR1 and AR2.

  Level II includes two group computers GR1 and GR2 that control and monitor the synchronous group operation of several winches / machines. The two group computers preferably operate 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 computer AR1 of level I via a bus B1, preferably a waveguide type optical bus. Preferably, the bus B1 is designed as a Simolink bus or an equidistant Profi bus.

  The waveguide-type optical bus B1 enables a simple and space-saving ring-shaped cable wiring, not a star-shaped cable wiring, and reliably reduces sensitivity to irradiation interference. The Simolink bus is a deterministic bus, as is the equidistance Profi bus. In a deterministic bus, the cycle time of a computer program is always constant and is not affected either temporarily or irregularly by intermittent procedures that are computationally expensive. Because it is connected at a high transfer rate of 11 Mbit / s regardless of the length of the line, this design does not use a deterministic bus, the transfer rate is less than 11 Mbit / s, and the bus line is used for signal transmission. This means that the control, adjustment and monitoring of the drive are clearly superior to the influencing control system.

  Thanks to the above-mentioned safe and high-speed signal transmission via the Simolink waveguide optical bus B1, the level I drive can be controlled sufficiently synchronously and very fast, so that in the theater There is a clear improvement with respect to noise, an important issue, allowing a very fast and synchronized shutdown of the winch / machine in the event of a failure or defect. Thus, the “divergence” of synchronized and coupled drives can be essentially reduced. This is particularly important in theaters. This is because theaters often require large, heavy landscape parts to be lifted and moved by a number of winches / machines. Under these landscape panels, there are actors, performers, and stage workers, and any excessive divergence of the drive causes the landscape to break or fall over, or the drive is overloaded and the cable breaks. There can be.

  Via the bus B1, the first group computer GR1 transmits a command corresponding to the protocol used to the first axis computer AR1, and receives a signal from the axis computer. The command transmitted by the first group computer GR1 is converted by the first axis computer AR1 into control signals to the frequency converter FU, ie to the winch / machine motor.

  Signals received by absolute value transducer AIWG1 and AIWG2 and safety sensor S (overload, light load, slack cable, emergency stop, overspeed, winding fault, traction error (position misalignment), bus fault, etc.) Is used to monitor and control the synchronous execution of the drive, after which at least a portion is transferred to the group computer by the axis computer.

  When a failure occurs, the group computer GR1 stops the synchronous drive device, and the stop is also synchronized at that time.

  The first axis computer AR1 of each winch / machine also directly monitors the functions of the individual winches / machines in the drive, and if a failure occurs, the power is turned off later than the group computer GR1. If the group computer GR1 fails, the faulty drive unit is also turned off by the first axis computer AR1. However, when several axes move synchronously, if one axis fails, it is usually necessary to stop all the drives synchronously, not just the faulty drive. The stop by the first axis computer AR1 occurs later than the stop via the group computer GR1.

  Therefore, if a failure occurs, both the first axis computer AR1 and the first group computer GR1 respond. The group computer GR1, which has encountered a failure in the drive, verifies that other winches / machines are also operating in sync with the interrupted unit. When operating, the group computer GR1 decides how to brake and / or stop the synchronized winch / machine. In the preferred case, all winches / machines running synchronously in the group are braked synchronously (but at high speed).

If the first group computer GR1 cannot stop the winch / machine due to a failure of the first group computer GR1, the winch / machine that is running synchronously is also stopped. Because of such a stop, there is a second group computer GR2 that also monitors the synchronization group operation as a backup of the level II synchronization control system.

The second group computer GR2 is connected to the winch / machine second axis computer AR2 via a second bus B2, preferably a waveguide optical bus. Here, the transfer rate is as high as 12Mbit / s. The above description regarding the first bus B1 applies similarly to the second bus G2.

  The second axis computer AR2 of each winch also receives all the above information about the winch / machine status via the second absolute value transducer AIWG2 and the safety sensor S. The second axis computer AR2 also passes this information to the further group computer GR2 via the bus B2. Thus, information about winch / machine status is doubly present at level II. That is, once in the group computer GR1 and once in the group computer GR2.

