Communication system for monitoring a process unit

Abstract

The invention relates to a communication system (1) for monitoring process units (20, 41 to 46), having at least one process unit (20, 41 to 46) which is configured such that it is connected via a communication interface (24) to a peripheral communication unit (30) belonging to it in order to transmit process variables (P1 to P4) to the peripheral communication unit (30), wherein the process variables (P1 to P4) transmitted to the peripheral communication unit (30) are configurable, wherein each peripheral communication unit (30) is configured such that it receives the configured process variables (P1 to P4) from the corresponding process unit (20, 41 to 46) and emits them as an advertising packet (32), and a central communication unit (40, 40a) which is configured such that it receives the advertising packets (32) from each peripheral communication unit (30).

Description

TECHNICAL FIELD

[0001] The present invention relates to a communication system for monitoring process units, wherein in particular process variables are configurable, which are transmitted from the process units via a communication interface to peripheral communication units and emitted as advertising packets from the peripheral communication units. BACKGROUND

[0002] In the use of the Bluetooth Low Energy (BLE) standard, data in the form of advertising packets can be sent or broadcast by a plurality of peripheral communication units independently of one another. A central communication unit receives the advertising packets without the need for a coupling between the peripheral communication units and the central communication unit. However, the data contained in the advertising packets is preset, so that a plurality of data of the process units, such as all process variables, are transmitted by the peripheral communication units to the central communication unit.

[0003] Since the advertising packets comprise only a data volume of 31 bytes according to the Bluetooth 4 standard, it is necessary to emit a plurality of advertising packets in order to transmit a plurality of data. This leads to an increased energy consumption of the peripheral communication units, which can lead to a shortened operating time, in particular in battery-operated peripheral communication units, in which the BLE standard is preferably used as an energy-saving radio technology. Furthermore, it is a burden for the user when monitoring the process units by means of such a BLE communication system to filter the important process variables from a plurality of received data in order to draw conclusions about the state of the process units. Furthermore, depending on the type of process unit and the manner of application, other data for monitoring the state of the process units are of interest. SUMMARY

[0004] It is therefore an object of the present invention to provide an efficient communication system, which allows the user to monitor the process units in a simple manner and method, so that the user has the ability to react correspondingly if an abnormal state occurs in one of the process units.

[0005] The object is achieved by a communication system for monitoring process units according to the present invention. Further advantageous design solutions of the present invention are described in the description and the drawings. BRIEF DESCRIPTION OF DRAWINGS

[0006] Embodiments of the present invention are described below with reference to the accompanying drawings. In which:

[0007] Figure 1 a schematic structure of a communication system according to a first embodiment is shown;

[0008] Figure 2 a user interface of a central communication unit is shown;

[0009] Figure 3 a schematic structure of a communication system according to a second embodiment is shown;

[0010] Figure 4 A schematic structure of a communication system according to a third embodiment is shown. DETAILED DESCRIPTION

[0011] First embodiment

[0012] Figure 1 A schematic structure of a first embodiment of a communication system 1 for monitoring a process unit is shown. In Figure 1 A process unit 20, in particular a valve, is exemplarily shown in the middle, which is connected with a peripheral communication unit 30 belonging thereto in order to emit an advertising packet 32, which is received by a central communication unit 40. However, it is self-evident that any number of process units each having a peripheral communication unit can be monitored.

[0013] The process unit 20 is a component of a facility (not shown) for carrying out a process and has at least one control unit 22 and a communication interface 24.

[0014] The control unit 22 is configured in such a way that it controls the operation of the process unit 20, detects a plurality of process variables P1 to P4 of the process unit 20 and connects with the communication interface 24 in order to transmit the process variables P1 to P4 to the peripheral communication unit 30. Said functions of the control unit 22 are defined in a firmware stored in a memory of the control unit 22 here. However, the control unit 22 is not limited to said functions and can in addition have other functions.

