Title of Invention

"CONTROL APPARATUS FOR CONTROLLING A MACHINE"

Abstract

Control apparatus (1) for controlling a machine, in particular an injection molding machine, comprising a bus board (24) which provides a multipoint connection via a bus system and which includes at least one plug contact (26) of first type into which a control module (14) can be plugged, as well as at least one plug contact of second type (28) into which a process board (12) can be plugged, at least one control module (14) having a plug of first type complementing the plug contact of first type for assuming control tasks on the machine, a wiring board (30) which is connectable to the process board(s) (12) via a plug contact of third type (32) and at least one process module having one or more process boards (12), of which at least one is connectable via a plug of second type complementary to the plug contact of second type (28) to the bus board (24) and connectable via a plug of third type complementary to the plug contact of third type to the wiring board (30), and which has or which have a base range of input/output connections to the machine to be controlled and which establishes a connection between bus board (24) and wiring board (30)

Full Text

The present invention relates to control apparatus for controlling machine. Description: The present invention relates to a control apparatus for a machine, in particular for use in the control of an injection molding machine. The control apparatus of an injection molding machine is typically of modular construction, with various modules assuming different control tasks and providing the connection with particular controllable devices of the injection molding machine, such as, e.g., pressure sensor and motor drive. These modules are interconnected by a back plane bus and oftentimes constructed for insertion in a so-called "rack" having a back wall which has attached thereto a so-called bus board with a back plane bus. The connection between modules and back plane bus is predominantly implemented via plug contacts. Heretofore, a module provides a SPC (stored-program control) in which a safety logic of the injection molding machine is stored. In addition, the control apparatus includes a so-called wiring board for realizing the wiring including the safety circuitry of the machine and providing a voltage distribution for the control apparatus. The wiring board thus provides the voltage distribution with fuse protection, the safety circuitry including possible safety relays as well as further assemblies as well as a greatest possible portion of the wiring of the machine and its safety circuitry. A so-called process module which is securely mounted onto the wiring board has a base range for analog and digital control input and output connections to the injection molding machine. The connection between the control modules and the bus board, respectively, and the assemblies upon the wiring board is realized separately vi a individ ual cabl es. Up to now, assembly of such a control has been very cumbersome because of the many separate components and thus also prone to failure. In particular the separate wiring of the individual units of the wiring board with the control modules lacked clearness and posed a risk factor. When the injection molding machine is upgraded and the number of controlling components is thereby increased, the existing control apparatus was faced with the problem to provide an adequate control operation. A further drawback resided in the necessity to individually wire each production line of injection molding machines. It is an object of the present invention, to provide a control apparatus for a machine which allows through standardization a reduction in costs and moreover exhibits little likelihood for error while being flexible in use and as compact as possible. This object is attained by a control device according to the features of claim 1. In accordance with the present invention, a control for a machine, used in particular in injection molding machines, includes a bus board for providing the communication connections between various units, preferably a local synchronous bus or field bus architecture, a wiring board, and a separate process module. The latter includes one or more process boards for providing a base range for a SPC (stored-program control). The process module is not designed, as previously, integrally with the wiring board but represents a separate component which includes plugs of second and third type, for allowing direct connection to the bus board and the wiring board and thereby providing a bridge, i.e. connection, between these two boards so as to reduce wiring therebetween. At least one control module, which assumes control tasks for the machine, is fabricated for insertion in the bus board via plug contacts of the first type. Further control modules may be, optionally, added. The control apparatus can thus easily be suited to varying machine requirements by adding additional control modules. The use of pre-fabricated plug contacts for