Abstract:
A device for communicating with a system, especially for operating and monitoring an automated industrial manufacturing system is described. The device contains a mobile communication device for wireless exchange of data with the system. Further, the device also includes a fixed installed connection for the communication device and a sensor recognizing whether the communication device is connected to the fixed installed connection.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to the German application No. 10344361.4, filed Sep. 24, 2003, and to the International Application No. PCT/EP2004/009597, filed Aug. 27, 2004 which are incorporated by reference herein in their entirety. 
     FIELD OF INVENTION 
     The invention relates to an apparatus for communicating with a system, in particular for operating and monitoring an automation system in industrial manufacturing. 
     BACKGROUND OF INVENTION 
     Input and output devices must be connected to industrial automation systems in order to run said systems; this is known as process interfacing. Output devices (monitoring devices) include e.g. check lights, alphanumeric or graphical displays, which inform the system operator about the current system state. Input devices (operator devices) include e.g. switches, rotary knobs or keyboards for alphanumeric input, which allow the operator to act on the system. 
     SUMMARY OF INVENTION 
     In order to allow communication between user and system, so -called operator devices and monitoring devices, subsequently referred to simply as communication devices, are usually installed permanently on the system itself or e.g. in the manufacturing hall where the system is located. A typical communication device has a convenient casing in which input and output devices are arranged. The data interchange with the system or its control unit takes place via an interface cable which is permanently installed. 
     Provision is also made for communication devices which are connected to the system via a cable of greater or lesser length and allow mobility for the operator at or along the system within the limits of the range of the cable, wherein the operator can take the communication device with him or her. 
     In the case of very large or relatively inaccessible systems, cable -based communication devices are no longer practicable. Mobile communication devices, i.e. freely movable communication devices which communicate wirelessly with the system and are battery powered, exist for this purpose and handle the data interchange with the system via radio connection. So-called docking stations exist for this type of communication device, e.g. in the form of a storage receptacle, and are used for housing the communication devices and charging the batteries which are present in the devices. The storage receptacles are located e.g. near the system or in a separate area such as the supervisor cabin. 
     In order to set up a manufacturing process on a system, said system is first started in a running mode which is known as setup mode or learning mode. Fine tuning of the system is performed via the connected communication devices in this context, e.g. the traverse paths of robot arms are configured. Communication devices which work in a wireless manner are normally only used during the setup mode, since here the operator requires maximal mobility at the system in order to be able to monitor and thus configure subprocesses accurately. 
     Once the manufacturing process has been set up on the system, the system is switched into the normal mode, e.g. its production speed is increased. During the normal mode, wireless communication devices are not usually required or are even undesirable because they are battery driven and therefore have only a limited service life or because they place an unnecessary load on the radio network of the system provider. The mobile communication devices are therefore stored away or, according to DIN, must even be locked away if they include safety-related functions (stop functions or permission functions). Communication with the system during the normal mode then takes place via conventional, permanently installed communication devices, which often also have different functionality, e.g. do not provide any specific functions for setting up the system process. 
     Until now, therefore, different running states of the system have required different communication devices, and these must therefore be procured concurrently. All communication devices must also be serviced, managed or programmed accordingly, thereby incurring significant expenditure in terms of cost and effort. 
     The present invention addresses the problem of specifying an apparatus for communicating with a system, wherein said apparatus is designed to be less resource intensive and less costly. 
     The problem is solved by an apparatus for communicating with a system, in particular for operating and monitoring an automation system in industrial manufacturing, which apparatus features a mobile communication device for wirelessly exchanging data with the system. The apparatus also includes a connection interface for the communication device, said connection interface being installed at a fixed location, and a sensor for detecting whether the communication device is connected to the connection interface. 
     As a result of the mobile i.e. freely movable communication device, which includes wireless functionality, the system operator has maximal freedom of movement at the system. In setup mode, the operator can freely select an optimal location in order to check or adjust the system function as effectively as possible. 
     Upon completion of the setup mode, the operator can connect the communication device to the connection interface which is installed at a fixed location. 
     In this context, installed at a fixed location means that the connection interface has a permanent connection to the system and is assigned a defined location at the system. This can also include a service line from the system to the connection interface, said service line being slightly flexible, such that the connection interface can be positioned in a user-friendly manner. 
