Method and apparatus for determining proximity between actuators and sensors in a facility

Abstract

The invention provides a method for determining a proximity relationship between an actuator (51) and a sensor (41, 42, 43, 44), wherein in an installation (1) for controlling a technical process, the sensor cooperates with the actuator and communicates with the actuator, wherein the actuator (51) influences the process and the sensor (41, 42, 43, 44) detects a measured value of a process variable, characterized in that the actuator (51) influences the process according to a predefined test pattern (17), searches for a sequence of measured values ​​obtained from the sensor (41, 42, 43, 44) as a response (16-41, 16-42, 16-43; 16'-41, 16'-42, 16'-42) to the test pattern (17), and identifies the sensor as the sensor with the greatest effective proximity to the actuator (51), whose response optimally meets predefined quality criteria with respect to response quality and response time.

Description

Technical Field

[0001] The invention relates to a method for determining a proximity relationship between an actuator and a sensor, which interacts with the actuator in an installation for controlling a technical process and communicates with the actuator, wherein the actuator influences the process and the sensor detects a measured value of a process variable.

[0002] The invention further relates to a device for determining a proximity relationship between an actuator and a sensor, which cooperates with the actuator in an installation for controlling a technical process and communicates with the actuator, wherein the actuator influences the process and the sensor detects a measured value of a process variable. Background Art

[0003] In facilities in the process industry, such as those producing chemicals, petrochemicals, pharmaceuticals, foods, and other products, decentralized field devices distributed locally at the field level perform predetermined functions within the framework of facility automation and, in doing so, exchange process-related, facility-related, and / or device-related information with components of a higher-level control and management system and, if necessary, with each other. Field devices include sensors (e.g., measuring transducers for fill level, flow, pressure, and temperature, analytical equipment for gas or liquid analysis, weighing systems) and actuators (actuators, position controllers for valves, other decentralized controllers, and frequency converters for electric drives such as pumps). The sensors transmit process data in the form of measured values ​​of process variables, while the actuators receive process data in the form of control data in order to influence the process.

[0004] Field devices are often equipped with self-monitoring functions that monitor their functionality during continuous operation and thus, for example, ensure the correctness of the measured values ​​provided. In particular, in the case of actuators, functionality checks can also be performed within the scope of self-tests outside of ongoing operation or in a manner that only significantly interferes with ongoing operation. The data obtained about the state or performance of the field device can be stored internally in the device or transmitted to, for example, the cloud and stored there.

[0005] The functionality of an actuator is determined solely in conjunction with other field devices, particularly sensors, that are installed in the immediate vicinity of the actuator in the installation. A typical composite component is, for example, a positioner with a regulating or control valve and a flowmeter transmission, which jointly regulate the flow rate. Another example is a pump with a frequency converter drive and a flowmeter transmission, which also jointly regulate the flow rate. In addition to or instead of the flowmeter transmission, the flowmeter transmission can be part of the composite component if the pressure is to be regulated.

[0006] The problem is that linking measured values ​​from different field devices requires a lot of manual engineering effort. Linking measured values ​​can be done, for example, in the management system, which plans process communication and makes the values ​​available to algorithms for further processing via the process image of the control unit. Local interconnection of measured signals via input / output cards (I / O cards) in the devices also requires manual design.

[0007] EP 2 506 096 A2 discloses a method for logically linking sensors and actuators within the context of commissioning an installation system. Each actuator, such as a dimmer, is associated with a mounting location attribute and an effective location attribute, wherein the mounting location attribute specifies the location of the actuator in the building, and the effective location attribute specifies the location at which the actuator is effective, such as the location of a luminaire controlled by the dimmer. The actuators are influenced by sensors, wherein each sensor, such as a switch or a brightness sensor, is associated with a mounting location attribute that specifies the location of the sensor in the building. Based on the effective location attribute of the actuator, a sensor group or sensors are selected based on their mounting location attributes, and a logical connection is subsequently established between the selected sensor and the actuator, wherein the actuator is to be influenced by the sensor group or sensors.

