Automatic monitoring of process controls

Abstract

Device (100) for monitoring process controls, wherein the device (100) comprises: - an engineering tool facility (10) which is trained to provide process control for an engineering product and to commission the process control of the engineering product; and - a monitoring tool device (20) which is designed to be implemented during the commissioning of the process control of the engineering product and to be coupled with the process control of the engineering product, wherein the monitoring tool device (20) is installed with project sources on a controller and is further designed to test and / or monitor the process control of the engineering product.

Description

Technical field

[0001] The present invention relates to systems for the automatic monitoring of process controls.

[0002] In particular, the present invention relates to a device and a method for the automatic monitoring of process controls. Technical background

[0003] In order to test or observe automation programs in operation, also known as "monitoring", the sources of the running control program are nowadays stored either on the controller or on a PC.

[0004] To read or change the values ​​of the running controller, an installed engineering product is needed, such as PLCnext Engineer, an engineering software platform for automation controllers.

[0005] It should be noted that the version of the engineering product installed on the user's system must be compatible with the version of the running project on the controller.

[0006] This leads either to high costs for the product manufacturer to keep newer product versions compatible with older project versions, or to the user, who has to maintain older product versions installed that match the projects on the controller. Furthermore, depending on the use case, only reading or overwriting values ​​should be possible, but not modifying the programs. Both of these are sometimes not possible with a product installed on the user's computer.

[0007] The standard DIN EN 61131-1 provides general information on programmable logic controllers.

[0008] The document by Szymanski, Jacek W. refers to integrated internet technologies for control systems.

[0009] Furthermore, DE 10 2017 210 453 A1 discloses a device and a method for monitoring data of an automation system.

[0010] DE 20 2016 105 686 U1 discloses an industrial plant which includes a control and / or regulating device by means of which automated fault and process diagnostics can be carried out.

[0011] Furthermore, a method and an application of the method for providing a data processing arrangement for condition monitoring of electronically monitored systems are known from DE 10 2013 217 353 A1. Summary of the invention

[0012] It is an object of the present invention to provide an improved device and an improved method for the automatic monitoring of the process control of a control unit.

[0013] This problem is solved by the subject matter of the independent patent claims. Further developments and embodiments can be found in the dependent patent claims, the description, and the figures in the drawings.

[0014] A first aspect of the present invention relates to a device for monitoring process controls, wherein the device comprises: an engineering tool device configured to provide a process control for an engineering product and to perform commissioning of the process control of the engineering product; and a monitoring tool device configured to be implemented during the commissioning of the process control of the engineering product and to be coupled with the process control of the engineering product, wherein the monitoring tool device is installed with project sources on a controller and is further configured to test and / or monitor the process control of the engineering product.

[0015] The present invention advantageously enables the creation of a monitoring tool, the monitoring tool device, which makes it possible to test or observe a project running on the controller with a computer without having to have a pre-installed engineering product that is compatible with the version of the project.

[0016] The tool should connect directly to the project running on the controller and specifically provide only the functions required for maintenance (only reading or overwriting values, setting breakpoints, stopping and restarting the controller).

[0017] The degree of intervention in the ongoing project should be predetermined by the tool, and further manipulation, such as changing the program logic, uploading new projects, or accessing additional control data, should be prevented.

[0018] Contrary to the prior art, the invention thus advantageously provides a self-contained package on the controller that automatically provides the application with its complete required environment, in order to be able to test the running program on a computer with an operating system without having to maintain a product installation on this computer.

[0019] Advantageous embodiments of the present invention can be found in the dependent claims.

[0020] In an advantageous embodiment of the present invention, the device is designed to be implemented on a programmable logic controller and / or on a multi-purpose computer according to an installation matrix.

[0021] In an advantageous embodiment of the present invention, it is provided that the monitoring tool device is designed to be installed together with the engineering tool device.

[0022] In an advantageous embodiment of the present invention, the monitoring tool device is designed to be started and / or operated by a maintenance system coupled to the device.

