WO2014111417A1

WO2014111417A1 - Microprocessor-controlled control device for an injection molding system, comprising a simulation computer

Info

Publication number: WO2014111417A1
Application number: PCT/EP2014/050693
Authority: WO
Inventors: Friedrich Werfeli
Original assignee: Netstal-Maschinen Ag
Priority date: 2013-01-17
Filing date: 2014-01-15
Publication date: 2014-07-24
Also published as: DE102013100465A1

Abstract

The invention relates to a microprocessor-controlled control device for an injection molding system (70), which uses at least one I/O controller (50) for a sensor/actuator unit (50) of an injection molding machine (71) to produce plastics parts in a coordinated manner. The I/O controller (50) is connected to a real-time computer (40) of the control device via a real-time ethernet connection (41). According to the invention, a simulation computer (100) has at least one real-time ethernet interface (101) which can be connected to the real-time ethernet connection (41) of said at least one real-time processor (40) instead of the associated I/O controller (50), the simulation computer (100) being designed such as to simulate at least one machine function (70, 71, 72, 73, 74). For doing so, the output signals of the control are processed in real time by the simulation computer (100) and the input signals for control are supplied by simulation models (160, 171, 172, 173, 174) such that the behavior of the machine function is simulated in real time.

Description

MICROPROCESSOR-CONTROLLED CONTROL DEVICE FOR AN INJECTION MOLDING SYSTEM WITH ONE

SIMULATION CALCULATOR

The present invention relates to a microprocessor-controlled control device for an injection molding system with the features of the preamble of claim 1.

STATE OF THE ART

Various microprocessor-controlled control devices for injection molding machines are known from the prior art. These are aimed at the use of an injection molding machine of the plant to produce parts with tools. In addition to at least one such tool, complex tools also require the inclusion of one or more auxiliary drives. In most cases, handling equipment and other peripherals are also involved. It usually comes together with a considerable production cell, where the machine often performs a clocking task.

The processes and tools are becoming more and more complex and the cost of commissioning and thus the service life of the plant is increasing, as well as the risk of damaging production equipment during the run-in and thus causing further downtime. The burden of the setters is growing.

In the known procedure, the production process on the production cell is parameterized step by step, configured and validated. Monitors are configured by the sensors and interlocks of the actuators and put into operation without tools to reduce the risk of damage. Temporaries must be created to validate the core pull lock without tools, for example. This takes a lot of time. From WO 2010/022495, a virtual model of an injection molding machine is provided as an aid for the selection of the components of such a production cell, for which a setter can select and virtually use various required components. A direct help with the real construction of a production cell with the selected parts is not given.

WO 2009/105797 discloses a method for the user-side creation, modification, monitoring and / or optimization of the overall machine sequence of a program-controlled machine or system supported by a graphics editor. The machine processes are to be programmed synchronized on a graphic editor in order to pre-configure the program-controlled machine.

PRESENTATION OF THE INVENTION

Starting from this prior art, it is an object of the present invention to show a way how this situation can be improved on the machine side, in order to allow the installer a faster and safer construction of a production cell.

This object is achieved by a control of the type mentioned by the features of claim 1. A microprocessor-controlled control device for an injection molding system uses at least one I / O controller for a sensor / actuator unit of an injection molding machine to produce plastic parts in a coordinated manner. In this case, the at least one I / O controller is connected to at least one real-time processor of the control device via a real-time Ethernet connection. A simulation computer is now provided which has at least one real-time Ethernet interface which can be connected to the real-time Ethernet connection of said at least one real-time processor instead of the associated I / O controller wherein the simulation computer is designed to simulate at least one machine function (eg, a machine function of the injection molding machine) by processing in real time the output signals of the control by the simulation computer and via simulation models the input signals for control in a manner which simulates the behavior of the machine function in real time.

The simulation computer or the simulation environment can deliver the input signals to the controller via the simulation models in a manner that simulates the behavior of the machine function in real time in such a way that the same behavior arises as in a physical execution.

The simulation computer or the simulation environment can therefore be designed in such a way as to simulate the physical behavior, for example of an actuator, of the mechanics moved by the actuator and / or of the sensors activated by the moving mechanics, by means of model calculations. The controller can generate control signals to the actuator, and in real time, through the model calculation of the simulation, obtains the reaction of the virtual mechanics and sensors, just as if physical execution of that function were present instead of the model calculation. As a function (machine function), an ability of the machine can be designated, e.g. the ability to move an axis. The axis may be the degree of freedom of a mechanism in a linear or rotational axis or a process with a degree of freedom of parameter. For example, moving an aggregate forward or backward; opening, closing and powering a closing unit (e.g., the injection molding machine); or retracting and extending a tool (e.g., tool core). For the simulation a self-contained function can always be treated.

