Patent Application
20090326685
This application claims priority of German application No. 10 2008 030 085.3 filed Jun. 25, 2008, which is incorporated by reference herein in its entirety.
The invention relates to mobile programmable control devices, a programming device for programming said control devices, and a system comprising a mobile programmable control device and a sensor.
A multiplicity of components, such as e.g. drives, sensors, final control elements, programmable logic controllers (PLCs), are deployed for the purpose of automating and controlling technological processes in the industrial environment (e.g. printed circuit board fabrication, baggage handling system control, automobile production). RFID readers and RFID tags (transponders) are also used in the field of automation engineering, however.
The international patent application WO 2007/059184 A2 discloses the integrative coupling of RFID tag data with programmable logic controllers (PLCs).
Patent specification U.S. Pat. No. 7,339,476 B2 discloses systems and methods for integrating RFID technology with industrial controllers.
The integration of programmable logic controllers (PLCs) with RFID transponders for the purpose of controlling technological processes is not yet optimal, however.
The object of the present invention is to provide a mobile programmable control device and a matching programming device which provide an improved integration of programmable logic controllers (PLCs) and RFID transponders.
This object is achieved by means of a mobile programmable control device which functionally combines within itself the traditional tasks of a programmable logic controller and an RFID transponder, the control device comprising:
a voltage supply by means of battery, rechargeable battery or power pack;
an interface for inputting and/or outputting data;
means for loading application programs from a programming device or engineering system;
a processor, an operating system and a runtime system for executing application programs;
an RFID transponder for receiving and transmitting radio signals, the RFID transponder being operatively connected to the processor, the operating system and the runtime system for the purpose of executing the application programs, the application programs containing instructions for processing functions of a programmable logic controller and simultaneously instructions for processing functionality of the RFID transponder. The control device according to the invention thus combines the characteristics of a programmable logic controller (PLC) and an active RFID transponder (tag) in one device.
The programming and configuration means for programmable logic controllers can therefore be used also for programming the RFID transponders. Personnel familiar with the underlying technical process and with the programming of programmable logic controllers can therefore be deployed also for programming the RFID transponders, without having to be familiar with the software-oriented programming paradigms for RFID transponders which are customarily to be employed. An additional software developer for programming the RFID transponder is consequently not required. Automating a technical process can therefore be carried out by a person with knowledge of PLC programming and tools. Furthermore, a common runtime system is sufficient in the control device in order to process the functionalities of PLC and RFID transponder. This is advantageous for the manufacture, configuration, shipment and maintenance of the control device. The mobile control device is easy to handle and to attach to stationary or also to mobile objects (e.g. driverless transportation system, conveying containers, tools), thereby enabling said mobile objects to be furnished with their own dedicated processing intelligence and their own processing status (data). The control device according to the invention thus offers the hardware- and software-oriented combination of the characteristics of a PLC and an active RFID tag.
A first advantageous embodiment of the present invention consists in the application program being produced using a development environment that is suitable for the programming of programmable logic controllers. Application programs for RFID transponders are typically programmed in a conventional microcontroller development environment, corresponding to the microcontroller on the transponder. If the microcontroller on the transponder is equipped with a corresponding runtime environment, means for programming programmable logic controllers, such as function block diagram, instruction list, ladder diagram etc., can be used for programming the chip on the active RFID transponder. PLC programmers familiar with the technological processes can thus also carry out the programming of the active RFID transponders. Accordingly, programming of the control device is accomplished from a “single source” and using one tool.
A further advantageous embodiment of the present invention consists in the data input and/or output interface being connected to sensors and/or actuators and/or keys and/or LEDs and/or a display for the purpose of communicating with the technological process or with an operator working therein and said technological process is managed and/or controlled by means of the input and/or output of the data. The control device according to the invention thus possesses the functionality of a programmable logic controller and consequently can replace a “pure” PLC. This results in advantages for manufacture (economies of scale). The battery and the radio link permit a wider and more flexible range of application than in the case of “pure stationary” PLCs.
A further advantageous embodiment of the present invention consists in the RFID transponder being operatively connected via the data input and/or output interface to sensors and/or actuators and/or keys and/or LEDs and/or displays of a technological process and/or its operators. Simple RFID transponders do not possess the capability of connecting actuators or sensors for the purpose of controlling technical processes. By integrating RFID transponders into the control device according to the invention it is also possible for actuators or sensors or simple HMI elements to be connected by means of the integrated transponder or, as the case may be, to be addressed and taken into account via the application programs. This can be realized either wirelessly (e.g. via radio, infrared) or via a fixed wiring arrangement.