     The sensor can be a light barrier, a proximity sensor or a contact loop, for example. It detects that the communication device is connected. The system control unit is connected to the sensor and is capable of analyzing this information and also notifying the communication device. The connecting of the communication device can therefore serve as a signal, for example, in order to switch the system into the normal mode and to deactivate the setup-specific functionality at the communication device. 
     It is therefore possible to influence the functionality of the communication device by utilizing the sensor information. For example, specific keys can be rendered inactive when the communication device is in the connected state, if said keys are only required for the setup mode. It is also possible for a graphical display on the communication device to show other information depending on its connection state. A wide variety of possibilities are available here via the programming of the system or the control unit. The subsequent operation of the system in the normal mode or manufacturing mode takes place using the same communication device, now connected to the connection interface, as was used during the setup mode. 
     It is financially advantageous for the system provider that it is only necessary to invest in a single communication device, with which the system can be operated and monitored in all running modes. A further advantage of the apparatus is that a defined position is established on the system, namely the permanently installed connection interface, at which the communication device is connected during normal mode and is there fore easy to find at any time. Therefore it is not necessary to lock the communication device away, since it is also intended for the normal mode of the system. 
     Additionally, it might be necessary during normal manufacturing briefly to switch the system into a correction mode which is similar to the setup mode, in order to make post-adjustments to parts of the system, for example. This would previously have necessitated the reactivation of the separate communication device having wireless functionality, wherein said communication device would often have to be retrieved first from the place where it was stored. 
     If the claimed communication device is removed again from the connection interface, which action would be detected by the sensor, the system switches into a correction mode, for example. In this context, specific additional functionality similar to that of the setup mode can be activated on the communication device. In this way, it is possible to perform corrections on the live manufacturing and then simply reconnect the communication device afterwards, without any additional expenditure in terms of devices or time. The system can then switch over to manufacturing mode again. 
     The detection of the device connection by the sensor can also be utilized e.g. for checking whether all of the communication devices available on the system have actually been reconnected to the intended positions at the end of a shift, for example. 
     In an advantageous configuration, the communication device features an interface cable and the connection interface includes a cable connection interface for this interface cable. In comparison with the complete freedom of movement allowed when the communication device is not connected, this allows the operator limited but nonetheless possible mobility, within the limits of the interface cable, when operating and monitoring the system even while the communication device is connected and the system is e.g. in the normal mode. The sensor interacts with the communication device via the interface cable in this case. Of course, the interface cable can also be detachable from the communication device. 
     The connection interface advantageously includes a storage location in which the communication device can be placed. As a result, there is a defined location at the system where the communication device can be stored for as long as it is connected. This avoids the need to place the communication device on an additional table or on the-ground, and the precise position where it can be found is known. In this case, the sensor detects whether the communication device is inserted in the storage location and is therefore attached to the system. 
     Furthermore, it is advantageous if the communication device is fixed in the storage location in a lockable manner. When it is in the connected state, for example, it cannot then be stolen or removed by unauthorized personnel, which would result in the system switching from the manufacturing mode into the setup mode or would allow the user to carry out settings or changes to the manufacturing processes by changing the functionality of the communication device. Any removal of the communication device is e.g. only possible using a key which is managed by the supervisor. 
     If the sensor is a switch which interacts with the communication device or its interface cable, it can be implemented in a manner with is particularly easy, interference -proof and inexpensive. 
     In a particular embodiment, the apparatus features a data connection interface for wire-based data interchange between system and communication device. This can be integrated in the interface cable or the storage location. In addition, the apparatus includes a changeover unit for changing over between wireless and wire-based data interchange. According to the invention, the changeover of the data interchange can take place in such a way that the process interfacing is not interrupted. The data connection interface can also include an integrated field bus coupling or even additional lines for safety -relevant functions, for example. 
     In general, wireless data interchange is always more interference-prone or unreliable than wire-based data interchange. Furthermore, radio mode normally requires greater energy expenditure, which must be provided by the communication device, and e.g. in the above mentioned normal mode of the system the wireless data interchange is not usually required since the communication device is connected in this case. The changeover to wire-based communication therefore results in communication which is more reliable and less interference-prone and e.g. causes less EMC burden on the system from radio waves. The load on the radio network is also reduced. 
     The apparatus is particularly advantageous if the sensor interacts with the changeover unit in such a way that an automatic changeover to wire-based data interchange takes place when the communication device is connected to the connection interface. This ensures, for example, that a changeover to the less interference-prone wire-based data interchange always takes place when the communication device is connected. In addition, the operator cannot forget e.g. to change over the type of data interchange manually. 