Based on the real-time Ethernet connections, communication channels can be provided for the individual functions. The communication channels or functions may or may not be limited to individual real-time Ethernet connections. The invention is based on the insight that an operating mode of the machine would be advantageous in that the machine and its components do not move, and so the programming and the parameterization of the control can be created and checked without the real components having to be available or, if available, do not need to be moved. The aim is that the simulated function behaves the same as the real function.

The real machine and its environment can thus be replaced by a simulation of the machine physics and the machine control with the simulation can behave the same as the machine control with the real machine with its environment. In other words, the simulation may reflect a function of the real machines.

Advantageously, the control and the machine simulation in an office without a production cell run, so that the configuration and the parameterization of the production process can be made detached from the machine in the work preparation. This requires a corresponding runtime environment, the machine data and the simulation models of the components involved. The simulation environment can have all relevant functions of the machine (machine functions) or the production cell. The simulation environment may be run on an extended controller (e.g., a simulation computer). Thus, the controller can autonomously simulate a machine or an injection molding machine without any additional equipment. The simulation environment processes the controller's output signals in real time and, via the simulation models, provides the input signals for control in a manner that simulates in real time the behavior of the physical execution (i.e., the machine function or the behavior of the real machine or machine component). Error situations and / or limit values can also be mapped in the models.

Preferably, furthermore, a selection structure can be realized, which allows functions to be selected, whether real, with preferably movements of the mechanism or can only run in the simulation without corresponding movements. When the simulation of all functions is activated, this allows a simulated production process to run, thus supporting the commissioning and allowing to check the configuration and parameterization of the injection molding system. If the physical system is put into operation in the next step, there is the certainty that the functions are set up correctly.

Furthermore, a logical switching device can be provided, with which in each case individual communication channels to functions (eg machine functions) via real-time Ethernet connections of real-time processors and I / O controllers either with the associated I / O controllers or with the associated real-time Ethernet interfaces (or communication partners or communication interfaces) of the simulation computer can be connected. Thus, it is possible to operate the simulation of the machine or production cell containing a machine, regardless of the physical presence of the described systems at any location on a suitable computer system. Recipes and processes can thus be developed and tested by making known the relevant data of the systems of the simulation, which is preferably done via data transmission.

Further embodiments are given in the dependent claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will be described below with reference to the drawings, which are given by way of illustration only and are not to be interpreted as limiting. In the drawings show:

Fig. 1 is a schematic representation of an injection molding machine with the

Circuit diagram of the components of a known controller; 2 is a circuit diagram of the controller according to a first embodiment of the invention; and

Fig. 3 is a circuit diagram of the controller according to a second extended embodiment according to the invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

Fig. 1 shows a schematic representation of an injection molding machine with the circuit diagram of the components of a known controller. Reference numeral 10 denotes an industrial PC which is connected to an operator console 20 via a computer-aided user interface 21 as a human-machine interface (HMI). The injection molding machine can further be connected via connected components 30 for a production control system (MES) and the monitoring and control of the technical processes in a control level (SCADA). This connection of the industrial PC 10 to the control system component 30 can be realized by an Ethernet connection 31 based on TCP / IP.

The industrial PC 10 of the injection molding machine further communicates via a non-real-time Ethernet 31 with real-time computers 40, which in turn operate a plurality of I / O controllers 50 which are connected to sensors and actuators, which in the schematic representation of FIG. 1 are provided with the reference numeral 60. The actuators / actuators form the actuators in the control loop of the units described below of the production cell 70 shown schematically. For the realization of the real-time Ethernet 41 connections and the interfaces of the real-time computer 40, different fieldbus systems with required bus cycles of less than 1 millisecond down to 100 microseconds, such as Ethernet / IP as an open industry standard, for which components are to be obtained, in particular, from members of the ODVA (Open DeviceNet Vendor Association). In this case, the connections between I / O controllers 50 and sensor / actuator units 60 are shown with a multiplicity of five connecting lines 51 in each case. In the present embodiment, the connection lines 51 represent logical connections and not physical lines. Alternatively, the connecting lines 51 may also be formed as connecting lines (ie, as physical lines). Both this number and the number and configuration of the I / O controller 50 is selected by way of example. The technical implementation of the injection molding system is denoted by the reference numeral 70 connecting all assemblies for the machine as a whole, which comprises the sensor-actuator assemblies 60, the plastic injection molding machine 71, the tools 72, the handling units 73 and / or any peripheral devices 74 are assigned. It should be noted that usually just in addition to the machine 71 itself also an exchange of information with tool, handling and / or other peripherals 72, 73 and 74 takes place or that they are controlled directly. Peripherals can have their own operator consoles (not shown here).

