WO2018147720A1

WO2018147720A1 - A universal smart machine controller system

Info

Publication number: WO2018147720A1
Application number: PCT/MY2018/000006
Authority: WO
Inventors: Erkan SABANOVIC
Original assignee: BAHRUDDIN, Amir Irman; BAHRUDDIN, Amir Irwan
Priority date: 2017-02-08
Filing date: 2018-02-07
Publication date: 2018-08-16

Abstract

According to embodiments of the invention, a smart machine controller system (100) or controlling a plurality of machine components in a distributed control system is disclosed. The system (100) may include an automated programing module (102) for generating a program code for controlling the machine components based on one or more user defined parameter(s), wherein the parameter(s) outline configuration of one or more machine components and a controller (104) for executing the program code to control the plurality of machine components.

Description

A UNIVERSAL SMART MACHINE CONTROLLER SYSTEM

Filed of Invention

The present Invention relates to control and. automation, systenvs and particularly to method and system, for machine data configuration for programmable controllers. Background of the Invention

the concept of distributed control systems, which have both a hardware and software component, is known i n the art, Machine makers have been using PLCs ^'{Programmable Logic Controliera ) as par t of their machine design part icular ly for distributed control systems. PLCs are used to monitor the state of the input devices and based on a certain program makes decision and control the output devices . Programmable logic controllers ("FLCs") are typically installed to manage independent parts of a factory floor, The PLC is used in control systems to provide coordinated, control of equipment, devices, and processes, PLC generally comprise a central processing unit ("CPU") and a plurality of input /output ("I/O") modules having I/O connection teriiiinais .. PLCs are ordinarily connected to various, sensors., switches;, or measurement devices that provide inputs to the PLC and to relays or other forms of output to control, the field equipment or other controlled elements ,

Program within the PLCs are usually developed using ladder logic programming. However, at. times, machine makers lack skilled resources especially in the area of ladder logic programming that not only affects development work, but also pose challenges for after sale service and support. Further for factory owners cost of support by the original manufacturers or change/modification in prevailing program is typically too expensive.

Hence there is a need for an improved system and method for configuration machine automation.

Smnmary of the Invention

According to embodiments of the invention, a universal smart machine controller system for controlling a plurality of machine components in a distributed control system is disclosed. The system may include an automated programing module for generating a program code for controlling the machine components based on one or more user defined configurable parameter ( s ) , wherein the parameter (s) outline configuration of one or more machine components and a controller for executing the program code to control the plural ity of machine components. In an embed linent , the cont ro11er 16 port ab Ie .

According to yet. another enu>odiruent , a controller for controlling a plurality or s¾art. machine conpponents in a distribut ed control system is disclosed. The disclosed universal smart machine controller includes an input module for receiving a program code and an output module for comounicat ing with smart machine components. The controller enables smart machine components coxvtroi based on execution of the program codec ,

Brief Description of the Drawings Other objects, features, and advantages of the invention will be apparent from the following description when read with reference to trie accompanying drawings. In. the drawings, wherein like reference numerals denote corresponding parts throughout, the several views :

Figure 1 Illustrates a block diagram of the smart, machine controller (SMC) system for controlling a plurality of machine components according to an embodiment;

Figure 2 illustrates an exemplary .block diagram of the automated programing module according to an embodiment of the invention; Figure 3 illustrate sn exemplary hardware block diagram of the controller according to an enhnodiment of the invention; Figure 4 illustrates an exemplary factory setup with many individual machines from various manufacturers;

Figure 5 illustrates an exemplary FISH TANK - AQUARIUM without SMC system; and

Figure 6 illustrates an exemplary FISH TANK - AQUARIUM with exemplary SMC system. Detailed Description of the Preferred Embodiments

The present invention will now be described in detail with reference to the accompanying drawings, Figure I illustrates a block diagram of a universal smart machine controller (SMC) system (100) tor controlling a plurality of machine components . The machine components may be a part of a distributed control system and may include one or more sensors, controllers, motors, I/O ports/devices, etc, The system (100) may include an automated programing module (102) . According to an embodiment, the automated programing module (102) may reside in a computing system such as, but not limited to, a desktop computer, a laptop computer, tablet, smart phone etc. According to another embodiment, the automated programing module (102) may be a software. The computing system may include a user interface for receiving one or sore configurable par araeter ( s ) from a

The par araeter ( s ) may outlining configuration of one or more .machine components. According to an embodiment, the automated, programing module (102) may generate a program code for controlling the machine components based on the user defined parameter is; . According to embodiment , the automated programing module ( 102) may generate the program codes cased on the user defined parameter ( s ) usingpredefined executable f lies/modules . The system (100) further includes a controller (104) for executing the program code to control the plurality of machine components. According to an embodiment, the controller (104) may be a firmware, such as, but not Limited to microcontroller..

