Control system and operating method for technical installation

Abstract

The application proposes a control system and an operating method for a technical installation, the control system comprising at least one operator station server and at least one operator station client connected to the operator station server, the operator station server being implemented to transmit visual information to the operator station client, the visualization information comprises a plurality of exchangeable facility images, and the operator station client is implemented for presenting the visualization information with the exchangeable facility images to an operator of the manufacturing facility or the process facility. The control system is characterized in that the control system is implemented to present a test image different from the plant image to an operator of the manufacturing plant or process plant during operation of the manufacturing plant or process plant, the test image comprising a color region having a color used in at least two plant images of the visualization information.

Description

Technical Field

[0001] The present invention relates to a control system for a manufacturing facility or a process facility, comprising at least one operator station server and at least one operator station client connected to the operator station server, wherein the operator station server is implemented to transmit visualization information to the operator station client, wherein the visualization information comprises a plurality of transformable facility images, and wherein the operator station client is implemented to present the visualization information with the transformable facility images to an operator of the manufacturing facility or the process facility. The present invention also relates to an operating method of the control system for a manufacturing facility or a process facility. Background Art

[0002] For operating and observing process technology facilities, symbolic facility images are created to abstractly represent process technology relationships - in particular relationships between process objects. The facility images consist of static symbols (e.g. lines, rectangles), dynamic symbols (e.g. lines whose color changes with process values, rectangles with filled levels), block symbols (for dynamic visualization of process technology process objects), complex controls (e.g. trend displays, message sequence displays), containers, in order to be able to visualize together content from independent and native sources such as webcams, facility images of modular system components (package units) or applications (e.g. controller optimizer, KPI calculation).

[0003] Furthermore, the facility image can also include a number of text fields, e.g. for specifying measuring points or inserting comments. The coloring of symbols etc. is usually based on symbol colors that are preconfigured at the central point of the engineering design of the process facility and used in the various editors. For a better intuitive display of events, the facility image content can flash at different frequencies depending on the process technology status.

[0004] The properties of the facility images are configured in engineering on appropriate workstations, although it is not possible to evaluate the resulting facility images under all boundary conditions they are used for operation and observation. This means that accessibility testing of facility images cannot be fully performed in engineering, as the boundary conditions are not all known, for example:

[0005] - the operator’s personal vision,

[0006] - the actual output device used (from mobile devices to large screens in the control room),

[0007] - Environmental conditions (from dimly lit control room to direct sunlight on site).

[0008] EP 3 876 046 A1 discloses a control system for a technical installation which enables an operator to adapt the presentation of visualization information by an operator station client to the operating time of the technical installation. Summary of the invention

[0009] The invention is based on the object of specifying a control system for a process or production facility in which the individual and environmental accessibility of a projected facility image can be temporarily checked at runtime if necessary in order to ensure that all relevant aspects of the existing facility image are perceived in the current situation for safe operation and observation.

[0010] This object is achieved by a control system for a process or a manufacturing facility having the features of the invention. This object is also achieved by an operating method according to the invention for a control system for a manufacturing or a manufacturing facility. Advantageous developments result from the dependent claims.

[0011] According to the present invention, a control system for a manufacturing facility or a process facility includes at least one operator station server and at least one operator station client connected to the operator station server, wherein the operator station server is implemented to transmit visualization information to the operator station client, the visualization information includes a plurality of transformable facility images, and wherein the operator station client is implemented to present the visualization information with the transformable facility images to an operator of the manufacturing facility or the process facility.

[0012] The control system according to the present invention is characterized in that the control system is implemented to present a test image different from the facility image to an operator of the manufacturing facility or process facility when the manufacturing facility or process facility is in operation, the test image including a color area having a color used in at least two of the facility images in the facility image for visualizing information.

[0013] The technical installation can be an installation from the process industry, such as chemical, pharmaceutical, petrochemical or an installation from the food and beverage industry. This also includes all installations of the production industry, installations for the production of cars or various goods.