  For further mutual monitoring, the two group computers GR1 and GR2 are synchronized and the information is compared either via a group computer GRV link or a common storage area.

  When a failure occurs, each system winches / receives via the main connection (group computer GR1 <> first axis computer AR1) or the second redundant connection (group computer GR2 <> second axis computer AR2). By acting on both the machine and its power off / stop mechanism FU / A, each can respond independently.

  In addition, the faulty drive can also be switched off via the axis computer AR2, which is directly involved in the winch / machine. This disconnection is also achieved by the first axis computer AR1 in order to guarantee a synchronized stop and to prevent any “divergence” of the drive due to, for example, too early application of the brake to a single drive. Similar to the disconnection, it occurs later than the disconnection by the group computers GR1 and GR2.

  Two independent group computers GR1 and GR2 that have a real-time operating system to control and monitor synchronous execution and monitor each other, and two bus systems B1 and B2 that are fast and reliable but separate and therefore different And two separate and independent distributed axis computers AR1 and AR2 on the winch / machine, several different independent power-off mechanisms (double brake, load shutoff switch, controller release prevention), and independent system Since there are dual safety sensors S (limit switches, load measurement, etc.) read and dual separate absolute value transducers AIWG1 and AIWG2 read into independent systems, the system as a whole is redundant, diverse and self-contained. It is supervised and therefore designed safely. If one of the control systems responds differently from the other, this is detected and reported.

  If either the first group computer GR1 or the second group computer GR2 is not ready for use, and if a failure occurs, only the first group computer GR1 or only the second group computer GR2 Can be used to move winch / machine. Therefore, even if the computer fails, maximum availability is guaranteed for the system. If both group computers fail, the control panel is attached to the second axis computer, so that each drive unit can be operated locally via the second axis computer AR2.

  The control system for winches / machines having a first group computer GR1 and a second group computer GR2 according to the invention follows the safety phase AK5 of DIN 19250 / V VDE 0801. If one of the two group computers fails, only the winch / machine control via the remaining group computers follows the safety phase AK4.

  Thus, existing components can be used to achieve a damage control or backup solution that allows the system to continue to operate even if the computer system fails. No additional components are required. This reduces the cost to the operator and reduces the impact of system failure by reducing components.

  Connection to one or more level III control consoles BP is made via Ethernet bus B3, preferably also in optical waveguide technology, so that between level II and level III This connection is not affected by the failure and can be implemented with a high transmission rate.

  At level IV, a service and diagnostic computer SDR is provided, which is connected via an Ethernet bus B3 to a level II computer and a level III control console BP.

  At level V, a remote monitoring computer FWR is provided, which is connected to a computer SDR via a telecommunications link B4, for example connection modems MD1 and MD2. Thus, between level IV and level V, access can be obtained directly to the level II group computer via the remote maintenance connection B4 to level V, which also exists. Therefore, Level II information, parameters and settings are also available for Level V remote maintenance.

  Preferably, the service and diagnostic computer SDR is connected to the winch / machine, preferably the winch / machine axis computers AR1 and AR2, and the frequency via the further bus 5 or via the existing bus lines B1, B2 and B3. It is also connected directly to the converter and thus to additional peripheral drives. This allows direct access via remote maintenance to all these components and the settings of information and parameters available there, and in particular to the settings of the absolute value transducer.

  In cooperation with the control system according to the invention, further improvements in safety can be achieved by applying a double brake on the winch / machine to the output shaft rather than the drive shaft.

  By placing one absolute value transducer AIWG1 on the input shaft and one absolute value transducer AIWG2 on the output shaft, gear, clutch, weld connection, shaft / hub connection, screw connection, other friction or form Any intermediate breakage or failure, such as a connection, can be detected and the winch / machine can be safely shut down by controlling the brake and applying it to the drive.

  Furthermore, with this arrangement of brakes, the safety factor 2 against permanent damage, which is prescribed for all components of mechanical drives for stage technology according to DIN, for example gears, shafts, clutches, is Since these components are placed behind the brakes, they can be reliably omitted. The winch / machine is at least 30% smaller and cheaper and also quieter because it uses smaller component sizes.