[0008] MMRashid et al., in "A Survey on Behavioral Pattern Mining from Sensor Data in the Internet of Things," IEEE Access, IEEE, USA, Vol. 8, February 14, 2020, pp. 33318–33341, provide an overview of behavioral pattern mining in large wireless sensor / actuator networks. Page 33328 explains that spatial correlations exist between data from adjacent sensors. Correlation analysis can identify relationships and dependencies within the data and formulate them in the form of rules. Context-sensitive association rules can be used to invoke the correct actuator execution for sensor values.

[0009] DE 10 2010 032 712 B3 discloses a method for configuring a building automation system in which a large number of sensors and actuators are networked. To configure the sensors, a user selects an actuator on a mobile terminal, which then transmits information about the selected actuator to the building automation system. The user manually activates the sensor associated with the selected actuator and logically associates it with the selected actuator. Summary of the Invention

[0010] The object of the present invention is to automate the determination of the proximity relationship between actuators and sensors in an installation, thereby reducing the engineering effort for checking the functionality of the actuators using the measured values ​​of adjacent sensors.

[0011] According to the invention, this object is achieved by the method described in the invention and the device defined in the invention, advantageous developments of which are described in the dependent claims.

[0012] The subject matter of the present invention is therefore a method for determining a proximity relationship between an actuator and a sensor, which cooperates with the actuator in an installation for controlling a technical process and communicates with the actuator, wherein the actuator influences the process and the sensor detects a measured value of a process variable, characterized in that the actuator

[0013] - influence the process according to pre-set test patterns,

[0014] - searching for a sequence of measurement values ​​obtained from the sensor in response to the test pattern for a preset test pattern, and

[0015] The sensor with the greatest effective proximity to the actuator is identified as the sensor whose response best meets the predefined quality criteria with respect to response quality and response time.

[0016] The subject matter of the invention also relates to a device for determining a proximity relationship between an actuator and a sensor, which cooperates with the actuator in an installation for controlling a technical process and communicates with the actuator, wherein the actuator influences the process and the sensor detects a measured value of a process variable, characterized in that the actuator is designed for

[0017] - influence the process according to pre-set test patterns,

[0018] - searching for a sequence of measurement values ​​obtained from the sensor in response to the test pattern for a preset test pattern, and

[0019] The sensor with the greatest effective proximity to the actuator is identified as the sensor whose response best meets the predefined quality criteria with respect to response quality and response time.

[0020] The actuator can then use the measured values ​​of the closest identified sensor to check its functionality in the setting.

[0021] The predefined test pattern can be a sequence of individual influences of the process, which can have different time intervals with respect to one another and / or can be of different intensities.

[0022] The measured value sequence obtained from the sensor as a response to a predefined test pattern is searched for and evaluated with respect to response quality and response time. Response quality specifically encompasses the accuracy with which the test pattern is reproduced in the measured value sequence obtained as a response, i.e., the degree of correlation between the test pattern and the response. An additional quality criterion can also be the amplitude of the test pattern detected in the response, i.e., how strongly the process variable detected by the sensor reacts to the influence of the actuator on the process. The response time corresponds to the time interval during which the test pattern manifests itself in the response after the actuator has influenced the process.

[0023] By evaluating the sensor's response to process influences using the test mode, the sensor whose response best meets the predefined quality criteria in terms of response quality and response time is identified. In the best case, this is the sensor whose detected process variable reacts most quickly, most precisely, and most robustly to the process influence using the test mode. The response of a sensor with a short response time and insufficient response quality does not meet the quality criteria, or meets them more poorly than the response of another sensor with a longer response time but better response quality. The quality criteria are thus a measure of the effective relationship between actuators and sensors in a technical installation.

[0024] The functionality of the actuator can now be determined in conjunction with the selected sensors. This means that in addition to the actuator data, the measured values ​​of the selected sensors are also used to assess the functionality or performance capability of the actuator.

[0025] The actuator can activate the sensor according to a predefined test pattern to transmit the measured values ​​detected during the influencing process according to the predefined test pattern. Alternatively, the sensor can be activated to store the measured values ​​detected during the influencing process according to the predefined test pattern and the stored measured value sequence can then be transmitted to the actuator.