[0014] In this context, a control system is understood to be a computer-aided technical facility which includes functions for displaying, operating and managing process engineering facilities. The control system can also include sensors and various actuators for determining measured values. In addition, the control system can include so-called process- or production-related components for controlling actuators or sensors. In addition, the control system can have, in particular, devices for visualizing method technical facilities and for engineering design. The control system can also optionally include additional computing units for more complex control as well as systems for data storage and processing.

[0015] At present, an "operator server" is understood to be a server that centrally records data from operating and monitoring systems and usually records alarms and measured value archives from the control system of the technical installation and makes them available to users. The operator server usually establishes a communication connection with the automation system of the technical installation and passes the data from the technical installation to the so-called operator clients for visualization, which are used to operate and monitor the operation of individual functional elements of the technical installation. The operator server can have client functionality to access the data (archives, messages, variables, tags) of other operator servers.

[0016] This means that the operating images of the technical facilities on the operator station server can be combined with the variables of other operator station servers (server-server communication). The operator station server can be (but not limited to) a SIMATIC PCS 7 industrial workstation server from SIEMENS.

[0017] An operator of the technical facility can access the operator station server via an operator station client, which can be, for example, a tablet computer, a smartphone, a personal computer, etc., in order to operate and monitor the technical facility.

[0018] Currently, a visualization is understood to be a graphic presentation made by an operator station client for an operator. Typically, the operator station client has appropriate functionality to generate the desired visualization using the relevant visualization information it receives from the operator station server. The visualization can typically include, in a manner known per se, a facility image, a graphic window with a progress display of measured values, a message display, graphic objects representing technical objects of the technical facility, etc. In the case of a process system, such a facility image can include, for example, graphic representations of pumps, valves, tanks, pipelines, combustion chambers, etc. The graphic representation can include current process measurement values, status values, (alarm) messages, etc.

[0019] The control system according to the invention is implemented for visually presenting to the operator a separate test image different from the actual plant image during the runtime of the technical plant (i.e. during the operation of the technical plant). The test image comprises the colors of at least two plant images generated in the engineering of the manufacturing plant or process plant (i.e. when configuring the automation of the manufacturing plant or process plant) and available to the operator station server. The colors can be represented in any way. For example, a circle or a square can be displayed with the colors used in the at least two plant images.

[0020] With the help of this test image, the operator is able to immediately check which color scheme he is able to recognize in case he wants to use the facility image to operate and monitor the production or process facility and, if necessary, initiate corrective measures. As part of this, the operator is able to check whether he is able to correctly recognize the colors yellow and red, as these colors indicate warnings or alarms and the operator must be able to recognize them clearly and immediately. Usually, predefined symbol colors are used for the configuration / engineering of the facility image, which are defined at a central location in the engineering. For example, the medium "water", the alarm category "critical" etc. always have the same color. Therefore, symbolic colors are crucial and it must be ensured that different colors can be clearly distinguished from each other. For this check, the symbol palette is placed in the automatically generated "visual verification" facility image.

[0021] The test image takes into account the colors of at least two facility images. Preferably, all facility images created in the project and transmitted to the operator station server are taken into account as the test image.

[0022] In addition to colors, the test image can also include a text area containing the fonts and font sizes used in the facility image. Facility images usually contain multiple text fields and various texts for specifying symbols, measurement points, etc. These texts can be configured in different fonts and font sizes in the facility image. All fonts or font sizes used in (at least two, preferably all) facility images can be taken into account and displayed in the test image. However, it is also possible to display only the smallest font size used in the facility image. This enables the operator to directly see whether he can correctly identify all fonts / font types.

[0023] Intermediate sizes can also be taken into account in the test images in order to better identify "readable" transitions. Depending on the output device, lighting conditions and eyesight, operators can individually check whether they are currently able to decipher the smallest text in the facility images.

[0024] The test image particularly preferably comprises a flashing area with a flashing frequency used in the installation image. In the installation image, symbols or status displays can be animated by flashing at different frequencies. The perceptibility of the flashing frequency can vary depending on the device, environmental influences, etc. The flashing frequency configured in the installation image can be visualized in the test image using a status symbol for inspection by the operator.

