Ethernet APL gateway

Abstract

The invention relates to an Ethernet APL gateway, in particular to a device having a plurality of interfaces for the connection of an Ethernet APL and PROFINET-based connection to a field device of an industrial installation, in particular a process installation or a manufacturing installation, and having an interface for the connection of a PROFINET-based connection to a superordinate automation device of the industrial installation, the apparatus is configured to act as a communication switch between a superordinate automation device and a field device. The device is characterized in that it acts as a PROFINET IO device in the context of a connection with the superordinate automation device and as a PROFINET IO controller in the context of a connection with the field device in order to act as an Ethernet APL gateway in the context of a connection with the field device and the superordinate automation device.

Description

Technical Field

[0001] This invention relates to a device having multiple interfaces for connecting field devices in industrial facilities, particularly process or manufacturing facilities, via Ethernet APL and PROFINET, and having an interface for connecting to higher-level automation equipment in the industrial facility via PROFINET. The device is configured to act as a communication switch between the higher-level automation equipment and the field devices. Furthermore, the invention relates to automation equipment and methods for operating industrial facilities, particularly manufacturing or process equipment. Background Technology

[0002] Ethernet APL (Advanced Physical Layer) is increasingly being used in the process industry. The advantage here is that when the last mile to the field device is also connected via Ethernet technology, significantly higher communication performance can be achieved compared to technologies such as HART (High-Speed ​​Addressable Remote Sensor Protocol).

[0003] Field devices in today's configurations are independent bus participants and, for example, in PROFINET (Process Field Network), result in a high number of participants on automation systems. Known automation devices, such as Siemens' AS410, have the problem that they cannot, or can only, map the same number of field devices in PROFINET-APL at a high burden, as they are currently capable of doing with HART or PROFINET. This is primarily due to the additional communication and computational burden generated by the PROFINET-APL device within the automation equipment.

[0004] In automation technology, so-called APL switches are known, which are deployed between various APL-capable field devices and upper-level automation equipment. An APL switch has been disclosed in DE 10 2021 101 498 A1. Here, each field device has a direct logical connection to the automation equipment, which imposes a high communication and computational burden on the automation equipment. Summary of the Invention

[0005] The purpose of this invention is to configure communication between automated equipment and field devices when using APL.

[0006] This objective is achieved by an apparatus having the features of claim 1. Furthermore, this objective is achieved by an automation system according to claim 11, a method for operating an industrial facility according to claim 13, and a method for operating an industrial facility according to claim 14. Advantageous improvements are derived from the dependent claims.

[0007] According to the invention, an apparatus having multiple interfaces for connecting to field devices in industrial facilities, particularly process facilities or manufacturing facilities, based on Ethernet APL and PROFINET, and having an interface for connecting to higher-level automation equipment in the industrial facilities based on PROFINET, wherein the apparatus is configured to act as a communication switch between the higher-level automation equipment and the field devices, characterized in that the apparatus is configured to act as a PROFINET IO device in the scenario of connecting to the higher-level automation equipment, and as a PROFINET IO controller in the scenario of connecting to the field devices, and the apparatus is configured to act as an Ethernet APL gateway in the scenario of connecting to both the field devices and the higher-level automation equipment.

[0008] Industrial facilities can be equipment from process industries, such as chemical, pharmaceutical, and petrochemical industries, or from the nutrition and luxury goods industries. This also includes equipment from manufacturing industries, such as factories producing automobiles or all types of goods. Industrial facilities suitable for carrying out the methods according to the invention can also originate from the energy production sector. Wind power generation equipment, solar power equipment, or power plants used for energy production are also included in the concept of industrial facilities.

[0009] Automated equipment can be part of a control system, used for the automation of industrial facilities. In the current context, a control system is understood as a computer-supported process system that includes functions for displaying, operating, and controlling industrial facilities. A control system can also include sensors for measuring values ​​and various actuators. Furthermore, a control system can include so-called process or production-related components for driving actuators or sensors. Additionally, a control system can have devices for visualizing and engineering industrial facilities. Optionally, a control system can also include additional computing units for complex control and systems to handle data storage and processing.

[0010] Field devices are understood as process units in the field of automation technology, directly involved in the production process. Here, "field" refers to the area outside the electrical cabinet or control room. Field devices can represent not only actuators (control components, valves, etc.) in factory and process automation, but also sensors (measurement transducers).

[0011] The present invention relates to a device with multiple interfaces, on which field devices can be connected to the device. Interfaces based on Ethernet APL and PROFINET are involved, with the latter being based on the Ethernet standard. Here, PROFINET (short for Process Field Network) represents the open, industrial Ethernet standard of the PROFIBUS user organization (PNO) for automation. APL stands for "Higher Physical Layer" and represents the development of physical data transmission in Ethernet networks. A feasible approach is that Ethernet data is exchanged via two metal wires between the field device and the device.