According to embodiments of the invention, the controller (104) takes care of ail communication with the hardware or machine components such as, but not lcmited to, sensors, inputs, outputs, protocol, etc., while the automated programing module (102) deals with data processing, firmware and program itself (set by the user) .

According to yet another embodiment, a controller (104) for controlling a plurality of smart machine components in a distributed control system. (100) is disclosed. The disclosed universal smart machine controller (104) may include an input module (106) for receiving a program code and a:^'; output module (108? lor eommun icat i.;vg with smart machine component s . The controller i i 04 ) may enable smart machine components control based on execution of. cue prograri; codes. The controller { 1045 rosy have a user interface. According to another embodiment , the user interface may be a LCD Screen. According to yet another embodiment, the user Interface (104} may be a control system, consisting of LED .Lights and. posh buttons .

The codes for controlling one or more machine components in a distributed control system .may be generated in a personal computer using the automated programing moduie (1025 , According to an embodiment, the Generated codes may be directly transferred to the controller {.104} through wired link such as, but not limited, to, Led, DSL, ADSL, VDSL, etc, or wireless link such as,- but not limited to, vy.m-.hy P.P--TLU wi- Max, UMTS , LIE, Bluetooth, etc, According to another embodiment, the codes / instructions may be transferred from the automated programing module {102} to the controller (104; by a removable memrary device {110}, such as but not limited to, and SD memory card, USB stick, data card, etc. According to an embodiment, the codes/instructions may be transferred from the automated programing module {102) to the removable memory device {110} through wired such as, bet .not limited to, LAN, LSI, ADS I,, VDSL, etc. or wireless nesvmirk such as, but not limited to, tf.LA.hb ¾i-Fi, Wi-hhax, UMTS, LIE, Bluetooth, etc. The controller tlQ4) may toe designed in such way that, smart machine controller <10«) doesn't require any programming, Instead, the distributed control. system user say lust communicate with the smart machine controller gtbC) system (100) indicating the bar dwa.ro/ signals attached. to the distributed control system and its electrical parameters through the user interface and the system (100; generates requires codes/instructions for performing required task. Once codes/ instructions are generated, the same may be transferred to the controller (IGs) .

Figure 2 illustrates an exemplary block diagram of the automated programing module (102) according so an embodiment of the invention. As i 1 lustrated the automated programing module (102) may have a Kernel (112? and a boot loader (lie? , The Kernel. (112) may be connected to a data memory -116}, a program memory (118) and an EEPROb (120) .

Figure 0 illustrate an exemplary hardware block, diagram or the controller (lOa? according to an embodiment of the invention. As illustrated, the controller (10^) may be in communication with one or moms machine components of a distributed control oyster;;. According to on embodiment, the machine components rosy have one or mors sensors. According to yet another enhtodiment, the machine components may be operated by Analog or digital I/CP According to an embodiment, the controller. (104) may nave a logic gate (102) and a voltage gate (204) . The machine components may communicate with the controller (104) throagh the logic gate is; (202} and the voltage gate's} (20-1} for receiving instructions and operating voltage respectively , The logic gate (202} and the voltage gate (204) may be connected to a processing board (206; for recti eta.) respective operating instructions. Typically the processing board (206} may act on instructions originally stored, in the firmware m.emory (203) , According to another embodiments or the invention, a configurator memory (210) may be provided, that may be configurable by minimum inputs using the user Interface. According to another embodiment, an A/D converter (212} may be provided between Processing Board (206) ana Voltage gate (204) .