As mentioned above, in the known procedure of setting the control of the production process on the production cell 70, this parameterized stepwise, configured and validated.

FIG. 2 now shows a circuit diagram of the controller according to a first exemplary embodiment according to the invention, based on the controller according to FIG. 1. In other words, it is assumed in the embodiment of the invention of the presented production cell 70 and the control by the industrial PC 10 and the new control elements shown schematically. Identical features are provided with the same reference numerals in all drawings. Of course, the control elements explained below are also in other embodiments of a microprocessor-controlled control device for an injection molding system with at least one control interface 22 and at least one processor for at least one I / O controller 50 and a sensor / actuator unit 60 of a tool 72nd a production cell 70 of the injection molding machine 71 can be used. The simulation environment 100 assumes a connection through the real-time Ethernet connections 41; Thus, it starts at the I / O controllers 50 of FIG. The real-time computers 40 of the known controller according to FIG. 1 are connected via their individual dedicated real-time Ethernet connections 41 to corresponding real-time Ethernet interfaces 101, 102, 103 and 104 of the simulation environment 100. Real-time Ethernet is also called shorter than RT-Ethernet. Alternatively, the real-time Ethernet links 41 may also represent logical connection. Furthermore, it is not important how many connections exist or how they are arranged, rather it is important that the identical signals that would otherwise be exchanged with the I / O controllers are fed to the simulation environment 100.

The simulation environment 100 provides for each function of the controller (machine function) a simulated model of physical machine execution, which ideally behaves like the real physical machine function including the mechanics and / or error cases. The controller therefore sees simulated I / O devices (eg, I / O controllers) and simulated sensors and actuators 160 with simulated functions of the machines 171, 172, 173, 174, and may be different from the physical designs (ie, of the real machine components). The simulation environment 100 in FIG. 2 consists of one or more computers (simulation computer) with real-time operating systems 140 or computers with operating systems without real-time capability 110 that are connected via Ethernet 31 or real-time Ethernet connections 41. The reference numerals 171, 172, 173, 174 designate a simulated plastic injection molding machine, a simulated tool, a simulated handling unit and a simulated peripheral device, which are to be understood as pure software which, depending on real-time requirements and computing power requirements, on the computers mentioned 1 10 and 140 is processed. Parent is the simulation management 200, which preferably includes a remote control via an Ethernet line 31. Thus, the simulation can also be configured and parameterized remotely from an office or by the application engineer at the machine manufacturer. The simulations lationsverwaltung 200 provides access to a model library, from which the models (eg simulation models of the individual machine components) can be obtained. The elements of the simulation software per se are familiar to the person skilled in the art, for example from WO 2010/022495 and WO 2009/105797. Essential in the context of the present invention is the connection of the simulation environment 100 to the real controller via the real-time Ethernet connections 41 present there to the real-time Ethernet interfaces 101, 102, 103, 104.

Fig. 3 shows a circuit diagram of the controller according to a second extended embodiment according to the invention. The units 20 and 21 of FIG. 1 have been combined with the industrial PC 10 in an operating computer 22. The exemplary embodiment of FIG. 3 comprises both the known actual machine 70 from FIG. 1 and the further elements simulation environment 100 from FIG. 2. In addition, a logical switchover controller 300 is illustrated schematically, which is connected via one or more real-time Ethernet interfaces 301, 302, 303, 304. An essential distinction to the embodiment of FIG. 2 is that the addressees and receivers of the messages or signals can be changed by the switching controller 300, so that the control either with the physical function (ie, with the real machine or plant) exchanges the information or signals with the simulated function. In other words, the controller may be selectively connected to the injection molding equipment 70 (or to its individual components 71, 72, 73, 74) or to the simulation environment 100 by the switching controller 300. The switching controller 300 is activated by a mode of operation of the controller and switched by appropriately selecting the functions. This switching is a function of the controller and is performed in the embedded CPU 40. The function of the non-selected characteristic or machine function is deactivated.