[0012] The interface between the device and higher-level automation equipment is based on PROFINET. Ethernet specifications can also be applied to the physical transport layer.

[0013] Here, the device is configured in a known manner to act as a communication switch between higher-level automation equipment and field devices. Accordingly, the device represents a distributor that delivers data packets exchanged bidirectionally between automation equipment and field devices to the correct destination address (e.g., an IP address).

[0014] According to the present invention, the device is configured to act as a PROFINET IO device in scenarios involving connection to higher-level automation equipment, and as a PROFINET IO controller in scenarios involving connection to field devices. In other words, this means that the device acts as a "PROFINET device" when connected to automation equipment, and as a "PROFINET host" when connected to field devices. Thus, each APL-capable field device has a direct logical connection to the device acting as a PROFINET host, where the physical transmission is based on Ethernet APL. The device appears as the sole device relative to the automation equipment, which makes the data transmission configuration between the automation equipment and the device significantly smaller than in cases where the device is a conventional communication switch according to the prior art. Instead, the device according to the present invention acts as an Ethernet APL gateway in scenarios involving connection to field devices and higher-level automation equipment. Here, the term "gateway" implies that data transmitted by the device (either from automation equipment or from field devices) is processed by the device to be delivered to its (destination) address.

[0015] The APL gateway functionality according to the present invention, combined with the function of a communication switch, reduces the communication and computing load of (central) automation equipment. This enables the application of automation equipment to larger parts of industrial facilities. Connections to individual field devices are managed through this device. The complete integration of the gateway and switch within the device simplifies integration in large projects and configurability in engineering scenarios of industrial facilities, for example, with the aid of Siemens' SIMATIC PCS 7 or PCS neo.

[0016] The data transmission requirements between this device and automation equipment can be relatively low, which is why the interface for connecting to higher-level automation equipment in industrial facilities can be configured based on PROFINET compliance level A. However, due to higher requirements for explosion protection, particularly between field devices and this device, the interface for connecting to field devices can be configured based on PROFINET compliance level B.

[0017] Automated equipment can be programmable logic control systems, particularly Siemens' SIMATIC S7-410. Programmable logic controllers can perform specialized functions, such as process control, thereby controlling not only process and machine inputs but also output signals.

[0018] In an advantageous improvement of the invention, the conditions under which an HTTPS (Hypertext Transfer Security) connection from automation equipment to field devices can be predefined via appropriate input through the device's user interface. In other words, security applications can be executed on the device that can specifically block or allow data packets to pass through, so that, for example, an HTTPS connection for network management of field devices can be established only when needed.

[0019] Preferably, the device has an aggregator function to enable filtering of data sent from the device to the automation equipment. This allows, for example, the filtering out of specific data and preventing its transmission to the automation equipment, thus avoiding unnecessary processing demands.

[0020] Here, the aggregator function can involve neural networks or similar methods.

[0021] Particularly preferably, the device has a controller optimization function to preprocess data sent from the field device to the automation device in preparation for controller optimization to be performed subsequently in the automation device.

[0022] Among the multiple interfaces to the field device, at least one interface can be configured as a current loop interface so that the connection to the field device can be based on a current received by the field device with a current intensity between 4mA and 20mA.

[0023] Preferably, the interface for connecting to field devices can be configured based on the HART protocol. Here, data transmission between the field devices and the device is implemented via Frequency Shift Keying (FSK) according to the Bell 202 standard. A low-frequency analog signal is superimposed with a high-frequency oscillation (±0.5mA). The digit "1" is represented at a frequency of 1.2kHz (1200Hz) and "0" is represented at a frequency of 2.2kHz (2200Hz).

[0024] Furthermore, the previously stated objective is achieved through an automated system having automated equipment and the apparatus according to the preceding claims, wherein a disconnectable connection is established between the automated equipment and the PROFINET-based apparatus. Here, the concept of a "disconnectable connection" means that the connection is not configured to be fixed (welded / wired or similar), but rather can be reversibly established, for example, by insertion into a plug interface. Here, the automated equipment and the apparatus are considered physically separate components, preferably arranged in mutually separate spaces.

[0025] Preferably, the automation system includes multiple field devices whose corresponding interfaces are disconnectably connected to the device. Here, the concept of "disconnectable" is defined in the preceding paragraphs.

[0026] Additionally, the automation system can include systems for operation and monitoring, such as operator station servers and operator station clients. In this case, these are connected to the automation equipment via a device bus. The device bus can be configured, for example, as an industrial Ethernet network without limitations. Here, the operator station client is configured to generate visual views, which are received by the operator station client from the operator station server and used for operating and monitoring the industrial facility.

