Patent ID: 12196231

DETAILED DESCRIPTION

FIG.1shows a commissioning system1comprising a pneumatic actuator device2and a graphical display device3separate from the actuator device2, wherein the graphical display device3is in particular a mobile device. The graphical display device3is, for example, a tablet computer or a mobile phone. Exemplarily, the commissioning system1further comprises a higher-level controller4, for example a programmable logic controller, PLC, and a compressed air source5. The actuator device2comprises a pneumatic drive cylinder6and a pneumatic control module7mounted on the pneumatic drive cylinder6.

The commissioning system1is used to commission the pneumatic actuator device2, in particular to assist the user in connecting the control module7communicatively with the higher-level control4and/or to connect the control module7pneumatically with the drive cylinder6and/or the compressed air source5.FIG.1shows the commissioning system1in a state in which these connections have already been made and the commissioning has already been completed to that extent.

After commissioning, the pneumatic actuator device2can be used in an industrial application, in particular in industrial automation. The display device3can then continue to be used together with the actuator device2, for example to control or monitor it. Furthermore, it is possible to remove the display device3after commissioning and to use it, for example, for commissioning another pneumatic actuator device.

The drive cylinder6has a cylinder body8, which is in particular elongated. On an outer side9, in particular a longitudinal side, of the cylinder body8there is a groove arrangement10(shown inFIGS.2and3) to which the control module7is attached. The drive cylinder6comprises a piston arrangement11with a piston12and a piston rod13. The piston12divides an inner space of the cylinder body8into a first pressure chamber14and a second pressure chamber15. The drive cylinder6comprises a first drive cylinder hose port16, which is pneumatically connected to the first pressure chamber14, and a second drive cylinder hose port17, which is pneumatically connected to the second pressure chamber15.

In an exemplary embodiment, the control module7has a cuboidal basic shape. The control module7has a main section19and a fastening section18with which the control module7is fastened to the drive cylinder6, in particular to the groove arrangement10. The fastening section18has a receiving section20, which is in particular box-shaped. The main section19is attached to the receiving section20, in particular inserted therein. The fastening section18further has two fastening devices21, which are in particular designed as clamping devices and serve to fasten the fastening section18to the groove arrangement10. The fastening devices21are arranged in front of and behind the receiving section20in the longitudinal direction of the drive cylinder6. The fastening devices21each comprise clamping projections inserted in the groove arrangement10, and a clamping mechanism by means of which the clamping projections can be moved relative to one another in order to fixedly clamp the clamping projections in the groove arrangement10.

The control module7has a communication port22to which a communication cable23is connected, via which the control module7is communicatively connected to the higher-level controller4.

The control module7further includes a first hose port24, which is a first pneumatic working output of the control module7, and a second hose port25, which is a second pneumatic working output of the control module7. The first hose port24is pneumatically connected to the first drive cylinder hose port16via a first hose26. The second hose port25is pneumatically connected to the second drive element hose port17via a second hose27.

The control module7further includes a third hose port28, which serves as a compressed air supply input of the control module7. The third hose port28is pneumatically connected to the compressed air source5via a third hose29.

The control module7further comprises a compressed air outlet30which is used for discharging compressed air, in particular into the atmosphere. The compressed air outlet30represents a compressed air sink.

The control module7comprises a valve device31. The valve device31is used to provide compressed air, in particular at the first hose port24and the second hose port25, to actuate the drive cylinder6. The valve device31receives the compressed air from the third hose port28, and can discharge compressed air via the compressed air outlet30. The valve device31can selectively aerate, de-aerate and/or block the first hose port24and the second hose port25, each independently. Exemplarily, the valve device31comprises four 2/2-way valves32connected as a full bridge. The 2/2-way valves32are preferably pilot-controlled, in particular with piezo valves.