According to an embodiment, the controller (i02) may include hardware and f freeware . The firmware may enable the controller (104) to control the specific, machine components. The functioning of the firmware wii.l depend on. the codes generated by the automated programing module (102) . According to an embodiment, the system works like lock and Key arrsngemei-t, wherein the codes generated by che aucon-ated programing module f 102 ) act as a ke\ for the controller (104) , The disclosed arrangement enables quick modification in the control. arrangement without major system/hardware modif icatione/corbiigurscions, since mode i icati on/updat ing only involve firmware upgrade to add/modify various hardware into its library from time to time. According to yet another embodiment., the firmware is an independent of operating system (03) ,

.According to embodiments of the i event ion, a system user may configure operational parameters of a distributed control system without any specialised software knowledge and with m..1. r i i ma 1 eon£igur ati rdi.ng to embodiments of the invention, vie programming is required for modifying conf igurationai. parameters. The configuration may be performed using a simple Data Configurator GUI. .According to yet another embodiment, the user: may not require specialised knowledge of the pores (sensors) types such as di gitai /analog for configuration. The disclosed system can easily be extended for irnsreasing/decreasiug the I/O ports/ sensors. .According to yet another emiroiimcr v. , the disclosed, system, may be upgraded easily using any removable memory such as, but not limited to SD-oard for future additional device/protocol support. Advantage of the disclosed system, axe:

i ) Parallel data processing

The disclosed system utilizes parallel data processing approach similar to general purpose comparing on graphic processing unit {GPGPUi but on a single processor . The disclosed system also utilises binary space partitioning over virtual thread,

ii ) Data driven system

The disclosed system, is data driven systera which utilising dynamic interleaving pipeline approach to achieve hardware agnostic and software level only sofid deterministic.

iii ) Un A.que schedui ing techn ique

The disclosed system uses unique scheduling technique to handle interrupts and. virtual threads.

iv) Flexibility

The disclosed system offer flexibility in terras of usage with various Data and transfer protocols, Hardware drivers, 8, 16 or 32 bit chip architecture etc. According to exemplar-y embodiments of the invention, a user co y create 'progracd or codes, for controlling SMC using a personal computer, To make the progrnsp the user can. simply click on she modules shown over a graphic user interface (GUI; and. dot require any programing knowledge. The program will be stored inside a PROJECT FOLDER and may be selected/transferred for execution at a later stage. The GUI may enable the user to add/delete a specific process from the already existing list of processes. The user may select from the list of processes that machine actually does. Once the process to be added or deleted is selected, one or more machine components such as sensors, stepper motors, relay drives, AD converters, etc, may fee selected and corresponding electric parameters for each of mentioned devices may be indicated. Once all the hardware machine uses are attached, SMC program is crated automatically by the automated programing nioduie (102). The generated copy may be saved in a 3D card. Then 3D memory card may be inserted in the controller (104) SMC slot, and SMC will run the machine. invention will now be described with reference to exemplary implementations. The illustrated implementations are exemplary in nature and the invention is not restricted to these illustration in any way, Figure 4 illustrates an exemplary factory setup with many individual machines from various manufacturers. Typically in such setup, machines are designed to perform independent function/process without considering function/process of other .machines. This imply that, each machine is either fully automated for its own task and at same time, require operator which serve that machine. This will result in increased labor and therefore maintenance related to each. individual process within factory itself. Moreover large number of individual. processes /machines ., compii cates process execution and decreases factory output , One way to resolve this issue is to replace the existing factory setup wish more efficient and connected new factory setup, which involve huge investment and is practically impossible. An alternative to improve efficiency of such a system is to implement SMC according to she illustrated embodiments of the present invention , According to embodiments of the present inventions, first step will be integration of disclosed SMC system in to every individual machine within factory, integration o.t the SMC system with each individual machine will enable complete automation on bndividuai ievel. This means, each machine oouid perform its own tasks automatically. The second step will be to connect the each SMC system from each machine to a network, The network choice may depends on factory setup. According to illustrated exemplary invention implementation, the preferred method is trough F.S<135, which offers great data speed, and at same time, very minimal wiring i¾ wires tor bidirectional dot s ; , and offers large distances between SMC units, without any data amplifier in bet soon, and also great resistance to signal noise. Once ail SMC units are attached to the preferred network, .tally automated process can take place, ft result, each machine controlled by SMC wi.il know exactly what to do and when. Communication between process paired machines will be automated and executed precisely when certain machine is ready for it, writ cue any human intervention. In case that one of line machines, chained in the process, fail or malfunction for whatever reason, 3MC will alert technician, who will be assisting process of machine repair. All other machines an process chain will queue, until, process of repair as done. If alternate machine: (to the one which is failed; exists, system will redirect itself through that machine and production will not, scop.