[0023] In an advantageous embodiment of the present invention, the monitoring tool device is configured to perform a plurality of permitted accesses to the process control of the engineering product.

[0024] In an advantageous embodiment of the present invention, the monitoring tool device is designed to be implemented in a project code of the process control of the engineering product.

[0025] In an advantageous embodiment of the present invention, the monitoring tool device is designed to perform a control of operating parameters and values ​​of the process control of the engineering product.

[0026] In an advantageous embodiment of the present invention, the monitoring tool device is configured to make changes to operating parameters and values ​​of the process control of the engineering product.

[0027] In an advantageous embodiment of the present invention, the monitoring tool device is configured to perform a change and / or a setting of breakpoints of the process control of the engineering product, particularly preferably a stopping and / or a restarting of the process control of the engineering product.

[0028] According to a second aspect of the present invention, a method for monitoring process controls is provided, wherein the method comprises the following process steps: As a first step, process control for an engineering product is provided using an engineering tool setup. The monitoring tool setup is installed on a controller along with project data sources.

[0029] As a second process step, the process control is commissioned using the engineering tool setup.

[0030] As a third procedural step, a monitoring tool setup is carried out during the commissioning of the process control system of the engineering product.

[0031] As a fourth process step, the monitoring tool setup is coupled with the engineering tool setup.

[0032] As a fifth procedural step, the process control of the engineering product is tested and / or observed using the monitoring tool setup.

[0033] According to a third aspect, the present invention comprises a computer program or a computer program product comprising instructions which, when the program is executed by a computer, cause the computer to perform the steps of the method according to the second aspect or any embodiment of the second aspect.

[0034] According to a fourth aspect, the present invention comprises a computer-readable storage medium comprising instructions which, when executed by a computer, cause the computer to perform the steps of the method according to the second aspect or any embodiment of the second aspect.

[0035] The described configurations and training programs can be combined in any way desired.

[0036] Further possible embodiments, developments and implementations of the present invention also include combinations of features of the present invention described previously or subsequently with regard to the embodiments that are not explicitly mentioned.

[0037] The accompanying drawings are intended to provide a further understanding of the embodiments of the present invention.

[0038] The accompanying drawings illustrate embodiments and serve, in connection with the description, to explain concepts of the present invention.

[0039] Other embodiments and many of the aforementioned advantages become apparent with regard to the figures in the drawings. The elements depicted in the figures in the drawings are not necessarily shown to scale. Brief description of the characters

[0040] They show: Fig. 1: a schematic representation of a matrix for use on the controller and / or PC according to an embodiment of the present invention; and Fig. 2: a schematic representation of a flowchart of a startup routine according to an embodiment of the present invention; Fig. 3: a schematic representation of a process from tool creation to deployment according to an embodiment of the present invention; Fig. 4: a schematic representation of the process from project creation to the application of the monitoring tool according to an embodiment of the present invention; Fig. 5: a schematic representation of a device for monitoring process controls according to an embodiment of the present invention; Fig. 6: a schematic representation of a flowchart of a method for monitoring process controls according to an embodiment of the present invention. Detailed description of the exemplary implementations

[0041] In the figures of the drawings, identical reference numerals denote identical or functionally equivalent elements, components, parts or process steps, unless otherwise stated.

[0042] According to one embodiment of the present invention, a virtualized monitoring tool is used, which is stored directly with the project and its sources on the controller or a PC.

[0043] The virtualization of the tool application includes, in addition to the tool itself, a package with all the necessary runtime routines, configurations and system components required for execution.

[0044] The term "engineering tool," as used, for example, in the description of the present invention in the term "engineering tool setup" or elsewhere, describes an aid for creating a control unit. In other words, an "engineering tool" describes a "production and configuration aid" for designing and / or configuring a control unit.