In an exemplary manner, the control module7comprises a pressure sensor arrangement33for measuring the pressure at the first hose port24, the second hose port25, the third hose port28and/or the compressed air outlet30. Exemplarily, the control module7further comprises a stroke sensor arrangement34for measuring the strokes of the valve members of the valve device31, in particular of the 2/2-way valves32. Preferably, the control module7comprises an acceleration sensor35which is used in particular to detect the orientation of the control module7in space—in particular relative to gravity.

The control module7comprises an operating device38which, by way of example, has a plurality of operating elements, in particular operating keys. The operating elements comprise in particular a first operating key39, which may also be referred to as a confirmation key. The operating elements further comprise, in an exemplary manner, a second operating key40, by means of which, for example, an extension of the piston rod13can be effected, and/or a third operating key41, by means of which, for example, a retraction of the piston rod13can be effected.

The control module7comprises an LED arrangement42, exemplarily comprising a plurality of LEDs. The LEDs are arranged on the outside of the control module7—exemplarily on its upper side. In particular, the LEDs are arranged at the upper corners of the control module7.

The control module7comprises a control unit37, for example a microcontroller, which has an open-loop control model and/or a closed-loop model and is configured to control the valve device31in accordance with the open-loop control model and/or the closed-loop control model in order to effect the provision of the compressed air, in particular at the first hose port24and/or the second hose port25. The control unit37is communicatively connected to the valve device31, the pressure sensor arrangement33, the stroke sensor arrangement34, the acceleration sensor35, the operating device38, an environmental sensor arrangement56and/or the communication port22.

Exemplarily, the control module7is of modular construction. The control module7comprises a pneumatic sub-module44comprising the valve device31. Exemplarily, the pneumatic sub-module44further comprises the pressure sensor arrangement33, the stroke sensor arrangement34, the first hose port24, the second hose port25, the third hose port28and/or the compressed air outlet30. The pneumatic sub-module44is attached to the fastening section18, in particular with its underside. The pneumatic sub-module44has its lower side facing the drive cylinder6. Exemplarily, the pneumatic sub-module44has a cuboidal basic shape. The pneumatic sub-module44comprises a communication interface45(shown inFIG.3), which is arranged on the upper side of the pneumatic sub-module44and serves to provide a communication link with a control sub-module46.

The control module7further comprises the control sub-module46, which is detachable from the pneumatic sub-module44and comprises the control unit37. Exemplarily, the control sub-module46further comprises the acceleration sensor35, the operating device38, the LED arrangement42, and/or the communication port22. Exemplarily, the control sub-module46is plate-shaped and is attached to the upper side of the pneumatic sub-module44. The control sub-module46may further comprise the environmental sensor arrangement56, for example comprising a temperature sensor and/or a humidity sensor.

The pneumatic sub-module44and the control sub-module46together form a cuboid body. In particular, the pneumatic sub-module44and the control sub-module46together form the main section19.

Optionally, the control sub-module46is configured to provide an auxiliary function, in particular a monitoring function, in a state removed from the pneumatic sub-module44. The control sub-module46can thus preferably also be used without the pneumatic sub-module44. The auxiliary function, in particular the monitoring function, is performed, for example, using the acceleration sensor35and/or the environmental sensor arrangement56.

The display device3is separate from the control module7. In particular, the display device3is offset and/or remote from the control module7, in particular from the actuator device2. In particular, the display device3is a stand-alone device. In an exemplary embodiment, the display device3comprises a device housing47and a graphical display48arranged in particular on the outside of the device housing47. The graphical display48is a pixel display having a plurality of pixels. For example, the graphical display48is a touch screen. In particular, the graphical display48comprises an LCD display or an OLED display.

The commissioning system1further comprises a communication link49between the control module7and the display device3. In an exemplary embodiment, the communication link49runs through the higher-level controller4and suitably comprises a first connection section51between the control module7and the higher-level controller4and a second connection section52between the higher-level controller4and the display device3. The first connection section51is in particular wired and is for example provided by a bus, in particular a field bus. The bus is for example Ethernet based. The communication cable23is in particular part of the bus. The second connection section52is in particular wireless. Alternatively, the second connection section52may be wired.