[0015] The control unit 22 open-loop controls or closed-loop controls the process unit 20 on the basis of the process variables P1 to P4. For this reason, the control unit 22 detects the process variables P1 to P4 and further process variables P1 to P4 which occur as a response to the open-loop control or closed-loop control of the process unit 20. The control unit 22 is connected to the sensors (not shown) for detecting the process variables P1 to P4 directly for this purpose, wherein the sensors are designed as digital and / or analog sensors which are connected to the control unit 22 wirelessly and / or by wire. For the case of using analog sensors, the control unit 22 has an analog-digital converter in order to convert the analog input signals into digital signals. The control unit 22 can furthermore also obtain the process variables P1 to P4 from other control units of the plant, for example via a communication connection, such as a bus connection. For the process unit 20, several hundred process variables P1 to P4 can thus be provided, such as pressures, currents, voltages, temperatures, etc. In the firmware of the process unit 20, limit values of the process variables P1 to P4 are furthermore determined which should be adhered to in order to ensure a normal or error-free operation of the process unit 20. The control unit 22 thus has the ability to determine a normal state or an abnormal state of the process unit 20 when the current value of one of the process variables P1 to P4 lies within or outside the operating range. An abnormal state of the process unit occurs if the value of one of the process variables P1 to P4 lies outside the operating range. The control unit 22 is configured in such a way that it recognizes the abnormal state of the process unit and generates a fault notification.

[0016] However, it is often necessary during the operation of the process unit 20 that only certain selected process variables P1 to P4 must lie within the operating range, so that the remaining process variables P1 to P4 do not need to be monitored. The core of the present invention is thus that the process variables P1 to P4 which are provided by the control unit 22 to the peripheral communication unit 30 via the communication interface 24 are configurable in the firmware of the control unit 22, so that only the important process variables P1 to P4 are emitted by the peripheral communication unit 30. The configuration of the process variables P1 to P4 is described in the following paragraphs. It is noted at this point that the states of the process unit 20 are also referred to as process variables P1 to P4 below. The process variables P1 to P4 which illustrate the states can thus enable a distinction between the normal state and the abnormal state of the process unit 20. Furthermore, as already mentioned above, in the case of an abnormal state, a fault notification or a fault code is generated which allows the user in a simple manner to identify the cause of the abnormal state of the process unit 20. The totality of the data is referred to as process variables P1 to P4 in the scope of the present specification in short.

[0017] The communication interface 24 of the process unit 20 is configured in such a way that it provides the process variables P1 to P4 detected by the control unit 22 and allows access to the control unit 22. The communication interface 24 is provided for this purpose by the control unit 22 itself or in other ways and methods, for example by an interface converter or the like. The communication interface 24 is a standard interface, but can also be a proprietary interface. The individual process variables P1 to P4 are provided via the communication interface 24 in specific time intervals. It is also conceivable, however, that only those process variables P1 to P4 are provided via the communication interface 24 which have undergone a predefined change (for example 2%), so that the data quantity to be transmitted is further reduced.

[0018] The communication system 1 according to the application has a peripheral communication unit 30 which is connected to the communication interface 24. The process variables of the process unit 20 can thus be transmitted to the peripheral communication unit 30 and received or actively read out by it. The peripheral communication unit 30 according to the application is configured in such a way that it can implement data transmission according to the Bluetooth Low Energy (BLE) standard. The BLE standard enables data to be emitted or broadcast in the form of an advertising packet 32 without the need for a central communication unit 40 to be coupled to the peripheral communication unit 30. The peripheral communication unit 30 is thus configured in such a way that it reads out the process variables P1 to P4 from the communication interface 24 in turn and emits them as advertising packets 32 at a predefined time interval. The peripheral communication unit 30 can however also be configured in such a way that it reads out the process variables P1 to P4 in parallel and subsequently arranges them in the advertising packets 32 in turn. The peripheral communication unit 30 is designed here as a plug-and-play unit which can be plugged onto the communication interface 24 of the process unit 20. The peripheral communication unit 30 can also be designed as an integrated component of the process unit 20 or the control unit 30.