[0025] The test image can also include a symbol area, which includes symbol images contained in the facility image selected according to certain criteria. (Dynamic) symbols are used for abstract graphical representations of the method and technical processes. Some graphical symbols can be determined and placed for the test image so that the operator can check individually, depending on the environment, whether he can perceive these symbols and their dynamics in detail. The symbol images are preferably selected according to their size so that the symbol area includes a certain number of minimum symbol images.

[0026] The operator of the manufacturing or process facility can preferably specify during the operating time of the manufacturing or process facility which facility image is to be taken into account for generating the test image. The operator can variably specify, for example, whether he wants facility image X and facility image Y to be taken into account when generating the test image, because these two facility images have a particularly great influence on him.

[0027] In the context of a preferred development of the invention, the control system is designed to intuitively present the installation image to the operator when selecting an area of ​​the test image, which was taken into account when generating the area. For example, if the operator selects a color in the color area or a font in the text area, the operator station server or operator station client displays the installation image including this color or font. This enables the operator to recognize which system layout may cause him problems. He is also able to see the color or font in the context of the relevant area of ​​the system and is therefore better able to assess whether a perceived problem will actually occur.

[0028] The control system is preferably implemented for generating an alarm message associated with the test image, which alarm message can be acknowledged by an operator. An alarm message is a message which generally requires an immediate response from an operator of the technical installation. A message is understood as a report of the occurrence of an event which represents a transition from a discrete state to another discrete state within the technical installation. The (unacknowledged) alarm message makes it clear to the affected operator or other operators that an operator's evaluation of the test image is still pending. The alarm message can also be easily integrated into existing alarm reporting mechanisms in the control system.

[0029] The alarm message associated with the test image has been acknowledged. In other words, the operator must actively acknowledge the test image before operating and observing using the facility image considered by the test image. This ensures accessibility to the actual inspection facility image.

[0030] The alarm messages are implemented so that operators can annotate the alarm messages. For example, these comments can be read by a project engineer of a production or process facility, who can adjust the facility image. For example, an operator can inform the project engineer or other operators that the "red" in facility image Z or the text in facility image XY cannot be correctly identified, so the project engineer can adjust the contrast or color saturation, for example.

[0031] The generation of the alarm message preferably depends on the position and / or identity and / or role of the operator. For example, if the operator is in a special environment (darkness, fog, scattered light, etc.), it may be particularly important to confirm the alarm message.

[0032] The object is also achieved by an operating method for a control system of a manufacturing facility or a process facility, the control system comprising at least one operator station server and at least one operator station client, the operator station server being implemented to transmit visualization information to the operator station client, wherein the visualization information comprises a plurality of transformable facility images, and wherein the operator station client is implemented to present the visualization information with the transformable facility images to an operator of the manufacturing facility or the process facility, wherein the control system provides a test image to the operator during operation of the manufacturing facility or the process facility, the test image comprising a color area having a color used in at least two of the facility images in the visualization information. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The above-mentioned features, characteristics and advantages of the present invention, as well as the methods for achieving these, will be more clearly understood in conjunction with the following description of the embodiments, which will be explained in more detail in conjunction with the following drawings. As shown in the drawings:

[0034] Figure 1 shows a graphical representation of a test image according to the first aspect;

[0035] Figure 2 A graphical representation of a facility image is shown;

[0036] Figure 3 showing a graphical representation of a test image according to the second aspect; and

[0037] Figure 4 The control system according to the invention is shown in a schematic diagram. DETAILED DESCRIPTION

[0038] Figure 1 Shows a visualization Figure 1 , operator station client (see Figure 4 ) to an operator of the process facility for operating and observing the process facility. In addition to the operating elements 2, which are not described in more detail here, the visualization also includes a test image 3, which is Figure 1 The dashed boxes are used to allow for better identification.