interconnecting individual elements of the control provides flexibility, when designing the control apparatus, and decreases the wiring complexity. As a consequence, the control can be configured compact and space-saving. The use of pre-fabricated components provides additional cost reduction. The process module provides, i.a.7 various digital and/or analog input and outputs by which the connection with the machine can be established. In addition, particular interfaces, like e.g. for an EEPROM, may be provided. Contacting is realized preferably via pre-fabricated plugs. A particularly preferred embodiment involves the provision of a control module in the form of a CPU module for executing tasks of a SPC. Also, a bus circuitry may be provided as a control module which serves as interface to an external CPU which then assumes the SPC tasks or expands the output range of the SPC. It is, however, also possible to provide a CPU directly in the process module for the SPC tasks to thereby save slots. The wiring board essentially includes the safety circuitry of the machine. Position switches may, for example, be directly connected which are used in accordance with the European standard EN 201 for monitoring protective doors of an injection molding machine. The program used for the supervision, the so-called safety logic, can be stored in a non-volatile memory, for which a so-called EN 201 module is used. This module is preferably provided on the wiring board but may also be disposed in the process module. In addition to the non-volatile memory, this module preferably includes its own controller which processes the safety logic and is connected, for example, via an 8 bit bus with the SPC of the machine. The module operates via separate outputs the safety circuitry of the machine to be controlled and thus ensures that the machine being controlled by the control apparatus according to the invention complies with safety regulations. Thus, it is possible, for example, to switch off various voltage supplies to digital outputs for the machine in unsafe state via safety relays as hardware that are integrated on the wiring board. Furthermore, the wiring board provides a standardized wiring to the machine to be controlled, which is realized, preferably by plug connectors, and the voltage distribution for the entire control apparatus. The board is preferably configured such that the provided safety circuitry can be expanded in accordance with production lines and selected options. The individual components provided in the wiring board can thus be contacted as far as possible by prefabricated cable bundles via plugs. Advantageously, the signals can be directly measured at the plug contacts. Variables that are frequently measured are hereby combined preferably to a 37 pole D-sub plug. Examples of components provided on the wiring board include hardware relay, safety relay, EEPROMs for the machine memory and various measuring points. The process module may, however, also include a non-volatile memory with a safety logic as well as a controller which runs the safety logic which operates essentially the safety circuitry, arranged on the wiring board, of the machine to be controlled and thus ensures that the machine controlled by the control according to the invention complies with safety regulations. According, to the present invention, the process module can be randomly expanded by one or more expansion modules to allow application also for machines of greater complexity. This expansion module provides additional sets of input and output components and includes an input protective circuitry and output drive circuitries, the operation is assumed by the process module. in order to configure the control especially compact, the bus boards and the wiring board may, advantageously, be designed integrally on separate regions of a single board. The control according to the invention is held, preferably, by a module carrier for attachment of the bus board, the wiring board, and the process board as well as possible expansion modules. It is hereby especially advantageous, when the board or boards of the process module are so held on the module carrier as to be arranged perpendicular to the integral board or boards of the bus and the wiring. Latter boards are supported in substantial plane-parallel relationship to the holder. The bus board and the wiring board are preferably secured to a rear side of the module carrier, whereas the process module is mounted to a front side of the module carrier because in this way, the input/output connections provided on the process module for the machine to be controlled are easier to access. The module carrier is preferably provided with recesses through which the plug contacts between various modules and boards can be guided, i.e. between the control modules and the bus board as well as between bus board and wiring board, respectively, and the process board. Recesses above the wiring board allow the direct routing of the connections of the safety circuitry. In addition, the module carrier should include