[0019] The advertising packet 32 has a maximum length of 31 bytes and a predefined structure according to the BLE standard. The first byte specifies the length of the following data. The second byte specifies the data type, which is transmitted in the advertising packet 32. Each data type is assigned a data type value here according to the Generic Access Profile (GAP). The following bytes specify the value of the data. However, the GAP provides only a limited number of data type values, so the data can also be provided as manufacturer-specific data by means of the data type value "0xFF". The manufacturer-specific data type has a slightly changed structure here, so that the data transmitted thereby can be recognized. The first byte again specifies the length of the following data. The second byte has the value "0xFF". The third and fourth bytes specify the company identification code, so that a manufacturer-specific interpretation of the following data is possible. The following data is structured such that the first byte of the data, i.e. the fifth byte, has an identifier (ID), which specifies the manufacturer-specific data type. Thus, for example, it can be specified by means of the ID "0x01" that the following bytes specify the value of the process variable P1, for example the pressure of the process unit 20. The structure can be used individually for each process variable P1 to P4.

[0020] The advertising packet 32 is not limited to the fact that only the value of one of the process variables P1 to P4 is transmitted per packet. Rather, the values of a plurality of process variables can be transmitted in succession in the advertising packet 32, as long as the maximum length of 31 bytes is not exceeded. In the following, Figure 1 the values of the process variables P1, P2, P3 and P4 are transmitted in succession as an example. The position of the bytes described above for the process variable P2, P3 or P4 is thus shifted in each case according to the length of the bytes transmitted in advance. The advertising packet 32 can also have a length of less than 31 bytes.

[0021] In addition, the variable configuration of the manufacturer-specific data can be implemented such that the ID is also determined such that a plurality of values of the process variables P1 to P4 are subsequently arranged in succession in a row, without the structure described above for each process variable P1 to P4 being required individually. For example, the ID "0x10" can be defined, which specifies that the value of the process variable P1 and the value of the process variable P2 are subsequently transmitted. In this way, however, it is noted that the length of the values for the individual process variables P1 to P4 is constant. In this way, the amount of bytes to be transmitted in the advertising packet 32 can be further reduced.

[0022] As already set out above, only specifically selected process variables are provided by the control unit 22 of the process unit 20 to the peripheral communication unit 30 via the communication interface 24 in accordance with the application. It is thus not necessary that the values of all process variables P1, P2, P3 and P4 are transmitted by the peripheral communication unit 30 in the form of the above-mentioned advertising packet 32. It is also possible, for example, that only the values of the process variables P1, P2 and P3 or values according to other combinations of the process variables P1 to P4 are emitted.

[0023] The communication system 1 in accordance with the application furthermore has a central communication unit 40 which is configured in such a way that it receives the advertising packets 32 from the peripheral communication unit 30. In accordance with the first embodiment, the central communication unit 40 is preferably a communication unit with a display, such as a smartphone, a tablet, a notebook or a desktop computer. However, the central communication unit 40 can also be a communication unit which is specially constructed for this purpose. The central communication unit 40 is also preferably a portable communication unit.

[0024] The corresponding central communication unit 40 shows and detects the advertising packets 32 of the plurality of process units 41 to 46 in Figure 2 and as already described above. In Figure 2 a part of the user interface is furthermore shown which is shown on the central communication unit 40. The central communication unit 40 is here configured in such a way that it shows the process variables P1 to P4 received by means of the advertising packets 32 so that the user has the ability to identify the status (normal status or abnormal status) of the plurality of process components 41 to 46 respectively. The user interface is here constructed as an application or app on the central communication unit 40, but can also be constructed in other ways and methods, for example as an operating system for the central communication unit 40 which is specially programmed for this purpose.

[0025] In the shown example, the individual process units 41 to 46 are shown in tabular form, wherein Figure 1 the process unit 20 in Figure 2 corresponds to the process component 46 in Figure 2 . It is however also conceivable that the process units 41 to 46 are shown in a spatial map which shows the location of the process units 41 to 46, for example in a map. Since usually a plurality of process components 41 to 46 are monitored, the user interface also provides a search field 48 for the targeted search for one of the process components 41 to 46.

[0026] The status of the individual process units 41 to 46 is set out below. It is to be noted that the status of the individual process units 41 to 46 in Figure 2 is shown by a hatched circle (normal status), a solid circle (abnormal status) and a hollow circle (no data transmission). However, other symbols can also be used, such as coloured circles, which can be implemented for the user to identify the respective status of the process component.