     In order to run the freely moveable wirelessly functioning communication device, it must be equipped with a source of electrical energy. An advantageous development of the invention therefore makes provision for the connection interface in the apparatus to include a power supply for the communication device. This can again be integrated e.g. in the interface cable or the storage location. As a result, the energy reserve in the communication device is spared in the connected state, or can even be recharged if it is an accumulator. This also ensures that, in the connected state, the communication device has sufficient energy e.g. to run lighting at maximum brightness on the communication device. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a further description of the invention, reference is made to the exemplary embodiments in the drawings in which, by means of a block diagram in each case, 
         FIG. 1  shows a freely moveable wirelessly functioning communication device in an industrial system in the unconnected state in the context of wireless data interchange with the system, and 
         FIG. 2  shows the industrial system from  FIG. 1  with the communication device in the connected state in the context of wire-based communication. 
     
    
    
     DETAILED DESCRIPTION OF INVENTION 
       FIG. 1  shows an automation system  1  including a permanently installed system part  2  and two mobile communication devices  3   a,b . The system part  2  comprises a manufacturing machine  4 , which is simply named machine  4  in the following, a control unit  5  which controls the machine  4 , and a radio station  6 . The machine  4  is very large and cannot be surveyed from a single standpoint by an operator. A first connection interface  7   a  is permanently attached, e.g. screwed on, at one end of the machine  4 . Near to the other end of the machine  4 , a second connection interface  7   b  is attached e.g. to the wall of the manufacturing hall (not shown) in which the machine  4  is located. Since they are located in the manufacturing area of the system  1 , the connection interfaces  7   a,b  are designed to be suitable for industrial use, i.e. water-protected, dust-protected and mechanically robust. 
     The connection interface  7   a  has a storage receptacle  24  which is used for holding the communication device  3   a , though this has been removed from the connection interface  7   a  or storage receptacle  24  in  FIG. 1 . The connection interface  7   a  includes a sensor  8  in the form of a switch and a data connection interface  9   a  which, together with contacts  18   a  for the power supply (usually 24 volts), is integrated in a connection interface socket  19   a.    
     The connection interface  7   b  likewise comprises a sensor  8  and a connection interface socket  19   a  including data connection interface  9   a  and contacts  18   a  for a supply voltage. The connection interface  7   b  is not designed as a storage receptacle, however, but as a connection interface port or so-called access point which is suitable for use in industry. A lock  25  which can be closed using a key (not shown) is also attached to the connection interface  7   b.    
     All components of the system part  2  are connected together via a field bus  10  for the purpose of data interchange. The data connection interface  9   a  therefore provides a field bus coupling. Further additional interface cables (not shown), e.g. having safety-related functionality, can be integrated in the connection interface socket  19   a . The contacts  18   a  are connected to the voltage network  20  of the automation system  1 . 
     The communication devices  3   a,b  when used as input devices have push keys  11  by means of which the machine  4  can be operated via the control unit  5 , and when used as an output device have a display  12  on which current machine parameters of the machine  4  are displayed and by means of which the machine  4  can therefore be monitored. Also attached to each of the communication devices  3   a,b  is a connection interface terminal  19   b  which corresponds to the connection interface socket  19   a  and includes the reciprocal contacts corresponding to the connection interface socket  19   a , e.g. a data connection interface  9   b  and contacts  18   b  for supply voltages. The power supply for the communication devices  3   a,b  in  FIG. 1  is provided by means of accumulators which are contained therein but are not shown. 
     The communication devices  3   a,b  differ by virtue of the connection interface terminals  19   b  which are attached thereto. In the case of communication device  3   a , the connection interface terminal is permanently attached to the casing, whereas it is attached to a removable contact unit  22  in the case of communication device  3   b . T he contact unit  22  in turn is permanently connected to the communication device  3   b  via a flexible service line  23 . 
     The communication between a communication device  3   a,b  and the control unit  5  takes place in each case along communication paths which are shown by the arrows  13   a,b . The communication paths  13   a,b  initially travel between communication device  3   a,b  and radio station  6  over radio sections  14   a,b  which are formed between the antennas  15 , 16  on the communication devices  3   a,b  and the radio station  6 . At the radio station  6 , the communication data is converted from the antenna  16  to the field bus  10  and transmitted via the field bus  10  to the control unit  5 . 