Example: In the baggage handling system of an airport it is possible, by means of the method presented, for a suitcase to remember whether it has already been “X-rayed”. It receives this information via a reader/writer when passing through the X-ray system and indicates this by, say, a green LED or a number on the suitcase/control device. However, it may be a requirement of the operational processes that this status can be cleared again locally by the handling personnel. This can be implemented by means of a key on the control device/suitcase. Such or similar logics (e.g. for dealing with different priorities for suitcases) can be programmed and processed in the control device according to the invention.
A further advantageous embodiment of the present invention consists in the application programs being processed cyclically as in the case of a PLC. The control device therefore not only enables the full substitution of the mode of operation of a programmable logic controller, but also offers a better integration and expansion of the mode of operation of the RFID transponder, in which application programs are usually executed after being triggered by events or, as the case may be, by being “freely” programmed.
The object is also achieved by means of a mobile programmable control device, in particular for controlling a technological process, the control device comprising:
a programmable logic controller; and
an RFID transponder with integrated microcontroller, the programmable logic controller and the RFID transponder operatively interacting for the purpose of controlling the technological process, and the mobile programmable control device functionally combining within itself the traditional tasks of a programmable logic controller and of an RFID transponder, a common application program being provided for the programmable logic controller and the microcontroller of the RFID transponder, and the application program being cyclically executable. The mobile control device possesses the same runtime environment as a PLC and is therefore able to execute application programs in accordance with a standardized PLC language (IEC 61131). That is to say that the application program is also cyclically processed on the control device and adapts to the cycle of the integrated PLC. The cycles of control device and integrated PLC thus run in synchronism and possess exactly the same cycle time. Because the application program for the control device according to the invention can be produced using a PLC language, no additional software developer is required for programming the microprocessor of the RFID transponder. The control device according to the invention provides the hardware- and software-related combination of the characteristics of a PLC and an active RFID transponder.
A further advantageous embodiment of the present invention consists in the application program being produced using a development environment that is suitable for programming programmable logic controllers. No additional programming or development environment is therefore required for programming the application program of the RFID transponder. The PLC and the RFID transponder of the control device can be programmed using one programming or development environment. This facilitates the development of application programs in the field of technological process automation.
A further advantageous embodiment of the present invention consists in the RFID transponder being able to be operatively coupled to sensors and/or actuators of the technological process via an input/output unit of the programmable logic controller. RFID transponders usually do not possess the capability of connecting actuators or sensors for controlling technical processes. By integrating RFID transponders into the control device according to the invention it is also possible to connect or, as the case may be, address actuators or sensors by means of the integrated RFID transponder. This can be realized either wirelessly (e.g. via radio, infrared) or via a fixed wiring arrangement.
A further advantageous embodiment of the present invention consists in the control device being fixable to a mobile object, and in the mobile object being thereby trained to act as an active object within the meaning of the object-oriented paradigm. The mobile control device possesses a robust and compact design and is thereby easily attachable to objects, in particular mobile objects (e.g. by means of screwed, plug-in or adhesive connections). This enables mobile objects (e.g. pieces of luggage, containers, driverless transportation systems) to be furnished with a local intelligence (microprocessor of the RFID transponder). The mobile objects can therefore be assigned status and behavioral information which can be interrogated during operation. Based on the chosen type of connection, control device and mobile object can be connected to each other permanently, temporarily or as a function of operational requirements. This means that e.g. a large number (e.g. 10,000) of circulating containers can also be represented by a relatively small number of mobile control devices (e.g. 100) which are attached to a container when the container is received in its own operational zone and removed again when it leaves the operational zone.
A further advantageous embodiment of the present invention consists in dedicated application program cycles being provided in each case for connecting the control device to an object and for separating the control device from the object. The control device according to the invention can be temporarily physically connected to an object, e.g. a mobile object (e.g. by means of screwed, plug-in or adhesive connections). The controlled and defined attachment and removal of the control device to and from the object and the response thereto defined by the programmer can be ensured by means of dedicated application program routines or application program cycles which are executed during the connecting or separating.