[0026] The functionality of an actuator can also be determined by combining two or more different sensor types, such as a flow transducer and a pressure transducer. In this case, the actuator can select sensors independently from a group of identical sensor types, with different quality standards being applied to each sensor group. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In the following, the invention is explained based on embodiments and with reference to the accompanying drawings; showing in detail:

[0028] Figure 1 An example of a technical installation is shown in which actuators and sensors interact with each other.

[0029] Figure 2An actuator and a plurality of sensors are shown, and a proximity relationship between the sensors and the actuator should be determined, and

[0030] Figures 3 to 5 An exemplary flow chart of the method according to the present invention is shown.

[0031] The same reference numerals have the same meaning in the different figures. The figures are purely schematic and not to scale. DETAILED DESCRIPTION

[0032] Figure 1 A simplified schematic diagram shows an example of a technical installation 1 in which a process is running and controlled by means of an automation system 2. The automation system 2 has a plurality of field devices 3, which perform predetermined measuring, control, and regulation functions at the field level, i.e., within the process. These sensors 41, 42, 43, 44, in particular, detect measured values ​​of process variables and, as actuators 51, 52, act on the process through regulatory interventions. Typical sensors are measuring transducers for fill level, flow, pressure, and temperature, analytical devices for gas or liquid analysis, and weighing systems. Typical actuators are actuators, position controllers for valves, other decentralized controllers, and frequency converters for electric drives, such as pumps.

[0033] The field devices 3 exchange process-, function- and / or device-related data with each other and with a higher-level control and management system 7 via a usually wired communication system 6, for which purpose the field devices 3 are connected to an automation device 10, such as the input and output components 9 of a programmable logic controller (SPS), via a fieldbus 8. The field devices are in turn connected to the higher-level control and management system 7 individually or via a central facility bus 11.

[0034] Figure 1 The arrangement of the field devices 3 shown in FIG. 1 follows their connection to the fieldbus 8 of the communication system and does not reflect their actual location within the installation.

[0035] Figure 2 As an example, an actuator 51 in the form of a position controller with a control valve and sensors 41, 42, 43, here flow measuring transducers, are shown. The actuator 51 and sensors 41, 42, 43 communicate via a communication system 6, the structure of which is not important here. In principle, the field devices 3 can also communicate with one another via alternative communication paths, such as wireless communication, since the sensors relevant to the present invention are typically located in the same plant as the actuators or not too far away from them.

[0036] To determine the sensor with the greatest effective proximity, the actuator 51 includes an application (additional program) 12. During commissioning according to a predefined test pattern, the actuator acts on the process to determine the sensor that provides the fastest and most accurate response to the test pattern, particularly with the detected measured values. For this purpose, the sensors 41, 42, 43 include corresponding applications 13 to transmit their measured values ​​to the actuator as a response to a process stimulus via the actuator 51.

[0037] In the case of a position controller, the test mode can consist of a sequence of characteristic control movements (opening / closing) of the control valve. The sequence can be initiated manually via a user interface (the device's own keyboard or a manual operating tool, such as a smartphone, PDA, or handheld device), or automatically as part of the device startup process. The sequence is preferably short in duration and / or low in intensity so as not to affect the actual process. On the other hand, the sequence is long enough and strong enough to allow the sensors 41, 42, 43 in the vicinity of the actuator 51 to detect the test mode. Depending on the process, there are options for adjusting the sequence duration and / or its repetition rate. In particular, if the process is sufficiently slow, the sequence duration can be increased to increase the likelihood of detecting the test mode in the measured values ​​of the sensors 41, 42, 43. Depending on the effect of the test mode on the process, it can also be performed during operation or at specific intervals to continuously verify the proximity of the actuator 51 to the sensors 41, 42, 43.