further recesses in the form of a "rack" into which the control modules can be plugged. The modules can thus easily be secured through simple plugging on the front side of the module carrier, whereby a connection between the control modules and the bus board can be established at the same time by plugs and plug contacts of first type which extend through the first mentioned recesses. The module carrier of a control according to the invention is preferably provided beforehand with sockets for possible expansion modules of the process module. In this way, the number of input/output connections between injection molding machine and control can be expanded. To make the control according to the invention sfill more compact and its use more flexible, the input/output connections of the process module and its expansion modules can be realized as pre-fabricated front plugs. The plug connections of first type, which provide the connection of the control modules with the bus board, are preferably pre-fabricated and configured such as to be applicable for digital assemblies as well as analog structural assemblies. When using several process boards in the process module, the connection between the process boards is realized preferably via a transverse connection, and only one of the boards includes a plug of second and third type for connection thereof and the other boards with the bus board and wiring board. The same is true for the use of expansion modules which also are not directly connected with the boards, but have contact thereto, for example, by means of a transverse connection via the process module. Activation of the individual elements of the control is preferably implemented by a high-speed field bus system providing a multipoint connection on the bus board. The present invention realizes a standardization of the interface between control and performance of the wiring board by using a separate process board. The process module provides the bridge, i.e. the connection, between wiring board and bus board. In order to further enhance the flexibility of the control apparatus during use, further sockets for auxiliary units, like relays, can be provided on the wiring board, while random control modules can be plugged into the bus board. Moreover, diverse position measuring systems, e.g. using P interfaces and potentiometers, can be used. It is also possible to suit the cylinder recognition to actual needs and to use several inputs or pre-fabricated plug connections for data transmission. In this way, the interface to the cylinder of the injection molding machine can be standardized. As a consequence of the modularity and flexibility, the control apparatus according to the present invention can be used and easily suited for diverse production lines. An example of an embodiment of a control according to the invention will now be described with reference to the attached drawings, in which: Fig. 1 shows a schematic plan view of an embodiment of the control according to the invention, and Fig. 2 shows a schematic functional block diagram of the control of Fig. 1. The control apparatus 1 illustrated in Fig. 1 and provided in particular for controlling an injection molding machine, includes a module carrier 2 made of stamped and shaped sheet metal with varying recesses 4, 8, 22. Retained on this module carrier 2 are various elements of the control. Schematically shown in Fig. 1 on the left-hand side is a process module casing 10 which accommodates a process module 12. The open top of the process module allows connections of the process module 12 to be routed away. Preferably provided for contacting are predominantly prefabricated plug contacts or plugs in the form of front plugs which are guided through the open top. To the left next to the process module casing 10 is a socket 22 for an optional expansion module. The region of the module carrier 2 located to the rear and right in Fig. 1 is designed as so-called rack 6 for allowing securement of the plug-in modules 14, which involve control modules, via a snap-in mechanism. Snap connection recesses 8 are hereby provided in the area of the rack 6. Also provided in this area are recesses 4 through which the plugs of first type of the control modules 14 can be guided. In the present case, the control modules 14 are designed as compact control elements which provide a second contacting option via a plug contact 16 protected by a covering hood 18 and which may be provided with LEDs for indication of operation as well as other functional elements. Further provided in the area of the rack 6 is a CPU module 20 which requires in Fig. 1 two slots or, as an alternative, a bus circuitry for implementing a connection to an external CPU which assumes the functions of a control module or a SPC. The connection between the CPU module 20 or the bus circuitry and the other control modules 14 is realized via a bus board 24 disposed on the backside of the module carrier 2 in the area of the rack 6. Provided on the bus board 24 are plug contacts of first type 26 into which the control modules 14 