     The sensors  8  are connected to the control unit  5  via the field bus  10 . The sensors  8 , which are open because the communication devices  3   a,b  have been removed in  FIG. 1 , enable the control unit  5  to detect that the communication devices  3   a,b  have been removed, i.e. are not connected. In this running state, there is no connection bet ween the connection interface sockets  19   a  and the connection interface terminals  19   b  on the communication devices  3   a,b.    
     The utilization of the information from the sensors  8 , i.e. that the communication devices  3   a,b  have been removed, is freely programmable in the control unit  5 . In  FIG. 1 , the control unit  5  is programmed such that the machine is in setup mode as a result of the communication devices  3   a,b  being removed. A different functionality may also be desirable for other systems, however. 
     In the setup mode, as a result of the process interfacing to the machine  4  via radio, an operator handling the communication device  3   a,b  can freely select an optimal position to occupy at the system part  2  or change said position without restriction, and operate and monitor the machine  4  from there. 
     In  FIG. 2 , the communication devices  3   a,b  are inserted in the connection interfaces  7   a,b . As a result of this, the sensors  8  are pressed down and therefore in a closed position. By means of the sensors  8 , the control unit  5  detects that the communication devices  3   a,b  are inserted and notifies the communication devices  3   a,b  of this. This information can be used by the control unit  5  to now run the machine  4  in the normal manufacturing mode, for example. The communication devices  3   a,b  can also e.g. change their functionality as a result of this, i.e. specific keys  11  can be rendered inactive or other machine parameters can be indicated on the display  12 , for example. 
     In  FIG. 2 , both communication devices  3   a,b  are connected to (e.g. engaged in) their respective connection interfaces  7   a,b . In the case of communication device  3   b , the contact unit  22  is separated from the actual device body and plugged into the connection interface  7   b . While the communication device  3   a  is now connected in a fixed location, the communication device  3   b  is still mobile within the reach of its service line  23  although it is likewise connected. Therefore an operator of this communication device  3   b  still has room to move and can moreover, within certain limits, choose his or her position in relation to the machine  4 . The contact unit  22  is locked into the connection interface  7   b  in  FIG. 2 , since the lock  25  has been swung forwards and locked, using the key, against swinging back again. It is therefore impossible to remove contact unit  22  from the connection interface  7   b  again without a key. 
     The connection interface sockets  19   a  are connected to the connection interface terminals  19   b , thereby connecting the data connection interfaces  9   a  and  9   b , the contacts  18   a  and  18   b  for the power supply and any other lines which are included. The communication devices  3   a,b  are therefore supplied with energy from the system part  2  via the voltage network  20 , and no longer require energy from their integrated accumulators. These are recharged via the power supply, such that sufficient energy is stored for the next radio mode as per  FIG. 1 . In this way, it is also possible e.g. to increase the brightness of the back-lit display  12  to maximal luminosity, since sufficient energy is available for this purpose from the power supply of the system part  2 . In the accumulator mode according to  FIG. 1 , the brightness is usually reduced in order to save energy. 
     Since the control unit  5  is informed by the depressed sensors  8  that the communication devices  3   a,b  are connected, the data interchange between communication device  3   a,b  and control unit  5  is changed over from wireless to wire-based, and the antennas  15 , 16  are therefore not in use. The data traffic travels along the communication path  13   a,b  which now travels from the communication device  3   a,b  via the data connection interfaces  9   a,b  and the field bus  10 . 
     In order to change over between wire-based and wireless data interchange, a changeover unit (not shown) is integrated in the control unit  5 , for example. This can be a program section of the control program, but it can also be an actual switch. In the present case, the changeover unit is linked to the sensors  8  in such a way that the changeover takes place automatically as soon as the switch state of the sensors  8  changes. 
     The operation of the overall system  1  therefore continues to be coordinated using the same communication devices  3   a,b  as in  FIG. 1 . The changeover from cable-based back to radio mode can take place at any time during the running of the system  1 , by removing the communication devices  3   a,b  from the connection interfaces  7   a,b  again. 
     Of course, it is also possible to remove only one communication device  3   a  or  3   b  from the corresponding connection interface  7   a,b  and to operate only this communication device wirelessly while the other communication device  3   b,a  continues to communicate in a wire-based manner with the control unit  5 . The utilization in the control unit  5  and in the communication devices  3   a,b  of the information from the corresponding sensors  8  in such a case must of course be adapted to the needs of the production system  1  concerned.