[0027] The process unit 41 has a normal state. Thus all process variables are within the respective operating range. However, for the process unit 41 no values of the individual process variables are emitted and thus not shown on the user interface. The process unit 41 is in addition marked as the most preferred process unit by the marking 47, which means that said process unit is shown in the upper section of the user interface. The process unit 42 is likewise in a normal state, wherein additionally the current value of the pressure of 120 bar is shown. It is to be noted that the display of process variables is not limited to one value, but rather for example a plurality of values of process variables are shown above and below. The process unit 43 indicates that no values are transmitted from its peripheral communication unit to the portable central communication unit 40. In addition it is stated that the central communication unit of the process unit 43 is outside the transmission area of the peripheral communication unit of the process unit 43. The process unit 44 has an abnormal state, wherein no process variables are transmitted. The process unit 45 likewise indicates a state in which no values are transmitted from its peripheral communication unit to the portable central communication unit 40. However, in contrast to the process unit 43, no reason for the lack of communication connection is stated. The process component 46 (process unit 20) indicates that an abnormal state occurs. In addition the process component 46 states that a fault notification "F4037" occurs, which in the shown example states that the maximum pressure is exceeded. In addition, it is stated that the current value of the pressure is 160 bar. However, it is also possible that only one of the two process variables, the fault notification or the current value, is stated.

[0028] Thus, the present application enables that the user can identify the state of the individual process components 41 to 46 in a simple manner and method without having to analyze a plurality of data.

[0029] In addition, the central communication unit 40 is configured such that it establishes a connection or coupling between the central communication unit 40 and one of the peripheral communication units (not shown) of the process units 41 to 46. The connection is established here by a selection operation on the central communication unit 40. The display of the central communication unit 40 is for this purpose preferably designed as a touch display, such that the user can establish the connection to the peripheral unit of the process unit 41 to 46 by touching the section in the touch display at which the process component 41 to 46 is displayed. For the case that the central communication unit 40 does not have a touch display, the connection can also be established by other selection operations, such as by clicking with a mouse or by selection with a joystick.

[0030] It is assumed in the following that the user establishes the connection to the peripheral unit of the process component 46, i.e. to the peripheral unit 30 of the process unit 20. For this purpose, as in the example shown in Fig. 1, the user touches the section in the touch display of the central communication unit 40 at which the process component 46 is displayed. The connection is established and the process component 46 is displayed in the upper section of the user interface. The process component 46 is in addition displayed in a different color than the other process components 41 to 45, which indicates that the process component 46 is in an abnormal state. In addition, the process component 46 displays the fault notification "F4037", which in the shown example states that the maximum pressure is exceeded. In addition, it is stated that the current value of the pressure is 160 bar. However, it is also possible that only one of the two process variables, the fault notification or the current value, is stated. Figure 1As shown in Fig. 1, a connection 34 is established, so that a Generic Attribute Profile (GATT) service for transmitting data between the peripheral communication unit 30 and the central communication unit 40 can be provided.

[0031] In this regard, a user interface (not shown) provided by the control unit 22 of the process unit 20 is displayed for the user on the display of the central communication unit 40, which user interface differs from the user interface shown in Fig. 1. On the user interface of the control unit 22, the user can monitor all process variables of the process unit 20 and set or change process parameters of the process unit 20 in the control unit 22. Process parameters are understood in the following as variables, for example the opening duration of a valve, by means of which the operation of the process unit 20 can be influenced. Figure 2

[0032] The setting of the process parameters becomes possible because, after the establishment of the connection between the central communication unit 40 and the peripheral unit, the data transmitted to the peripheral communication unit 30 are transmitted via the communication interface 24 to the control unit 22 of the process unit 20. The user can thus change the process parameters in the control unit 22 of the process unit 20. In particular, the user can change at least one process parameter in response to an abnormal state of the process unit 20.

[0033] In addition, the user can configure the process variables P1 to P4 on the user interface, which process variables are emitted by the peripheral communication unit 30 as advertising packet 32. For this purpose, the user selects the desired process variables P1 to P4, so that the process variables are saved in the form of a list in the firmware of the control unit 22. In normal cases, the configuration of the process variables P1 to P4 to be transmitted for the process unit 20 takes place when the facility is put into operation. However, the configuration can be changed at any time.