Furthermore, it is possible that the display device3is directly connected to the control module7; that is, that the communication link runs directly from the display device3to the control module7. The communication link may be wired or wireless.

The control module7is configured to transmit a control module state of the control module7to the display device3via the communication link49. The display device3is configured to display a plurality of commissioning steps to be performed for commissioning the actuator device. The display device3is further configured to display the commissioning steps taking into account the transmitted control module state.

The display device3displays the commissioning steps, in particular sequentially. Preferably, the display device3is configured to switch from a currently displayed commissioning step to a next commissioning step in response to a received control module state and to display this (next) step.

The display device3displays each commissioning step, for example by means of a text message53and/or a graphic54, in particular a graphic representation of the actuator device2, in particular on the display48. The graphic54may in particular comprise an animation of the actuator device2. In particular, the display device3indicates to the user, for each commissioning step, what the user should do in the respective commissioning step.

In the following, an exemplary method for commissioning the actuator device2using the display device3will be explained. In the method, a plurality of commissioning steps to be performed for commissioning are displayed by means of the graphical display device3separate from the control module7, wherein the graphical display device3is in particular a tablet computer or a mobile telephone, and the control module state is transmitted from the control module7to the display device3via the communication link49between the control module7and the display device3, and the display of the commissioning steps is performed taking into account the transmitted control module state.

The method starts in a state in which the control module7is not yet pneumatically connected to the drive cylinder6and/or is not yet communicatively connected to the higher-level controller4and/or the display device3. Further, the method may start in a state in which the control module7is not yet attached to the drive cylinder6.

If the control module7is not already attached to the drive cylinder6, the control module7is being attached to the drive cylinder6, in particular by means of the fastening section18.

Expediently, the drive cylinder6is further being identified, in particular by means of the display device3. For example, the identification is performed by a manual user input, in particular by means of the display device3. Further, the identification may be performed by retrieving an identification information, in particular from the cloud, in particular by means of the display device3. Further, the display device3may have an image sensor and may detect with the image sensor a code, in particular a QR code, arranged on the drive cylinder6, by means of which the drive cylinder6is identified. Based on the identified drive cylinder6, a graphical representation of the drive cylinder6on the display device3may be adapted and/or a commissioning procedure to be displayed on the display device3may be selected. In particular, the type of the pneumatic actuator device2is detected, for example by means of the identification information, and a graphical representation of the pneumatic actuator device2is displayed on the display device3based on the detected type. In particular, the commissioning procedure shall be referred to as the entirety of commissioning steps displayed on the display device3within the commissioning procedure.

Preferably, in a state in which there is not yet a communication link to the control module7, the display device3displays a commissioning step relating to connecting the communication cable23to the control module7. This commissioning step shall also be referred to as the cable connection step. For example, the displayed cable connection step prompts the user to connect the communication cable23to the communication port22by means of a corresponding text message53and/or a graphic54. For example, the graphic54shows how to connect a communication cable to a communication port. The user connects the communication cable23to the communication port22, expediently establishing the communication link49. Preferably, in response to the communication link49to the control module7being established, the display device3automatically switches to a next commissioning step and displays the next commissioning step. Optionally, the LED arrangement42indicates, for example by means of an illumination of the LED arrangement42, that the communication link49has been successfully established.

By establishing the communication link49, the control module7is set to a connected state. The connected state represents, for example, a control module state which is transmitted to the display device3and on the basis of which the display device3displays the commissioning steps, in particular changes to a next commissioning step.

Furthermore, the display device3may be adapted to receive control module identification information via the communication link49, in particular from the control module7. Based on the control module identification information, the display device3may, for example, adapt the commissioning procedure and/or a graphical representation of the control module on the display device3. In particular, the type of the pneumatic actuator device2is detected, for example using the identification information, and a graphical representation55of the pneumatic actuator device2is displayed on the display device3based on the detected type. Optionally, the graphical representation55comprises an representation of the LED arrangement42, which representation lights up and/or changes color in synchronization with the LED arrangement42.