[0045] The term "monitoring tool," as used, for example, in the description of the present invention in the term "monitoring tool device" or elsewhere, describes an aid for monitoring a control unit. In other words, a "monitoring tool" describes a system for monitoring and checking the operation of a control unit, whereby active intervention is also possible.

[0046] The Fig. Figure 1 shows a schematic representation of a matrix for use on the controller and / or PC. For example, four combinations are possible, as shown in the... Fig. 1 shown.

[0047] Furthermore, the monitoring tool is installed using the engineering product. The monitoring tool can then be used during the commissioning of the controller via the engineering product, according to the project sources listed in the table above, for later testing or monitoring on the controller or a PC, according to the combination of the above-mentioned and in Fig. The matrix shown in section 1 is stored in the vicinity of the plant operator or manufacturer.

[0048] Uploading the source code and the required monitoring tool is offered as an option directly during the creation and transfer of the project code to the controller in the engineering product.

[0049] The Fig. Figure 2 shows a schematic representation of the startup routine according to an embodiment of the present invention.

[0050] In the first process step S21, the directly executable (virtualized) monitoring application is loaded from the controller.

[0051] In a second process step S22, the source code or source text of a computer program of the project currently running on the controller is loaded, for example including the connection parameters to the controller.

[0052] In a third process step S23, the monitoring tool is started and initialized with the previously loaded control project.

[0053] In a fourth process step S24, an automatic connection is made to the project running on the controller and the monitoring mode is started.

[0054] According to one embodiment of the present invention, this tool can be transferred directly from the controller and / or a PC to a connected maintenance computer and executed without installation.

[0055] A pre-installed startup routine, as in the Fig. Figure 2, according to an embodiment of the present invention, ensures that the transferred tool automatically loads the source project from the controller to a PC upon startup and connects to the running project on the controller for testing or monitoring.

[0056] This ensures that only authorized access (such as displaying values, overwriting values, setting breakpoints, stopping and restarting the control) is possible in the provided tool.

[0057] The Fig. Figure 3 shows a schematic representation of a process from tool creation to deployment according to an embodiment of the present invention.

[0058] The Fig. Figure 4 shows a schematic representation of the process from project creation to the application of the monitoring tool according to an embodiment of the present invention.

[0059] The Fig. Figure 5 shows a schematic representation of a device for monitoring process controls according to an embodiment of the present invention.

[0060] The device 100 for monitoring process controls comprises an engineering tooling unit 10 and a monitoring tooling unit 20.

[0061] The engineering tool facility 10 is trained to provide process control for an engineering product and to carry out the commissioning of the process control of the engineering product.

[0062] The monitoring tool device 20 is designed to be executed during the commissioning of the process control of the engineering product and to be coupled with the process control of the engineering product.

[0063] The engineering tool device, as used as a term in the present invention, can therefore, according to an embodiment of the present invention, for example, provide an aid for programming in graphical and textual form according to IEC-61131.

[0064] Similarly, the engineering tool or engineering tool device 10, according to an embodiment of the present invention, can be configured to perform a configuration of fieldbus / Ethernet components and network systems. The monitoring tool device 20, for example, according to an embodiment of the present invention, is configured to monitor the function of the components and systems during operation of the fieldbus / Ethernet components and network systems.

[0065] Likewise, the engineering tool or engineering tool device 10 according to an embodiment of the present invention can be configured to provide a connection configuration of process data with program input and output parameters, or to create test and operating visualizations for control and / or production systems.

[0066] The monitoring tool device 20 is, for example, designed according to an embodiment of the present invention to monitor the control and / or production systems and to monitor ongoing process control, for example by monitoring the process data and / or the associated program-specific input and output parameters.

[0067] Likewise, the engineering tool or engineering tool device 10, according to an embodiment of the present invention, can be configured to perform programming and / or configuration of safety-related controllers according to IEC 61508. The monitoring tool device 20, for example, according to an embodiment of the present invention, is configured to monitor the safety-related controllers according to IEC 61508.