or the CPU module 20 can be plugged through the recesses 4. The bus board 24 includes at least one plug contact of second type 28 via which a connection to the process module or process board 12 can be realized. According to Fig. 1, a wiring board 30 is attached in a front and right-hand region to the back of the module carrier 2 of the control 1 according to the invention for arrangement of essentially a safety circuitry as well as the wiring of the machine to be controlled as well as a voltage distribution for the control. Components as well as wiring connections, shown only schematically in Fig. 1 and arranged on the wiring board, can be routed through the recesses 4 in the module carrier 2. The wiring board 30 further includes a plug contact of third type 32 for allowing connection to the process board(s) 12 and via the latter to the bus board, Not shown is the voltage distribution, provided on the wiring board, for the overall control. Fig. 2 shows the conceptual configuration of the control 1 according to the invention; the essential information flows are depicted schematically by arrows in boxes to the left of the Figure. The upper area refers to few control modules 14 with possible assignments. For example, a so-called temperature module 150, an analog mixer module 140, a P interface 130 for position measuring systems or the like may be provided. The unoccupied slots 160 may, optionally, receive further control modules. Further control modules, such as, for example, rare auxiliary units 120, functions dependant on the machine type, or other special options, may be incorporated via the CPU 20, shown on the upper right-hand side, or via the bus wiring. Located on the wiring board 30, shown at the bottom of Fig. 2, is the voltage distribution and fuse protection 170 and 180, respectively, for the overall control apparatus 1 as well as for the control modules. Disposed are the EN 201 module, containing the safety logic, the safety circuitry according to EN 201 for the supervision of protective doors to ensure the safety of the machine at operation, as well as various structural components 190, e.g., hardware relay, measuring points, safety relays, and elements for the fixed wiring such as bridges, eraser members, and the like. The connections to the machine are predominantly realized via pre-fabricated cable bundles so that the tendency of the wiring for errors is decreased, the clearness is enhanced, and the required space is minimized. The process module 10, 12 disposed in Fig. 2 on the left-hand side between the control module region and the wiring board 30 includes a SPC base range and essentially provides the input and output connections from the control to the injection molding machine. The process module may include one or more process boards 12, whereby in case of more than one board, the boards are interconnected by transverse contacts configured preferably for plug connection. The process module has the task to provide bridging, i.e. the connection, between the wiring board 30 and the bus board 24. In the illustrated embodiment, the process module should include at least the following elements: 32 digital inputs, 24 digital outputs with 2 A imposition, 8 digital outputs with 0.7 A imposition, 7 analog temperature inputs, 1 KTY input for oil temperature, 4 analog outputs of +A10 V, 3 analog differential inputs of 0-10 V, 8 digital inputs in conformity with the safety standard EN 201, as well as 4 transsonar inputs. In addition, an interface card for ultrasonic position measuring systems with P interface may be provided. As a consequence of the modular construction of the control 1 according to the invention, i.e. in particular the option to add-on any control modules 14 to the rack, without exceeding a predefined space for the overall control, the standardized bridging of bus board 24 and wiring board 30 as a result of the use of the process module 12 according to the invention, and the expandability of the process module 12, the control apparatus 1 is very flexible for use with any machine production lines. This is further enhanced by the possibility to use the plug contacts of first type 26, provided for the connection of the control module 14 to the bus board 24, for digital as well as analog assemblies. In order to be able to expand the control apparatus in an most cost-efficient manner, when machines of greater complexity are involved, an expansion assembly may be added to the process module and include, for example, 8 analog outputs of 0-10 V, 8 analog inputs of 0-10 V as well as 8 digital inputs and 8 digital outputs of 2 A. This assembly essentially includes only plug contacts for the inputs and outputs, an input protective switch as well as output driver circuits, the control is assumed by the actual process module. The advantages of the present invention thus reside in the standardization of a modular control apparatus while enhancing the flexibility at the same time, so as to reduce costs and save space in the switch cabinet, and to allow an advantageous universal use of the control