The object is further achieved by means of a programming device for the control device according to the invention, the programming device comprising:
input means for inputting user commands for application programs for the control device;
output means for representing edited application programs and process data of individual or interconnected control devices;
programming software executing on a processor of the programming device for the purpose of converting the input user commands for the production of the application programs, the produced application program simultaneously including instructions for processing functions of a programmable logic controller and for processing functionality of a microprocessor of an RFID transponder. The programming device enables the development of application programs for the control device which can be executed both by the PLC and by the microprocessor of the RFID transponder. Accordingly, only one programming tool is necessary. Furthermore, the use of just one means for programming the data continuity between PLC and RFID transponder and the data continuity and process integration of the control device according to the invention with other established automation devices is very easily ensured.
A further advantageous embodiment of the present invention consists in the application programs being written in a standardized language, in particular a language conforming to IEC 61131, for programmable logic controllers. Programming tools for programmable logic controllers that support the international standard IEC 61131 are widely available and are offered by many manufacturers. Thus, the developer is not limited to or reliant on proprietary programming tools when programming the control device according to the invention.
A further advantageous embodiment of the present invention consists in the application programs being implementable as a ladder diagram, as a function block diagram, as an instruction list, as a runtime language, as structured text or as a sequential function chart. Many automation specialists are skilled in the IEC 61131-compliant programming languages or means. No costly additional training courses are therefore necessary for programming the control device according to the invention. The microprocessor of the RFID tag can also be programmed in accordance with IEC 61131 and requires no extra programming environment that supports other additional software engineering concepts.
The object is further achieved by means of a system comprising the mobile control device according to the invention and a sensor for determining whether the control device is disposed on a (mobile or stationary) object or whether it is “alone”. If the sensor detects that the mobile control device is no longer disposed on the object, the application program cycle for orderly and defined removal of the control device is started automatically. Thus, even after removal from the object, the control device is also in a defined status that is specifiable by the programmer. If the sensor detects that the mobile control device is (once again) located on the object, the application program cycle for orderly and defined connection of the control device is started automatically. Thus, even after connection to the object, the control device is also in a defined status that is specifiable by the programmer.
An exemplary embodiment of the invention is illustrated in the drawing and explained below.
Brief description of the figures:
The radio link V1 between the RFID transponder T1 and the RFID reader RW1 is implemented via antennas on both sides. The microprocessor P1 of the transponder T1 can be embodied as complex and have a von Neumann architecture. RFID transponders T1 of this type are typically small in terms of their design format, adapted to the application conditions and implemented as power-saving. They can also be used for demanding automation tasks.
In order to solve the problems described it is proposed to combine the characteristics of a programmable logic controller SPS1 and an active RFID transponder T2 in a mobile programmable device SG1. In concrete terms this means that both the PLC and the RFID transponder can be programmed using a standardized PLC language and therefore also possess the same runtime environment for executing application programs.
A programmable logic controller is characterized by the following properties:
cycle-oriented, i.e. the application program is processed cyclically,
programmable in accordance with a standardized language, typically IEC 61131,
hard-wired and installed in the switching cabinet,
inputs and outputs.
Active RFID transponders are characterized by the following properties:
radio-based,
programmable dependent on the microcontroller provided,
mobile,
robust and small design.
Uniting these features to create a mobile programmable control device SG1 provides the following advantageous attributes and properties:
cycle-oriented, i.e. the application program is processed cyclically,
programmable in accordance with a standardized language, typically IEC 61131,
radio-based,
mobile and movable,
robust and small design,
possible connection options for radio-based or hard-wired inputs and outputs.
The software- and hardware-related combination of the properties of a programmable logic controller SPS1 and an active RFID transponder T2 thus provides the following advantages:
Knowledge of different programming environments is no longer necessary for programming the control device SG1. Both devices can therefore be programmed by the same person. Both the programmable logic controller SPS1 and the RFID transponder T2, in other words, therefore, the control device SG1, are programmed using a standardized PLC language, typically IEC 61131 (function block diagram, instruction list, ladder diagram, structured text). The IEC 61131 standard is concerned with the basics of programmable logic controllers (PLCs), the third part of said standard defining the five programming languages with which a programmable logic controller can be programmed: instruction list, ladder diagram, function block language, runtime language and structured text.