[0027] Furthermore, the previously stated purpose is achieved through a method for operating industrial facilities, particularly process facilities or manufacturing facilities, with the previously configured apparatus.

[0028] Furthermore, the previously stated purpose is to utilize a previously configured automated system through a method for operating industrial facilities, particularly process facilities or manufacturing facilities. Attached Figure Description

[0029] The above-described features, characteristics, and advantages of the present invention, as well as the ways and methods of implementing them, are clearly and understandably illustrated in conjunction with the following detailed description of embodiments with reference to the accompanying drawings. As shown herein:

[0030] Figure 1 This is a schematic diagram of an automation system according to the present invention; and

[0031] Figure 2 This is a schematic diagram of the device according to the present invention. Detailed Implementation

[0032] Figure 1 An automation system 1 for a process facility or manufacturing facility is schematically illustrated. Automation system 1 includes automation equipment 2, devices 3, and multiple field devices 4a, 4b, 4c. Field devices 4a, 4b, 4c are configured, for example, as sensors or actuators.

[0033] Device 3 has multiple interfaces 5a, 5b, and 5c, each of which can be disconnected from one of the field devices 4a, 4b, and 4c. The connections 6a, 6b, and 6c between the interfaces 5a, 5b, and 5c of device 3 and the field devices 4a, 4b, and 4c are implemented based on Ethernet APL and PROFINET, respectively.

[0034] Furthermore, device 3 has an interface 7 that connects to automation device 2 via a disconnectable connection 8 configured based on PROFINET. Automation device 2 is configured as a programmable logic controller (PLC) on which automation programs run, thereby enabling the driving and evaluation of field devices 4a, 4b, and 4c. Automation device 2 has a connection 9 to a system for operation and monitoring, such as an operator station server, and an operator station client (not shown) connected thereto.

[0035] The device 3 is configured to act as a PROFINET IO device in a scenario involving connection 8 with the upper-level automation device 2. Here, "PROFINET" stands for "Process Field Network." This refers to the open standard for Industrial Ethernet managed by Process Fieldbus and Process Field Network International (PI, PROFIbus & Profinet International) and the PROFIBUS User Organization Association (PNO). The transmission is based on Ethernet and TCP / IP (Transmission Control Protocol / Internet Protocol). Data communication within PROFINET follows a provider-consumer model, where the upper-level automation device 2 is currently the provider or IO (Input / Output) controller in the PROFINET sense, while the device 3 used to connect with the automation device 2 is the user or IO (Input / Output) device in the PROFINET sense.

[0036] Interface 7, used for connecting to the higher-level automation equipment 2 in the industrial facility, is configured based on PROFINET conformance level A. PROFINET conformance level A (CC-A) is the simplest level and has the smallest functional range. It includes real-time communication and supports standard TCP / IP functions and basic features such as topology information.

[0037] Furthermore, the device 3 is configured to act as a PROFINET IO controller in scenarios involving connections 6a, 6b, and 6c with field devices 4a, 4b, and 4c. Accordingly, in these connections 6a, 6b, and 6c, field devices 4a, 4b, and 4c act as IO devices according to the PROFINET definition. The interfaces 5a, 5b, and 5c used for these connections are configured based on PROFINET conformance level B. Functional level B includes the functions of level A (see previous description) and also includes network diagnostics and topology identification functions.

[0038] Based on the features of its interfaces 7, 5a, 5b, and 5c described above, device 3 acts as an Ethernet APL gateway for field devices 4a, 4b, and 4c connected to it. This means that field devices 4a, 4b, and 4c turn to device 3 to communicate with automation system 2, which, in turn, acts as a gateway to process and convert these requests and transmit them to automation system 2. Therefore, unlike known devices such as APL switches, field devices 4a, 4b, and 4c do not communicate directly with automation system 2, making the data exchange configuration between field devices 4a, 4b, and 4c and automation system 2 more efficient and less burdensome.

[0039] The device has a user interface 10, through which, by corresponding input, it is possible to predefine the conditions under which HTTPS connections from automation equipment 2 to field devices 4a, 4b, and 4c can be established. This improves the security of connections 8, 6a, 6b, and 6c to field devices 4a, 4b, and 4c.

[0040] Furthermore, the device 3 has an aggregator function to filter data sent to the automation device 2 from field devices 4a, 4b, and 4c. This aggregator function is based on the participation of a neural network. Pre-filtering reduces the communication or workload of the automation device 2.

[0041] Furthermore, the device 3 has a controller optimization function to preprocess data sent to the automation equipment 2 by field devices 4a, 4b, and 4c in preparation for subsequent controller optimization to be performed in the automation equipment 2. This also reduces the workload of the automation equipment 2.