[0038] Application 12 in actuator 51 provides communication access to sensors 41, 42, and 43 for the actuator. Initially, actuator 51 sends a request 14, for example, as a multicast or broadcast, to communication system 6 containing a request that a sensor of a predetermined sensor type—here, a flow transducer—should be registered. This request may initially simply include a request for the sensor's communication address, followed by a separate request for the sensor's measured values. Alternatively, the request may also include a request for the measured values ​​to be provided, or the sensor may perform this operation automatically. Finally, the request may also include a request that the sensor 41, 42, and 43 store the measured values ​​it detects in data logger 15 for a predetermined duration or until actuator 51 is called again. Sensors 41, 42, and 43 send the requested information and data 16 to actuator 51.

[0039] Simultaneously with or shortly before a request for measured values ​​from sensors 41, 42, 43, actuator 51 executes a process according to a test mode and reads the measured values ​​provided by sensors 41, 42, 43. After a predetermined time, actuator 51 requests sensors 41, 42, 43 to stop transmitting their measured values. Alternatively, the actuator can inform sensors 41, 42, 43 in advance of the time interval within which they are to transmit their measured values.

[0040] Based on the measured value sequences received from the individual sensors 41, 42, 43, the application 12 in the actuator 51 determines the sensor that is most likely located downstream of the actuator in the direction of action in the installation 1, for example, on a process pipe. This is done by evaluating the measured value sequences obtained with respect to response quality and response time. This means that the sensor is most likely located in direct, effective proximity to the actuator 51, and that the measured value sequence provided by the sensor best meets a predefined quality standard.

[0041] Figure 3 A flow chart is shown for a first example of determining the sensor with the greatest effective proximity to an actuator. As already explained, the actuator sends an identification request 14 to a sensor in the installation 1. This identification request 14 can be primarily for a specific sensor type, such as a flow meter, and can be repeated later for other sensor types, such as a pressure gauge, if necessary. The sensors, here 41, 42, 43 ( Figure 2 ) in its response 16-41, 16-42, 16-43 sends its communication address in the communication system 6 to the actuator 51, which then sends a request 14'-41, 14'-42, 14'-43 to the sensor at a later appropriate time, either automatically or after an operation input via the above-mentioned user interface, to transmit the measured values ​​detected by it. The sensors 41, 42, 43 then send the measured values ​​detected by them in their responses 16'-41, 16'-42, 16'-43 to the actuator 51 until the actuator calls the sensor by multicast or broadcast: the transmission of the measured values ​​is completed. At the same time as or shortly after the request for the measured values ​​from the sensor, the actuator 51 acts on the process according to the test mode 17. Finally, the sequence of measured values ​​received from the individual sensors 41, 42, 42 and temporarily stored in the actuator 51 is evaluated (18) in order to determine the sensor that is located behind the actuator 51 in the direction of action with the highest probability in the installation, as described above.

[0042] exist Figure 4 The embodiment of the method according to the invention shown in Figure 3The method of is different in that the actuator 51 requests the sensor, by means of an identification request 14 for the sensor, to send a measured value in its response 16 - 41 , 16 - 42 , 16 - 43 in addition to the communication address.

[0043] exist Figure 5 In the embodiment shown in FIG, the sensors 41, 42, 43 request, by means of a call 14, that the detected measured values, in particular, be temporarily stored (19) in their respective data loggers 15. After carrying out the influencing process according to the test mode 17, the actuator 51 again sends a multicast or broadcast command 14" to the sensors 41, 42, 43, which then transmit the recorded measured value sequence to the actuator 51 for evaluation 18.

[0044] In the following, the functionality check of the actuator 51 in the installation 1 is explained using the example of a position regulator having a regulating or control valve (actuator 51) and the flow measuring transducer (e.g. 43), wherein the flow measuring transducer is determined as the sensor with the greatest effective proximity to the actuator 51.

[0045] For a position controller, it is desirable to determine whether the control performance is still maintained via its operating time curve. To this end, the position controller forms a histogram function with 10 levels, for example, 0%, 10%, 20%, ... 100% opening. At the beginning of the operating time, the position controller is ramped, allowing a specific flow rate to be associated with each level. From then on, the position controller receives flow measurement values ​​from an adjacent flow transducer during the operating phase. If the position controller now detects a deviation from the calibrated correlation between the flow measurement values ​​and the histogram levels, this is an indicator of a malfunction or wear in the position controller. These performance characteristics (KPI values) can, for example, be provided to external applications.