[0034] The list of the process variables P1 to P4 to be transmitted can be compiled here in different ways and methods. On the one hand, a preconfigured list (by the manufacturer of the process unit) can exist depending on the type of the process unit 20 or the application for which the process unit 20 is set, so that a quick configuration is possible. On the other hand, a free configuration by the user himself is possible, wherein the configuration is stored as a new list. It is of course also possible that the user saves a plurality of self-configured lists in the memory of the control unit 22 in order to use the lists as required. The central communication unit 40 can then correspondingly interpret the individual process variables P1 to P4 on the basis of the IDs contained in the advertising packet 32, which can be associated one-to-one with the process variables P1 to P4. As already mentioned above, the process variables P1 to P4 are transmitted in turn, wherein an individual process variable P1 to P4 can only be transmitted when a pre-given change has been made.

[0035] ​The transmission of the reduced amount of important data for the corresponding process unit is achieved by the variable structure of the process variables Pi to P4 transmitted as advertisement packages 32. Thus, an energy-saving communication system 1 for monitoring the process units 20 is obtained. Furthermore, the important process variables Pi to P4 can be monitored by the user in a simple manner and method, so that the status can be easily identified. Moreover, the communication system 1 according to the present application can be implemented for a user, so that the user establishes a connection between the central communication unit 40 and the peripheral communication unit 30 of the process unit 20 in order to monitor all process variables Pi to P4 of the process unit 20, to change at least one process parameter in the control unit 22 of the process unit 20 or to change the configuration of the process variables Pi to P4 to be transmitted.

[0036] Second embodiment

[0037] In the following, reference is made to Figure 3 A second embodiment of the present application is described. It is to be noted that the configuration of the second embodiment is essentially the same as the configuration of the first embodiment, so that only the differences to the first embodiment are described.

[0038] In the second embodiment, the process units 20 are again connected with the peripheral communication units 30, so that the configured process variables Pi to P4 are transmitted as advertisement packages. According to the second embodiment, the central communication unit 40a is a gateway, which is connected with a server 50 via a communication connection 60, such as an internet connection, a VPN connection, a network connection or the like. The central communication unit 40a is configured so that it transmits the process variables Pi to P4 to the server. The server 50 is configured so that it stores the process variables in a data storage, such as in a database or a cloud storage, in order to record a history or a change process of the process variables Pi to P4, which are configured in the control units 22 of the process units 20.

[0039] Furthermore, the second embodiment provides the possibility that a user can access the central communication unit 40 via a remote access, such as a web service, a VPN tunnel or the like. The remote access is here preferably made by the central communication unit 40 according to the first embodiment, but can also be made by other suitable communication devices. By the remote access, the user is again provided with a user interface, as it is shown in Figure 2 In the described way, the user can change the process parameters in the control units 22 of the process units 20 by the remote access. Furthermore, the user can monitor all process variables Pi to P4 of the process units 20 via the remote access and change the configuration of the process variables Pi to P4, which are emitted as advertisement packages 32.

[0040] Furthermore, the server 50 can also be configured such that, when receiving the process variables P1 to P4 which indicate an abnormal state of the process unit 20, the server sends a message to a user. The server 50 sends an electronic message, such as an email, an SMS, a push notification, etc., preferably to the central communication unit 40 according to the first embodiment. However, the server 50 can also send the electronic message to other suitable communication units.

[0041] The second embodiment of the present application thus provides the advantage that a user is informed about an abnormal state of the process unit 20 without having to monitor the process unit 20 persistently. Furthermore, the user can access the peripheral unit 30 of the process unit 20 via remote access without the user having to be in the range of action of the peripheral communication unit 30 with the central communication unit 40. Furthermore, the process variables P1 to P4 configured in the control unit 22 are transmitted by the central communication unit 40a to the server 50 which is configured such that it stores the process variables in a data storage such that the process variables are available for a subsequent analysis.

[0042] Third embodiment

[0043] In the following Figure 4 A third embodiment of the present application is described. It is to be noted that the configuration of the third embodiment is basically the same as the first and second embodiments such that only the differences to the first and second embodiments are described.