[0068] Furthermore, the monitoring tool setup 20 enables automated diagnosis of running programs by setting breakpoints or by observing and / or overwriting values.

[0069] The engineering tool or engineering tool setup 10 can therefore also be designed, for example, as an aid for compiling programs and transferring the programs and configurations to a process control system. This can be done, for example, in the field of building technology and building automation; the engineering tool setup can initialize and configure heating, lighting, roller shutter, and garage door controls.

[0070] The engineering tool set 10 can therefore also be used, for example, as an aid in the field of industrial production, and enable the creation, configuration and maintenance of automated controls in entire production lines.

[0071] The engineering tool set 10 can also be used in the field of creating and configuring photovoltaic and wind power plants, process engineering plants, power plants, automated control and regulation systems in the railway, shipping or air transport sector, or traffic control systems such as traffic light systems.

[0072] The Fig. Figure 6 shows a schematic representation of a flowchart of a method for monitoring process controls according to an embodiment of the present invention.

[0073] The Fig.Figure 6 shows a method for monitoring process controls, wherein the method comprises the following process steps: As a first procedural step, S1 is provided by a process control system for an engineering product using an engineering tool setup.

[0074] As a second process step, commissioning of the process control is accomplished using the engineering tool setup.

[0075] As a third procedural step, a monitoring tool device (S3) is executed during the commissioning of the process control of the engineering product.

[0076] As a fourth process step, the monitoring tool setup S4 is coupled with the engineering tool setup.

[0077] It should also be noted that “comprehensive” and “showing” do not exclude any other elements or steps, and “a” or “an” does not exclude a multitude.

Claims

[1] Device (100) for monitoring process controls, the device (100) comprising: - an engineering tool device (10) which is designed to provide a process control for an engineering product and to carry out commissioning of the process control of the engineering product; and - a monitoring tool device (20) which is designed to be executed during commissioning of the process control of the engineering product and to be coupled to the process control of the engineering product, wherein the monitoring tool device (20) is installed with project sources on a controller and is further designed to test and / or monitor the process control of the engineering product. [2] Device (100) according to claim 1, wherein the device (100) is designed to be executed according to an installation matrix on a programmable logic controller and / or on a general-purpose computer. [3] Device (100) according to one of the preceding claims, wherein the monitoring tool device (20) is designed to be installed during installation of the engineering tool device (10). [4] Device (100) according to one of the preceding claims, wherein the monitoring tool device (20) is designed to be started and / or operated by a maintenance system coupled to the device (100). [5] Device (100) according to one of the preceding claims, wherein the monitoring tool device (20) is designed to carry out a plurality of permitted accesses to the process control of the engineering product. [6] Device (100) according to one of the preceding claims, wherein the monitoring tool device (20) is designed to be implemented in a project code of the process control of the engineering product. [7] Device (100) according to one of the preceding claims, wherein the monitoring tool device (20) is designed to carry out a control of operating parameters and values of the process control of the engineering product. [8] Device (100) according to one of the preceding claims, wherein the monitoring tool device (20) is designed to carry out a change in operating parameters and values of the process control of the engineering product. [9] Device (100) according to one of the preceding claims, wherein the monitoring tool device (20) is designed to carry out a change and / or a setting of breakpoints of the process control of the engineering product, particularly preferably to carry out a stopping and / or a restart of the process control of the engineering product. [10] Method for monitoring process controls, the method comprising the following steps: - Providing (S1) a process control for an engineering product by means of an engineering tool device (10), wherein the monitoring tool device (20) is installed with project sources on a controller; and - Carrying out (S2) commissioning of the process control by means of the engineering tool device (10); - Co-execution (S3) of a monitoring tool device (20) during commissioning of the process control of the engineering product; - coupling (S4) the monitoring tool device (20) with the engineering tool device (10); and - Testing and / or monitoring the process control of the engineering product using the monitoring tool device (20).

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