[0039] The test image 3 has a color area 4 , a text area 5 , a flashing area 6 and a symbol area 7 .

[0040] In the color area 4, all colors used in the various plant images of the automation system of the process plant are displayed in the column 8. In this case, the plant images are used for operating and monitoring the process plant. The colors are each displayed as a square. Figure 1 In the name column 9 shown on the left side of the color column 8 in FIG. 1 , indications such as “off”, “activated” or “stopped” are shown, respectively, which are associated with the use of the corresponding colors in the facility image.

[0041] The font used in the facility image is selected and displayed in the text area 5. For example, five fonts with the smallest font size and five fonts with the largest font size can be displayed in the text area 5.

[0042] The flashing animation used in the facility image is displayed in the form of flashing squares in the flashing area 6. Here, the squares are displayed individually according to the flashing frequency used.

[0043] In the symbol area 7, for example, five smallest symbols used in the facility image are shown. Figure 1 Only one symbol is shown schematically.

[0044] When the operator selects one of the areas 4, 5, 6, 7 of the test image 3, the facility image that was considered when generating the area 4, 5, 6, 7 is visually presented to the operator. For example, if the operator clicks on the word "Extraction" with the mouse or taps on it with his hand, the facility image using the word "Extraction" will be displayed by the control system or the associated operator station client (see Figure 4 ). This allows the operator to quickly and easily find the context in which the word appears.

[0045] The installation image on which the test image is based can be determined in the engineering planning phase or configuration phase of the automation system for the process installation. However, the operator can also determine directly which installation image should be considered for the test image 2 during operation of the process installation. Figure 2 1 shows a facility image 10 which the operator can consider as a test image. To this end, the operator only needs to select the corresponding request symbol 11 (by clicking with the mouse or tapping with a finger). Thus, the facility image 10 is considered for the test image 12 (see Figure 3 ).

[0046] The test image 12 shows the operator the same areas 4, 5, 6, 7, however, these areas now only have the content contained in the facility image 10. This "temporary" function allows the operator to check whether each facility image can correctly identify the content shown in the opened facility image. This is especially important when they want to operate and monitor process facilities on site using a mobile terminal device under strong sunlight.

[0047] Figure 4 Schematically shown is a control system 13 for operating and monitoring a process facility. The control system 13 includes an operator station client 14 and an operator station server 15 connected to the operator station client 14. The operator station server 15 and the operator station client 13 are connected to each other via a terminal bus 16 and are connected to an engineer station server 17 of the control system 13.

[0048] A user or operator can access the operator station server 15 via the operator station client 14 by means of the terminal bus 16 for operation and monitoring. The terminal bus 16 can be designed as, for example, industrial Ethernet but is not limited thereto.

[0049] The operator station server 15 has a device interface 18 connected to a facility bus 19. The operator station server 15 can communicate with automation devices (not shown) and with other components of the process engineering facility that are optionally present, such as peripheral devices (not shown), via the device interface 18. The facility bus 19 can be designed, for example, as an industrial Ethernet, but is not limited thereto.

[0050] The visualization service 20, the process image 21 and the configuration memory 22 (etc.) are implemented on the operator station server 15. The visualization service 20 integrated in the operator station server 15 initiates the transmission of visualization information to the operator station client 14. The operator station client 14 is implemented for displaying visualizations, i.e. graphic representations, in particular graphic representations of plant images, for operating and monitoring the process plant.

[0051] A snapshot of the (signal) status of devices and / or applications (not shown in the figure) connected to the operator station server 15 is recorded in the process image 21 of the operator station server 15. The alarm service 23 can read the alarm messages from the process image 21 and, for example, generate a graphic aggregation of the alarm messages that the operator station client 14 can display.

[0052] In the configuration tool 24, in particular, a plant image 10 for operating and monitoring the process plant is generated and loaded into the configuration memory 22 of the operator station server 15 by means of the loading service 25. Likewise, a test image 2 is generated by the engineering station server 17 and stored in the configuration memory 22. The visualization service 20 uses this information to present the plant image 10 and the test image 2 to the operator.