[0044] According to the third embodiment, the advertisement packet 32 issued by the peripheral communication unit 30 is received by the central communication unit 40 and the central communication unit 40a. This is possible because the advertisement packet is issued as a broadcast according to the BLE standard.

[0045] The third embodiment thus provides the advantage that, when the central communication unit 40 is in the range of action of the peripheral communication unit 30, a user can monitor the process variables P1 to P4 issued by the peripheral communication unit 30 of the process unit 20 as advertisement packets 32 via the central communication unit 40 without having to perform a remote access via the central communication unit 40a. At the same time, the process variables P1 to P4 are transmitted to the server 50 via the central communication unit 40a in order to record a history of the process variables P1 to P4.

[0046] The communication system according to the present application is set up for monitoring process units with advertisements according to the Bluetooth Low Energy standard, especially as a communication system in the field of industrial communication, for example in the so-called Internet of Things (IoT). However, the communication system according to the present application can also be used in other fields in which the content of the advertisement packet should be able to be adjusted by a user.

Claims

1. A communication system (1) for monitoring process units (20, 41 to 46), the communication system having: at least one process unit (20, 41 to 46) which is configured such that it is connected to a peripheral communication unit (30) belonging to it via a communication interface (24) in order to transmit process variables (P1 to P4) to the peripheral communication unit (30), wherein the peripheral communication unit (30) is configured such that it can implement data transmission in accordance with the Bluetooth Low Energy, BLE, standard, wherein the process variables (P1 to P4) transmitted to the peripheral communication unit (30) are configurable, wherein each peripheral communication unit (30) is configured such that it receives the configured process variables (P1 to P4) from the corresponding process unit (20, 41 to 46) and emits them as an advertising packet (32); and a central communication unit (40, 40a) which is configured such that it receives the advertising packet (32) from each peripheral communication unit (30), wherein the central communication unit (40, 40a) is configured such that the status of each process unit (20, 41 to 46) is displayed on a user interface in order to identify an abnormal state or a normal state of each process unit (20, 40 to 46), such that a connection can be established between the central communication unit (40, 40a) and the peripheral communication unit (30) of the process unit (20, 41 to 46) having an abnormal state, and wherein a connection is established between the central communication unit (40, 40a) and the peripheral communication unit (30) of the process unit (20, 41 to 46) having an abnormal state in order to change at least one process variable in response to the abnormal state.

2. The communication system (1) according to claim 1, wherein a connection can be established between the central communication unit (40, 40a) and each peripheral communication unit (30) in order to perform at least one of the following processes: monitoring all process variables (P1 to P4), setting at least one process variable, and configuring the process variables (P1 to P4) which are emitted as advertising packets.

3. The communication system (1) according to any one of the preceding claims 1 to 2, wherein the configuration of the process variables (P1 to P4) can be set arbitrarily.

4. The communication system (1) according to any one of the preceding claims 1 to 2, wherein the configuration of the process variables (P1 to P4) is initially set when the process unit (20, 41 to 46) is put into operation and can be set arbitrarily during operation of the process unit (20, 41 to 46).

5. The communication system (1) according to any one of the preceding claims 1 to 2, wherein the central communication unit (40) has a display and is operated in the range of action of the peripheral communication unit (30).

6. The communication system (1) according to any one of the preceding claims 1 to 2, wherein the central communication unit (40a) is a gateway, which is connected with a server (50), which is configured in such a way that it stores the process variables (P1 to P4) issued as advertisement packages (32) in a data memory.

7. The communication system (1) according to claim 6, wherein the server (50) is configured in such a way that it sends an electronic message to a communication unit when an abnormal state of the process unit (20, 41 to 46) occurs.

8. The communication system (1) according to claim 7, wherein a remote access of the communication units to the central communication unit can be established in order to perform at least one of the following processes: monitoring of all process variables (P1 to P4), setting of at least one process variable and configuration of the process variables (P1 to P4) issued as advertisement packages.

9. The communication system (1) according to any one of the preceding claims 1 to 2, wherein the communication system (1) has a plurality of central communication units, wherein the plurality of central communication units (40, 40a) receives the process variables (P1 to P4) issued as advertisement packages (32) from the peripheral communication unit (30) when a connection is not established between one of the central communication units (40, 40a) and the peripheral communication unit (30).

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