A further advantage resides in the fact that the same development environment PG (
In contrast to “standalone” RFID transponders, the control device SG1 according to the invention offers the possibility of connecting actuators and/or sensors. This can be implemented either via radio link or via a hard-wired arrangement. In the case of a hard-wired arrangement the sensors X1, X2 and actuators (or indicators) Y1 must be located on the carrier of the mobile control device SG1 (in the case of an electrical plug-in connection between a mobile object MO4 and the control device SG, they can also be mounted on the mobile object MO4).
The mobile control device SG1 can be connected via the interface SS2 to an RFID reader; a connection of this kind is usually realized via radio link. The mobile control device SG1 can also be connected to a computer system and to a database via the interface SS2. A connection of this kind can be realized via cable, as a USB connection for example, but also wirelessly (radio, infrared, Bluetooth etc.).
With the aid of the fixing means BF, the mobile control device SG1 can be attached physically either permanently or temporarily to objects, in particular mobile, but also stationary objects, in a technological process, for example by means of adhesive, plug-in or screwed connections BV, which can also be additionally embodied electrically for the purpose of the voltage supply or for sensors or actuators. A mobile object in a technological process (e.g. piece of luggage, driverless transportation system, container) can thus be equipped with a dedicated intelligence. A mobile control device SG1 trained in this way represents a mobile process object that also corresponds to an object with encapsulated status and behavior according to the object-oriented paradigms.
The sensors X1, X2 can be located directly at the or on a mobile control device SG1. The sensor X1 can be used e.g. for detecting a connection BV, the sensor X2 e.g. for determining the position of the control device SG1. The connection BV is a permanent or temporary mechanical or mechanical-electrical connection between the control device SG1 and the mobile object MO4. A connection BV is established via one or more fixing means BF. Actuators Y1 and/or pushbuttons and/or indicators can also be located on the mobile control device SG1.
The mobile control device SG1 can therefore be attached temporarily to a mobile object in a technological process. With the aid of a special sensor X1 it is possible to detect whether a mobile control device SG1 is physically located on a mobile object (e.g. piece of luggage, suitcase etc.). In this way the current status of the control device SG1 can be permanently detected. The position of the control device/object in space can also be detected via a further special sensor. Two special application program cycles are provided for the purpose of attaching and removing the mobile control device to and from an object. This ensures that the object is in a defined state as a process object when the control device SG1 is attached and removed. The defined removal of the mobile control device SG1 from mobile objects is beneficial because the mobile objects may be subject to wear and tear or turnover or can occur in infinite number in the process (e.g. suitcases) and the control devices SG1 can and must be either replaced or fixed to a new object.
In order to perform, that is to say automate, the technological process TP, different processing or handling steps are necessary, for the automation of which a multiplicity of components are employed, such as, for example, drives, programmable logic controllers, sensors, RFID transponders, RFID readers, etc. Many advantages for the automation of technological processes TP are produced as a result of bundling and combining programmable logic controllers, or, as the case may be, the functionality of programmable logic controllers, with RFID transponders in a common mobile control device SG1 to SG3. Thus, a common and coordinated configuration with application program for the control device SG2 to SG3 and SPS2 but also e.g. for drives included in the process can be produced by means of a common development environment PG, which application program can be executed by the microprocessor of the RFID transponder and by a PLC. Furthermore, mobile objects MO1 to MO3 (such as, for example, a piece of luggage), which are otherwise passive in information technology terms from the software engineering viewpoint, can be very easily and elegantly furnished with intelligence by the physical attachment of a control device SG1 to SG4 and said mobile objects MO1 to MO3 can represent real process objects. In this case the intelligence can be used further in the form of a finite number of devices for an infinite number of mobile objects.
Mobile programmable control device which functionally combines within itself the traditional tasks of a programmable logic controller (PLC) and an active RFID transponder (tag), or, as the case may be, which integrates a programmable logic controller (PLC) and an active RFID transponder in hardware and software terms. The application program for the control device, i.e. including PLC and RFID tag, can be written using a programming environment conforming to IEC 61131 (ladder diagram, FBD, instruction list, structured text, etc.). For that purpose the microcontroller of the RFID tag requires a corresponding runtime environment. The application programs in the control device can thus be executed cyclically and in synchronism with the PLC. By virtue of its small and compact design the control device can be physically attached to mobile objects of a technological process for the purpose of the latter's automation, control or tracking/documentation. By this means it is possible for said mobile objects also to represent process objects in the technological process both physically and in information technology terms.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2008 030 085.3 | Jun 2008 | DE | national |