Preferably, an orientation of the control module7in space is detected by means of the acceleration sensor35of the control module7and the graphical representation55of the pneumatic actuator device2and/or the control module7is displayed on the display device3according to the detected orientation. In particular, the orientation of the control module7is continuously detected and the graphical representation55is continuously updated based on the detected orientation. The display of the graphical representation55is expediently performed during commissioning, for example after the communication cable23is connected to the communication port22. The detected orientation of the control module7represents another example of a control module state that is transmitted to the display device3, and based on which the display device3adjusts the display of the commissioning steps.

Preferably, at least one of the commissioning steps concerns the connection of a hose26,27to the control module7and the drive cylinder6. A commissioning step concerning the connection of a hose shall also be referred to as a hose connection step. Suitably, the cable connection step is followed by at least one, optionally more, hose connection steps. For example, in response to the control module state that the communication cable23is connected, the display device3changes from the cable connection step to a hose connection step.

An individual hose connection step can be displayed on the display device3for each hose to be connected. Furthermore, a single, common hose connection step can be displayed on the display device3for several, in particular all, hoses to be connected.

For example, by means of a corresponding text message53and/or graphic54, each displayed hose connection step prompts the user to connect one or more hoses26,27,29to the respective associated hose port24,25,28. For example, the graphic54shows how to connect one or more hoses26,27,29to the respective associated hose port24,25,28. For example, for each hose26,27,29, the graphic54shows the respective associated hose port24,25,28to which that hose is to be connected. For example, the graphic54indicates that the first hose26is to be connected to the first hose port24and the first drive cylinder hose port16, that the second hose27is to be connected to the second hose port25and the second drive cylinder hose port17and/or that the third hose29is to be connected to the third hose port28and the compressed air source5.

Preferably, for at least one commissioning step, in particular each hose connection step, a visual indication signal is output by means of at least one LED of the control module7, in particular an LED of the LED arrangement42, for a user performing the commissioning. For example, by means of the visual indication signal, a hose port of the pneumatic control module7to which the hose is to be connected is indicated. For example, the LED of the LED arrangement42located closest to the hose port to which the hose is to be connected is illuminated. Preferably, the visual indication signal is being emitted in parallel, in particular simultaneously, with the displaying of the associated commissioning step, in particular hose connection step, on the display device3.

The user connects the control module7to the drive cylinder6and the compressed air source5via the hoses26,27,29. Exemplarily, the user connects the first hose26to the first hose port24and the first drive cylinder hose port16, the second hose27to the second hose port25and the second drive cylinder hose port17, and/or the third hose29to the third hose port28and the compressed air source5.

Expediently, the display of the commissioning steps on the display device3takes place in consideration of an operation performed with the operating device38, in particular the confirmation key39. The operation of the operating device38represents an example of a control module state which is transmitted to the display device3and on the basis of which the display device3displays the commissioning steps. For example, in response to the operation of the operating device38, the display device3changes from a current commissioning step to a next commissioning step and displays it. For example, the user operates the operating device38in particular by pressing the confirmation key39after completing the one or more hose connection steps. Provided that there is more than one hose connection step, the user can, by actuating the confirmation key39, respectively switch to the next hose connection step and/or to a further commissioning step following the last hose connection step. If there is only one hose connection step, one can switch to a further commissioning step following the hose connection step by pressing the confirmation key39.

Preferably, the completion of the one or more hose connection steps is signalled by means of the LED arrangement42, in particular by means of all LEDs of the LED arrangement42lighting up, for example in a first colour, in particular green. Expediently, it is detected by means of the pressure sensor arrangement33that compressed air is supplied to the control module7and on the basis of this detection a corresponding indication is signalled by means of the LED arrangement42, for example by a second colour, in particular orange.

Optionally, the commissioning steps further comprise an installation step in which the actuator device2is installed in the intended application. The installation step is expediently performed between the hose connection steps, in particular after the hoses26,27have been connected and before the hose29is connected. For example, by means of a corresponding text message53and/or a graphic54, the displayed cable connection step prompts the user to install the actuator device2into the intended application.

