Pilz: Mechatronics methods for automation

Smart factories, Industry 4.0 and autonomous production – the mechanical engineering department is now looking forward to a bright future. The pace of innovation and ever-shortening development moments are playing an increasingly important role in the global race. In order to streamline engineering processes and add reusability to individual components, planning engineers are focusing on modular planning of machinery, i.e. a mechatronic approach.

The mechatronics approach is a success factor in the development of new plant and machinery. The term mechatronics is a reflection of the interplay between the mechanical and electronic categories. A system built on the basis of a mechatronic approach is essentially made up of modules. Each module consists of sensors, fulfillment mechanisms, information processing and a mechanical base system (hydraulic and/or pneumatic).

In the medium and long term, when it comes to challenges, only a rigorous, interdisciplinary "modular thinking" can lead to success. The control system plays a key role here and is sure to provide support for the mechatronic approach. This is where the current system has reached its limits. On the one hand, although it is possible to create software modules, the commissioning of individual modules becomes very complex if they are implemented with a powerful, centralized control system. On the other hand, it is possible to automate the modules with a local control system, but this requires a fixed investment to establish a communication mechanism. Therefore, the number and layout of the control unit should be based on the overall mechatronics planning of the machine. It is often necessary to deal with these issues before planning to avoid the huge value that needs to be paid due to subsequent changes.

Pilz: Mechatronics methods for automation

　　The PSS4000 automation system supplied by Pilz opens up new possibilities in this area. Due to the decentralized structure of the system, decisions such as the selection of programmable logic manipulators for the appropriate planning and control structures can be delayed during the planning phase. This allows the planning engineer to concentrate on the components needed for the planning process, while functional and structural issues can be considered later. In traditional automation techniques, a separate, centralized control system monitors the equipment or machinery and processes all signals, while the PSS4000 allows the control function to be continuously distributed.

Specifically, the automation system PSS 4000 consists of hardware and software components, such as the real-time Ethernet SafetyNETp and various program editors for different areas, as well as operational utility blocks. The hardware consists of a control system with various levels of function. Through Ethernet, process or manipulation data, fault maintenance data, and diagnosis information can be communicated and synchronized. By consistently combining security and automation, the complexity of the communication domain can be reduced, and costs can be optimized together.

In addition, the control function is not affected by the handling of each program segment. Instead of operating a centralized control system, the operator operates the user programs in a centralized project that are scattered throughout the operating hours.

Modularity is the foundation of mechatronic operation

The Pilz Automation Suite PAS4000 software editor for PSS4000 automation systems. A key aspect of this is modularity: components are created from basic functions, which in turn are used to create modules, which in turn are used to create equipment and machinery, all by nesting them in layered blocks. Basic functions, components, and modules form the basis of software development, and due to their hermetically sealed and object-oriented features, they are suitable for reuse as software components.

Pilz is also able to support the program by providing software libraries containing the most common basic functions, components and modules. Picking out off-the-shelf components from software repositories is not new in itself. A special feature of PAS4000 is that these components have been given "features". This makes it possible to easily set the parameters of the desired function. This is a particular advantage in terms of functional standardization: previously it was necessary for users to consider how much functionality could fit into a utility block without adversely affecting clarity. In fact, the result is either a large number of utility blocks, or a too small number of utility blocks with a large number of parameters. Once the PAS4000 is chosen, the results are different. Here users can create their preferred components and establish a user level that is adapted to their use; This can then be used to select various functions. The results and functions can only be seen by the method of parameters; The components themselves are no longer complex and easy for users to manage.

Concurrent engineering

There is also an advantage to using components: programming and hardware planning can be separated and can be done in parallel, rather than sequentially as before. It is common practice to develop software only when the mechanical specification has been established and the initial circuit diagram is available. If you think and plan in terms of mechatronics, these processes can be separated and run in parallel. By simply creating components in the software library to standardize the functions of the machine, you can finally plan the overall structure of the machine you want to build with just a few initial information. The specific function of the component can then be set by individual features. The components required for the machine can be roughly deduced from the initial project agreement for all functions. Specific functions can be defined retrospectively by characteristics.

Module communication

In modern machine networks, there is a considerable amount of work to establish and maintain communication between users. If you consider that mechatronic modules are also hardware modules, and therefore each module contains intelligent control, then the communication between the modules, or more precisely, between the module control systems, will be a major problem.

With PSS 4000, the communication settings are no longer explicit, but implicit. First of all, all Internet users can know and use all information equally.

Secondly, the communication channels of the control module and the individual modules are known to the entire project team and can be set individually by the PSS 4000 based on assignments (e.g. program assignments).

Pilz: Mechatronics methods for automation

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