Alternatively, for example, in a physical interconnect configuration, reference numerals 301, 302, 303, and 304 for the interfaces are chosen to that they correspond both to the connections of the real-time Ethernet connections 41 of the control device from the real-time processors 40 to either the I / O controllers 50 according to FIG. 1 or the interfaces 101 to 104 of the simulated sensor / actuator units 160 of the simulation environment 100.

In other words, the switching controller 300 allows and allows the user to switch between the two modes of operation on the switching controller 300 for each machine function actually controlled by the controller via a real-time computer 40 (eg, for each actuator / sensor element 60) either to simulate this function or this element of the machine with the simulation environment 100 or to work with this function or element via the associated I / O controller 50 on the real machine. Since the operating mode can be selected for each movement axis, mixed operation is also possible.

If, for example, a tool is still missing, the monitoring and locking mechanisms of the core puller can be run using the tool simulation. It is then no longer necessary to provide provisional hydraulic cylinder with monitoring limit switch on the production plant.

If a sensitive tool is mounted, the auxiliary controls can be checked by the fact that the closing unit only simulates moving, but the auxiliary controls actually move. This can reduce the risk of tool damage.

There are more I / O controllers 50 shown in FIG. 3 than the four connections to the real-time processors 40. Basically, sensors / actuators 60 could be provided that are not simulated, although the possibility of full simulation is an advantageous embodiment.

The switching unit 300 according to FIG. 3 can alternatively be designed as a separate module. It can of course be connected via a simple Ethernet connection with their control devices such as the industrial PC 10 and its console 20, be connected to the simulation environment 100 or the simulation management 200, so that the switch is a downstream subordinate selection process. A method for starting up an injection molding machine or injection molding plant, for example, has a step of simulating machine functions despite the lack of system components by simulation of the components. Alternatively or additionally, the method may include a step for simulating machine functions with increased risk of damage.

LIST OF REFERENCE NUMBERS

Industrial PC 1 10 computers without real time

Operator console drive system

User interface 140 computer with real-time monitoring

Operating computer drive system

Control system components 160 Simulated sensor / actuator

Ethernet connection unit

Real-time computer 171 simulated plastic

Real-Time Ethernet Injection Molding Machine l / 0 Controllers 172 Simulated Tool

Connecting cable 173 simulated handling

Sensor / actuator unit

Production cell 74 simulated peripheral device

Plastic 200 simulation management

Injection molding machine 300 switching control

Tool 301 Real Time (RT) Ethernet

Handling unit interface

Peripheral device 302 RT Ethernet interface

Simulation Environment 303 RT Ethernet Interface

Real-Time (RT) Ethernet 304 RT Ethernet Interface

interface

RT Ethernet interface

RT et al. E nt

RT Ethernet interface

Claims

1 . Microprocessor-controlled control device for an injection molding system (70; 71, 72, 73, 74) having at least one operating interface (20, 21), at least one processor (10, 40) and at least one I / O controller (50) for a sensor / actuator unit (60) of an injection molding machine (71) to produce plastic parts in a coordinated manner, the at least one I / O controller (50) having at least one real time processor (40) of the controller via a real time Ethernet connection (41), characterized in that a simulation computer (100) is provided which has at least one real-time Ethernet interface (101, 102, 103, 104) connected to the real-time Ethernet Connection (41) of said at least one real-time processor (40) can be connected instead of the associated I / O controller (50), wherein the simulation computer (100) is designed to provide at least one machine function (70, 71, 72, 73, 74) by simulating the output signals of the controller are processed by the simulation computer (100) in real time and the input signals for the control are delivered via simulation models (160, 171, 172, 173, 174) in a manner which determines the behavior of the machine function (70, 71 , 72, 73. 74) in real time.

2. Control device according to claim 1, characterized in that a logical switching device (300) is provided, with the respective individual communication channels to machine functions via real-time Ethernet connections (41) of real-time processors (40) and I / O controllers ( 50) are selectively connectable either with the associated I / O controllers (50) or with the associated communication partners (101, 102, 103, 104) of the simulation computer (100).

3. Control device according to claim 1 or 2, characterized in that the I / O controller (60) is a sensor / actuator unit (50) of a tool (72) and that the simulation computer (100) has an associated tool simulation (172). includes.

4. Control device according to one of claims 1 to 3, characterized in that a simulation management (200) is provided, with which both the simulation computer (100) and the switching device (300) is controllable.

5. Control device according to claim 4, characterized in that the simulation management (200), the simulation computer (100) and the switching device (300) via a data communication connection, in particular an Ethernet connection, are connected.