For example, there is a first hose connection step in which the user is prompted by the display device3to connect the first hose26and the second hose27in the manner explained above. In particular, the first hose connection step is terminated by pressing the confirmation key39. The display device3then displays the installation step, which is expediently terminated by actuation of the confirmation key39. The display device3then displays a second hose connection step, in which the user is prompted by the display device3to connect the third hose29in the manner explained above. In particular, the second hose connection step is terminated by actuation of the confirmation key39.

Preferably, the display device3displays at least one available function of the actuator device2and the function is started by operating the display device3. In particular, the function is displayed after completion of the one or more hose connection steps. For example, the function is displayed as a control field on the display48configured as a touch screen and can be started by operating the control field. Preferably, the display device3displays a plurality of available functions of the actuator device2, in particular by means of a plurality of control fields on the touch screen.

The function is, for example, a test drive by which the control module7automatically performs a parameterization, in particular of its open-loop control model and/or closed-loop control model. For example, the test drive determines as parameters a friction value, a mass, an end position damping and/or system limits.

The completion of the test drive is expediently signalled by means of the LED arrangement42, in particular by lighting up in a specific colour, for example the first colour.

Commissioning is now complete. The actuator device2is now expediently being used for industrial automation, for example in an industrial plant. The control module7performs open-loop and/or closed-loop control of the drive cylinder6, in particular on the basis of the open-loop control model and/or the closed-loop control model. Exemplarily, the control module7receives a control command, for example a set point, from the higher-level controller4and performs the open-loop control and/or closed-loop control based on the control command.

The control module7may also be referred to as a smart box, and in particular represents a smart sensor/actuator module that may be mechanically attached to a standard component—the drive cylinder—to make the standard component a smart component.

The control module7optionally has a data logging function and is particularly adapted to record and store sensor data, for example sensor data from the pressure sensor arrangement33, the stroke sensor arrangement34, the acceleration sensor35and/or the environmental sensor arrangement56.

Further, the control module7may optionally have a machine learning component, for example an artificial neural network, and be configured to provide a predictive maintenance function using the machine learning component, for example a calculation of a service life and/or a maintenance point in time, in particular based on the sensor data.

Furthermore, the control module may optionally be configured to perform, using the machine learning component, the parameterization, in particular by means of the test drive.

By means of the method for commissioning the actuator device2, the user and/or commissioner can be guided interactively from the unpacking of the delivered components to a test operation via an assistant—the display device3. By means of images, animations and/or videos on the display device3, he receives step-by-step assistance and/or instructions for action by means of the successive commissioning steps. Preferably, the visualization—in particular the display device3—is coupled to the real actuator device2, so that status messages, feedback and an indication of connection points can be provided via LEDs of the LED arrangement42on the control module7. In addition to control elements in the visualization—for example control fields on the touch screen of the display device3—control elements—the control device38—on the control module7can also be used to acknowledge actions—in particular to complete individual commissioning steps.

At the start of commissioning, the user may be assisted in assembling and/or adapting the actuator device2by means of offline content.

Once the actuator device2is powered, an interactive connection—in particular the communication link49—can be automatically established to the guidance of the display device3, so that the commissioning procedure displayed on the display device3can respond and/or react to the user's activities.

The display device3represents in particular an interactive commissioning assistant. In particular, the communication link49provides an active connection between the component to be commissioned—the actuator device2—and the software (manual, instructions, representation of the graphical representation of the actuator device, dashboard, . . . ) of the display device.

Via the sequential display of the commissioning steps, in particular a guided step-by-step instruction takes place on the display device3with interaction to the real hardware—the actuator device2. In particular, a feedback and possible error detection with respect to the performed commissioning step is possible via the display device3.

Interaction between the user and the actuator device2may take place be via the display device3or the control device38.

Once commissioning has been completed, the available functions of the actuator device2can be executed as services and displayed on the display device3(e.g. starting a test run, auto-tuning, moving the piston arrangement11to a defined end position, intermediate position).