Figure 5 and figure 6 il lustrates an exemplary FISH TANK - AQUARIUM without and with exemplary SMC system respectively. Typically complete automation of an aquarium system is costly due to high cost for controller arid exferosion modules, variety of sensors included in such project is a bit more complex as require chemical detection of Ph factor, salinity, etc., apart from typical sensing features such as water level or temperature. This is why higher precision is needed and hence controller /external devices attached no such system, may be expensive. If manufacturer, of mentioned system is out of business, entire maintenance is subject to serious trouble as no replacement may be found and. as dedicated hardware is attached to specific modules, problems will be practically either extremely expensive or simply impossible to maintain. With use of the SMC system, if nrmnuracturer of one sensing^' probe is out, it is as complicated as recalibratiOn of SMC (appox. .10 minutes work) in so a new sensing probe, Functionality extension (light, heater, multiple fallback ριηηρ !sotor, various alarms, etc.) are as veil, subject of simple SMC update, against new hardware added.

According to embodiments of trie invention, disclosed solution is typically meant for iooai machine control system and not tor replacing SCAhA system in a true Distributed Control System where one will have a control room and SCADA software connected to various till in the whole factory. It however can be considered as ail in one umirm. SCADa like a controllers) in a local setup for a particular mach me/machines .

The disclosed invention may be implemented without any specific Operating System, hcco.rd.rng so embodiments of the invention, the disclosed solution is achieved by modularising ana layering the firmware architecture.

As will be readsiy apparent to those skilled in the art, the present invention may easily be produced in other specific forms without departing from, its essential characteristics. The present embodiments is, therefore, to be considered as merely illustrative arid not restrictive, the scope of uhe lever;tier; being indicated by the claims rather than the foregoing description, and ail changes which cose within therefore intended to be embraced therein.

Claims

1. A universal smart machine controller system ;100) for controlling a plurality of machine concoonen ta in a distributed control system, the system (100) comprising:

an automated programing module (102) for generating a program code tor controlling the machine components eased on one or more user defined configurable parameter ( s ) , wherein the par amet er { a } outline configuration of one or more machine components; and

a controller (104} for executing the program code to control the plurality of machine components.

2. The system (100· as claimed in claim I, wherein the codes are transferred from the automated prograofng module (102) to the controller (104) by a removable memory device (110) .

3. The system (100) as claimed in claim 1 , wherein che codes are transferred from the automated programing module (102) to the controller (104) through a wired network selected from a group comprising LAN, DSL , ADSL or VDSL.

4. The system (100) as claimed in claim I, wherein the codes are transferred from the automated programing module (102) to the controller (104) through a wireless network, selected from a group comprising WLAN, Wi-Fi, Wi-Max, UMTS or LTE.

The system (100) as claimed, in claim 1, wherein the oifigurat i on includes adding a. new machine component.

6, The system U.00} as claimed in claim h wherein the eonf igaratisr;: includes removing: as enisling machine component .

?. The system (100) as claimed in claim j ,· wherein the automated programing module dl.02) includes a Kernel (ill; and a boot loader ( 1 14).

8. The system ίϊθθί as claimed in claim 7, wherein the Kernel (112) is connected to a data memory (116) , a program memory (118) and an EEFROM (120).

9. The system (100; as claimed in claim 1, wherein the machine components includes one or more sensors.

10, A controller (104; tor cone. rolling a plurality of smart machine components in a distributed control system, the controller (104) comprising;

an input module (108) lor receiving a program code; and an output module (118) for communicating with one or more smart machine components, vnherein the controller enables smart machine components- oormroi based on execution of the program codes .

11. The controller (.101) as claimed in claim 10, wherein the controller (102) is a firmware,

12. The controller (104) as claimed in claim. 10, further comprising a nser interface.

13, The controller (104 ) as claimed in claim 10, further comprising a logic gate (202) and a voltage gate (204) .

14, The controller (104) as claimed in claim 13, wherein the logic gate (202; and the voltage gate (204) are connected to a processing hoard (206) for receiving respective operating instruct ions ,

15. The controller (104) as claimed in claim 12, wherein the user interface is a LCD Screen.

16, The controller (104} as claimed in cia.i.m 12, wherein the user interface is a control system consisting of LED lights and push but. tons ,

12. The controller (104) as claimed in claim 10, wherein the controller (104) includes a hardware and a firmware.

18. The controller ί J.04 ) as claimed in claim 10, wherein the firmware enables, the controller Π.02; to control the specific: machine component?;,

19, The controller ί 104} as claimed in claim 11 or 17, wherein the firmware fnnc Ln.oning depend on the codes generated by the automated programing module (102). 20. The controller (104⁾ as claimed in claim 11 or 17, wherein the firmware is independent of operating system (OS) .