[0046] The proximity of the actuator 51 to the sensors 41 , 42 , 43 can be determined once, for example, during commissioning of the actuator 51 , and can then be verified as needed or continuously, for example at predefined time intervals.

[0047] The main advantage of the present invention is the automatic identification of actuators and proximity detection of sensors, which can be performed without engineering effort. Based on this information, the functionality of the actuator can be determined, for example in the form of a KPI value.

Claims

1. A method for determining a proximity relationship between an actuator (51) and a sensor (41, 42, 43, 44), the sensor cooperating with the actuator in an installation (1) for controlling a technical process and communicating with the actuator, wherein: The actuator (51) influences the process and the sensor (41, 42, 43, 44) detects a measured value of a process variable, characterized in that the actuator (51) - affecting the process according to a pre-set test pattern (17), - searching for a sequence of measured values ​​obtained from the sensors (41, 42, 43, 44) as a response (16-41, 16-42, 16-43; 16'-41, 16'-42, 16'-42) to the predetermined test pattern, and - identifying the sensor with the greatest effective proximity to the actuator (51) as the sensor whose response best meets the predefined quality criteria in terms of response quality and response time, The response quality includes the degree of correlation between the test pattern and the response.

2. The method according to claim 1, characterized in that In order to check the functionality of the actuator in the installation (1), the actuator (51) uses the measured values ​​of the identified sensor.

3. The method according to claim 1 or 2, characterized in that In order to transmit the measured values ​​detected during the influencing of the process according to the predefined test mode (17) to the actuator (51), the actuator (51) activates the sensors (41, 42, 43, 44).

4. The method according to claim 1 or 2, characterized in that In order to store the measured values ​​detected during the influencing of the process according to the predefined test mode (17), the actuator (51) activates the sensors (41, 42, 43, 44) and subsequently transmits the stored measured value sequence to the actuator (51).

5. The method according to claim 1 or 2, characterized in that In the case of different sensor types, the actuators (51) each select the sensor from a group of identical sensor types.

6. A device for determining a proximity relationship between an actuator (51) and a sensor (41, 42, 43, 44), the sensor cooperating with the actuator in an installation (1) for controlling a technical process and communicating with the actuator, wherein: The actuator (51) influences the process and the sensor (41, 42, 43, 44) detects a measured value of a process variable, characterized in that the actuator (51) is designed to - affecting the process according to a pre-set test pattern (17), - searching for a sequence of measured values ​​obtained from the sensors (41, 42, 43, 44) as a response (16-41, 16-42, 16-43; 16'-41, 16'-42, 16'-42) to the predetermined test pattern, and - identifying the sensor with the greatest effective proximity to the actuator (51) as the sensor whose response best meets the predefined quality criteria in terms of response quality and response time, The response quality includes the degree of correlation between the test pattern and the response.

7. The device according to claim 6, characterized in that The actuator (51) is designed to use the identified measured values ​​of the sensor in order to check the functionality of the actuator in the installation (1).

8. The device according to claim 6 or 7, characterized in that The actuator (51) is designed to activate the sensors (41, 42, 43, 44) in order to transmit measured values ​​detected during the influencing of the process according to the predefined test pattern to the actuator (51).

9. The device according to claim 6 or 7, characterized in that The actuator (51) is designed to activate the sensors (41, 42, 43, 44) in order to store the measured values ​​detected during the influencing of the process according to the predefined test pattern (17) and subsequently transmit the stored measured value sequence to the actuator (51).

10. The device according to claim 6 or 7, characterized in that The actuator (51) is designed to select the sensor from a group of identical sensor types in the case of different sensor types.

11. The device according to claim 6 or 7, characterized in that The actuator (51) is a position regulator having a control valve, and the sensors (41, 42, 43, 44) are flow meters.

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