[0053] If an operator directly starts a test image 12 while the process plant is running, the subservice 26 of the visualization service 15 accesses the data associated with the plant image 10 from the configuration memory 22 and generates the desired test image 12 .

[0054] Although the present invention has been illustrated and described in detail by means of preferred embodiments, the present invention is not limited to the disclosed examples and other variations can be derived therefrom by those skilled in the art without departing from the scope of the present invention.

Claims

1. A control system (13) for a manufacturing facility or a process facility, the control system comprising at least one operator station server (15) and at least one operator station client (14) connected to the operator station server (15), wherein: The operator station server (15) is implemented to transmit visualization information to the operator station client (14), wherein the visualization information includes a plurality of exchangeable facility images (10), and wherein the operator station client (14) is implemented to present the visualization information with the exchangeable facility images (10) to an operator of the manufacturing facility or the process facility, It is characterized in that The control system (13) is implemented to present a test image (3, 12) different from the facility image (10) to an operator of the manufacturing facility or the process facility when the manufacturing facility or the process facility is running, the test image comprising a color area (4) having a color used in at least two of the facility images (10) of the visualization information.

2. The control system (13) according to claim 1, wherein: The test image (3, 12) includes a color region (4) having a color used in the entire facility image (10) of the visualization information.

3. The control system (13) according to claim 1 or 2, wherein: The test image (3, 12) includes a text area (5) having the font and font size used in the facility image (10).

4. A control system (13) according to any one of the preceding claims, wherein: The test image (3, 12) includes a flickering region (6) having a flickering frequency used in the facility image (10).

5. A control system (13) according to any one of the preceding claims, wherein: The test image (3, 12) includes a symbol area (7) having a symbol image contained in the facility image (10) selected according to a specific criterion.

6. The control system (13) according to claim 5, wherein: The symbol images are selected according to their size so that the symbol area (7) includes a to-be-determined number of minimum symbol images.

7. A control system (13) according to any one of the preceding claims, wherein: When the manufacturing facility or the process facility is in operation, an operator of the manufacturing facility or the process facility can specify which of the facility images (10) is to be taken into account for generating the test image (3, 12).

8. A control system (13) according to any of the preceding claims, which is implemented to, when selecting an area of ​​the test image (3, 12), visually present to the operator the facility image (10) that was taken into account when generating the area.

9. A control system (13) according to any one of the preceding claims, the control system being implemented for generating an alarm message associated with the test image (3, 12) and which alarm message can be acknowledged by the operator.

10. The control system (13) of claim 9, being implemented to prevent the operator from seeing a visual representation of the installation image (10) until the alarm message associated with the test image (3, 12) has been acknowledged.

11. A control system (13) according to claim 9 or 10, wherein: The alarm message is implemented to enable the operator to annotate the alarm message.

12. A control system (13) according to any one of claims 9 to 11, wherein: The generation of the alarm message depends on the location and / or identity and / or role of the operator.

13. A method for operating a control system (13) of a manufacturing facility or a process facility, the control system comprising at least one operator station server (15) and at least one operator station client (14), wherein: The operator station server (15) is implemented to transmit visualization information to the operator station client (14), wherein the visualization information includes a plurality of exchangeable facility images (10), and wherein the operator station client (14) is implemented to present the visualization information with the exchangeable facility images (10) to an operator of the manufacturing facility or the process facility, wherein the control system (13) presents a test image (3, 12) to the operator of the manufacturing facility or the process facility when the manufacturing facility or the process facility is running, the test image including a color area (4) having a color used in at least two of the facility images (10) in the visualization information.

14. The method according to claim 13, wherein: An operator of the manufacturing facility or the process facility specifies which of the facility images (10) is to be considered for generating the test image (3, 12).

15. The method according to claim 13 or 14, wherein: The control system (13) generates an alarm message associated with the test image (3, 12), and the alarm message can be acknowledged by an operator.

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