that can be suited to the demands at hand. List of Reference Characters: (Table removed) We Claim: 1. Control apparatus (1) for controlling a machine, in particular an injection molding machine, comprising: - a bus board (24) which provides a multipoint connection via a bus system and which includes at least one plug contact (26) of first type into which a control module (14) can be plugged, as well as at least one plug contact of second type (28) into which a process board (12) can be plugged, - at least one control module (14) having a plug of first type complementing the plug contact of first type for assuming control tasks on the machine, - a wiring board (30) which is connectable to the process board(s) (12) via a plug contact of third type (32). and - at least one process module having one or more process boards (12), of which at least one is connectable via a plug of second type complementary to the plug contact of second type (28) to the bus board (24) and connectable via a plug of third type complementary to the plug contact of third type to the wiring board (30), and which has or which have a base range of input/output connections to the machine to be controlled and which establishes a connection between bus board (24) and wiring board (30) 2. Control apparatus as claimed in 1, wherein a CPU module (20) is provided as a control module. Control apparatus as claimed in claim 1 or 2, wherein a bus wiring to an external CPU is provided as a control module. Control apparatus as claimed in one of the claims 1 to 3, wherein the wiring board (30) has a safety circuitry, a wiring for the machine to be controlled as well as a voltage distribution. Control apparatus as claimed in claim 4, wherein the wiring board (30) has a non-volatile memory with a safety logic and a controller which operates the safety circuitry. Control apparatus as claimed in claim 4, wherein the process module has a non-volatile memory with a safety logic and a controller which operates the safety circuitry disposed on the wiring board (30). Control apparatus as claimed in one of the claims 1 to 6, wherein the process module has a CPU. Control apparatus as claimed in one of the claims 1 to 7, wherein the process module has an expansion module which has input and output assemblies, output driver circuits and/or input protective circuitry. Control apparatus as claimed in one of the claims 1 to 8, wherein the wiring board (30) and the bus board (24) are designed integrally on separate regions of a single board. Control apparatus as claimed in one of the claims 1 to 9, wherein a module carrier (2) is provided for allowing attachment of the process module, the wiring board (30) and the bus board (24). 11. Control apparatus as claimed in claim 10, wherein the board or boards (12) of the process module is/are placed on the module carrier (2) perpendicular to the wiring board (30) and the bus board (24). 12. Control apparatus as claimed in one of the claims 10 or 11, wherein the wiring board (30) and the bus board (24) are mounted on a backside of the module carrier (2), and the process module is mounted on a front side of the module carrier (2). 13. Control apparatus as claimed in one of the claims 10 to 12, wherein the module carrier (2) has recesses (4) through which the plug contacts between the various modules (16) and boards (12, 24, 30) as well as individual components disposed on the wiring board (30) can be guided. 14. Control apparatus as claimed in one of the claims 10 to 13, wherein the module carrier (2) has additional snap-in connection recesses (8) in which the control modules (14) snap in. 15. Control apparatus as claimed in one of the claims 10 to 14, wherein the module carrier (2) is provided with sockets (22) for one or more expansion modules of the process module. 16. Control apparatus as claimed in one of the claims 1 to 15, wherein the input/output connections of the process module and/or its expansion modules are made by pre-fabricated front plugs. 17. Control apparatus as claimed in one of the claims 1 to 16, wherein the plug contacts of first type (26) are pre fabricated and so constructed as to establish a plug connection for digital as well as analog assemblies. 18. Control apparatus as claimed in one of the claims 10 to 17, wherein the boards (12) of the process module are linked by a transverse connection. 19. Control apparatus as claimed in one of the claims 10 to 18, wherein the module carrier (2) is made of sheet metal.

Documents:

2073-delnp-2005-abstract.pdf

2073-delnp-2005-claims.pdf

2073-delnp-2005-complete specification (granted) (as files).pdf

2073-delnp-2005-complete specification (granted).pdf

2073-delnp-2005-correspondence-others.pdf

2073-delnp-2005-correspondence-po.pdf

2073-delnp-2005-description (complete).pdf

2073-delnp-2005-form-1.pdf

2073-delnp-2005-form-18.pdf

2073-delnp-2005-form-2.pdf

2073-delnp-2005-form-3.pdf

2073-delnp-2005-form-5.pdf

2073-delnp-2005-gpa.pdf

2073-delnp-2005-pct-210.pdf

2073-delnp-2005-pct-304.pdf

2073-delnp-2005-pct-409.pdf

2073-delnp-2005-petition-137.pdf