In view of the control system according to the present invention, the following advantages and characteristics arise.
-Two independent group computers that monitor each other and a real-time operating system (eg Siemens RMOS) controls and monitors synchronous execution
Two different high-speed waveguide optical bus systems with -11Mbit / s
-Use of deterministic Simolink guided optical bus
-Two different independent distributed axis computers on the winch / machine
-Several different independent switch-off mechanisms, each controlled independently (double braking device, load interrupt switch, controller release prevention)
-Double safety sensors loaded into independent systems (limit switches, load measurement, slack cables, winding faults, etc.)
-Double absolute value transducers loaded on different independent systems and placed on input and output shafts
-Access, service and maintenance of all components of the control system, such as absolute value transducers and frequency converters, via ISDN, modem or Internet
-High availability of the system (no additional components required) by allowing all drive units to still operate in a synchronous manner through each redundant second group computer even if the group computer fails
-If both group computers fail, the drive can still be operated via local control at the winch / machine.
-All drive units by placing the brake directly on the cable drum (output shaft) instead of on the motor (input shaft), even if gear breakage, shaft breakage, or hub / shaft connection degradation occurs Can be safely stopped.
-Since the brake is placed directly on the cable drum, a safety factor of 2 for the element is no longer needed, so it is much smaller and therefore a more space-saving winch gear and other drive elements are built between the brake and the motor What can be done.

It is a figure which shows the structure of the control system by this invention. FIG. 2 shows a winch / machine control-related structure in a control system according to the invention.

Explanation of symbols

M1 winch / machine
M2 winch / machine
Mn winch / machine
AR1 First axis computer, axis computer
AR2 Second axis computer, axis computer
FU frequency converter
AIWG1 first absolute value transducer
AIWG2 second absolute value transducer
S Safety sensor
GR1 First group computer, group computer
GR2 Second group computer, group computer
B1 1st bus
B2 2nd bus
B3 3rd bus
B4 Remote communication link
B5 5th bus
GRV group computer link
MD1 remote communication link
MD2 remote communication link
BP control console
SDR service and diagnostic computer

Claims (14)