[0042] Interfaces 5a, 5b, and 5c are configured in this case as a current loop interface, according to... Figure 2 A detailed description is provided. Figure 2A schematic structure of the interface 5a of the device 3 is shown. The interface 5a includes a processing unit 11, an analog-to-digital converter 12, a HART circuit block 13, a DC voltage source 14, a current measuring device 15, a low-pass filter 16, an APL unit 17, and a terminal network 18.

[0043] On one hand, interface 5a can be used as a known APL interface for field devices 19 with APL capability. For this purpose, the application includes APL channel 20 comprising APL unit 17, terminal network 18, DC voltage source 14, and low-pass filter 16.

[0044] Interface 5a is also configured as a current loop interface, also known as a 4...20mA interface. For this purpose, the current measuring device 15 measures the current applied by the field device 19 with an amplitude between 4 and 20mA. The analog-to-digital converter 12 converts the measured current value into a digital signal value and passes it to the processing unit 11 for further processing. Here, the data applied to the current signal between the field device 19 and the device 3 can also be decoded by the field device 19 according to the HART protocol and further processed. In the opposite direction, the HART circuit block 13 generates the corresponding modulation for communication with the field device 19 based on the HART protocol.

[0045] Although the invention has been set forth and described in detail with reference to preferred embodiments, the invention is not limited to the disclosed examples, and other variations that can be derived by those skilled in the art do not depart from the scope of protection of the invention.

Claims

1. A device (3) having multiple interfaces (5a, 5b, 5c) for connection (6a, 6b, 6c) to field devices (4a, 4b, 4c) in an industrial facility, particularly a process facility or manufacturing facility, via Ethernet APL and PROFINET, and the device having an interface (7) for connection (8) to an upper-level automation device (2) of the industrial facility via PROFINET, wherein, The device (3) is configured to act as a communication switch between the higher-level automation equipment (2) and the field devices (4a, 4b, 4c). Its features are, The device (3) is configured to act as a PROFINET IO device in a scenario of connection (8) with the upper-level automation equipment (2), and as a PROFINET IO controller in a scenario of connection (6a, 6b, 6c) with the field devices (4a, 4b, 4c), so as to act as an Ethernet APL gateway in a scenario of connection (6a, 6b, 6c) with both the field devices (4a, 4b, 4c) and the upper-level automation equipment (2).

2. The apparatus (3) according to claim 1, wherein, The interface (7) for connecting (8) to the automation equipment (2) above the industrial facility is configured based on PROFINET conformance level A, and the interface (5a, 5b, 5c) for connecting (6a, 6b, 6c) to the field devices (4a, 4b, 4c) is configured based on PROFINET conformance level B.

3. The apparatus (3) according to claim 1 or 2, wherein, The automated equipment (2) is a programmable logic controller.

4. The apparatus (3) according to any one of the preceding claims, wherein, The field devices (4a, 4b, 4c) are sensors and / or actuators.

5. The apparatus (3) according to any one of the preceding claims, wherein, In particular, by means of appropriate input via the user interface of the device (3), it is possible to predefine under what conditions an HTTPS connection from the automation equipment (2) to the field devices (4a, 4b, 4c) can be achieved.

6. The apparatus (3) according to any one of the preceding claims, the apparatus having an aggregator function to enable filtering of data sent from the field devices (4a, 4b, 4c) to the automation device (2).

7. The apparatus (3) according to claim 6, wherein, The aggregator function is based on the participation of neural networks.

8. The apparatus (3) according to claim 6 or 7, wherein the apparatus has a controller optimization function to preprocess the data sent by the field devices (4a, 4b, 4c) to the automation equipment (2) in preparation for controller optimization to be performed subsequently in the automation equipment (2).

9. The apparatus (3) according to any one of the preceding claims, the apparatus having at least one interface (5a, 5b, 5c) configured as a current loop interface, the at least one interface being used for connection to the field device (4a, 4b, 4c) based on a current received by the field device (4a, 4b, 4c) with a current intensity between 4mA and 20mA.

10. The apparatus (3) according to claim 9, wherein, The interfaces (5a, 5b, 5c) used for connecting (6a, 6b, 6c) to the field devices (4a, 4b, 4c) are configured based on the HART protocol.

11. An automation system (1) comprising automation equipment (2) and means (3) according to any one of the preceding claims, wherein, A disconnectable connection (8) is established between the automation equipment (2) and the PROFINET-based device (3).

12. The automation system (1) according to claim 11, wherein the automation system has a plurality of field devices (4a, 4b, 4c), and the field devices are disconnectably connected to the corresponding interfaces (5a, 5b, 5c) of the device (3).

13. A method for operating an industrial facility, particularly a process facility or manufacturing facility, said industrial facility having apparatus (3) according to any one of claims 1 to 10.

14. A method for operating an industrial facility, particularly a process facility or manufacturing facility, said industrial facility having an automation system (1) according to claim 11 or 12.

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