A control system for a winch in a stage, a practice field and a theater and a machine related to the winch,
a. In any case, a two-axis computer for controlling and monitoring only one of several winches or machines (M1, M2,... Mn) assigned to the first control zone (I) ( AR1, AR2),
i. Both are connected to the winch or control circuit (FU) for the electric motor of the machine,
ii. A first axis computer (AR1) is connected to a first absolute value transducer (AIWG1) located on the winch or machine;
iii. Second axis computer (AR2) is connected to the second absolute value transducer disposed on the winch or machine on (AIWG2), a shaft computer,
b. Two group computers (GR1, GR2) assigned to the second control zone (II),
i. A first group computer (GR1) is connected to the first axis computer (AR1) via a first bus (B1);
ii. A second group computer (GR2) is connected to the second axis computer (AR2) via the second bus (B2) independently of the first bus (B1);
iii. A group computer connected together via a group computer link (GRV) or a common memory or storage area and exchanging information independently from the first and second buses (B1, B2). ,
The first absolute value transducer (AIWG1) is disposed on the winch or machine input drive shaft, the second absolute value transducer (AIWG2) is disposed on the winch or machine output shaft;
c. One or more control consoles (BP) assigned to a third control zone (III) and connected to the first and second group computers (GR1, GR2) via a third bus (B3) )When,
d. A service assigned to the fourth control area (IV) and connected to the first and second group computers (GR1, GR2) and the control console via a third bus (B3) And a diagnostic computer (SDR);
e. A remote maintenance computer (FWR) assigned to the fifth control zone (V) and connected to the service and diagnostic computer (SDR) via a remote communication link (B4, MD1, MD2);
f. A safety sensor (S) for detecting overload, light load, overspeed, winding fault, end position, etc. provided on the winch or machine, the output signal of the safety sensor being A safety sensor (S) supplied to the first and second axis computers (AR1, AR2),
The first and second axis computers (AR1, AR2) evaluate signals received from the safety sensor (S) and pass at least a portion thereof to the first or second group computer (GR2);
The first group computer (GR1) is configured to control and monitor the first axis computer (AR1), and the second group computer (GR2) is configured to control the second axis computer (AR2). Both group computers (GR1, GR2) are configured to monitor each other and exchange information about the winch or machine and axis computer for comparison, thereby When the other group computer fails, it is connected only by the first group computer (GR1) connected to the first axis computer (AR1) or to the second axis computer (AR2). The winch or machine is only by the second group computer (GR2) As is your monitored, the group computer (GR1, GR2) control system, wherein the control and monitoring has been carried out of the shaft computers (AR1, AR2) by.   2. Control system according to claim 1, characterized in that the first bus (B1) is configured as a waveguide optical bus.   The control system according to claim 1 or 2, characterized in that the first bus (B1) is configured as a Simlink bus or an equidistance Profi bus.   4. The control system according to claim 1, wherein the second bus is configured as a waveguide optical bus. 5.   The control system according to any one of claims 1 to 4, characterized in that the second bus (B2) is configured as a Simlink bus or an equidistance Profi bus.   Control system according to claim 1, characterized in that the third bus (B3) is configured as a waveguide optical bus, a radio bus or a mixed bus.   The control system according to any one of claims 1 to 6, wherein the third bus (B3) is configured as an Ethernet (registered trademark) bus.   The service and diagnostic computer (SDR) is connected to the winch or machine (M1, M2... Mn) via a fifth bus (B5) as well or alternatively. Item 8. The control system according to any one of Items 1, 6 and 7.   9. Control system according to any one of claims 1 to 8, characterized in that the first and second axis computers (AR1, AR2) are equipped with real-time operating systems.   The control system according to any one of claims 1 to 9, characterized in that the first and second group computers (GR1, GR2) are equipped with a real-time operating system.   11. Control system according to any one of claims 1 to 10, characterized in that the second axis computer (AR2) is equipped with a control panel for manual control of the winch or machine.   When a failure occurs, the first or second axis computer (AR1, AR2) performs cutting or stopping of the winch or machine with a delay from cutting or stopping by the group computer (GR1, GR2). The control system according to any one of claims 1 to 11, wherein the control system is characterized. Several winch and machine control processes in the stage, practice field and theater,
In either case,
A first axis computer (AR1) receives an output signal of a first absolute value transducer (AIWG1) arranged on the winch or machine (M1, M2... Mn);
Second axis computer (AR2) is, receives the output signal of the second absolute value transducer disposed on the same winch or machine (M1, M2 ··· Mn) ( AIWG2),
A first group computer (GR1) controls and monitors the first axis computer (AR1);
A second group computer (GR2) controls and monitors the second axis computer (AR2);
The first and second group computers (GR1, GR2) monitor each other, and the first and second axis computers (AR1, AR2) are the first and second absolute value transducers (AIWG1, AIWG2). Exchange information to compare the output signals of
On the one hand, a connection is made between the first and second axis computers (AR1, AR2),
On the other hand , a connection between the first axis computer (AR1) and the first group computer (GR1) is made via a bus (B1), and the second axis computer (AR2) and the The connection with the first group computer (GR1) is made via a bus (B2) separate from the bus (B1), and both buses (B1, B2) are preferably guided optical buses. And
The connection between the two group computers (GR1, GR2) is made via a group computer link (GRV) or a common memory or storage area,
The first and second axis computers (AR1, AR2) for detecting overload, light load, overspeed, winding failure, end position arrival, etc. provided on the winch or machine Evaluate the signal received from the safety sensor (S) and pass at least a portion thereof to the first or second group computer;
When the other group computer fails, only the first group computer (GR1) connected to the first axis computer (AR1) or the second axis computer (AR2) is connected. The first and second group computers (GR1, GR2) have the control of the axis computers (AR1, AR2) and so that only the second group computer (GR2) controls and monitors the winch or machine. A control process characterized by monitoring .   In the event of a failure, the first or second axis computer (AR1, AR2) will cut or stop the winch or machine with a delay relative to the cut or stop trigger by the group computer (GR1, GR2). 14. Control process according to claim 13, characterized in that it triggers.

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