SYSTEM FOR COLLECTING DATA FROM AN AUTOMATION TECHNOLOGY SYSTEM

Description

[0001] The invention relates to a system for collecting data from an automation technology system, wherein the system according to the invention comprises a head module and at least one terminal module.

[0002] Field devices are already known from the state of the art and are used in industrial plants. They are widely employed in process automation as well as in manufacturing automation. In principle, field devices are defined as all devices used close to the process that provide or process process-relevant information. Thus, field devices are used to acquire and / or influence process variables. Measuring instruments or sensors are used to acquire process variables. These are used, for example, for measuring pressure and temperature, conductivity, flow rate, pH, level, etc., and acquire the corresponding process variables such as pressure, temperature, conductivity, pH value, level, and flow rate. Actuators are used to influence process variables.These include, for example, pumps or valves that can influence the flow of a liquid in a pipe or the fill level in a container. In addition to the aforementioned measuring devices and actuators, field devices also include remote I / Os, radio adapters, and generally any devices located at the field level.

[0003] A large number of such field devices are produced and distributed by the Endress+Hauser Group.

[0004] In modern industrial plants, field devices are typically connected to higher-level units via communication networks such as fieldbuses (Profibus®, Foundation® Fieldbus, HART®, etc.). These higher-level units are usually control units, such as a PLC (Programmable Logic Controller). Among other things, the higher-level units are responsible for process control and commissioning the field devices. The measured values ​​acquired by the field devices, particularly sensors, are transmitted via the respective bus system to one (or possibly several) higher-level units, which may further process the measured values ​​and forward them to the plant's control center. The control center is used for process visualization, process monitoring, and process control via the higher-level units.In addition, data transmission from the higher-level unit via the bus system to the field devices is also required, in particular for the configuration and parameterization of field devices and for the control of actuators.

[0005] To operate the field devices, appropriate operating programs (operating tools) are necessary, which either run independently on the higher-level units (Endress+Hauser FieldCare, Pactware, AMS Fisher-Rosemount, PDM Siemens) or are integrated into applications of the control room (Siemens PCS7, ABB Symphony, Emerson Delta V).

[0006] From the prior art, EP 1096456 A2 discloses a sensor system with a plurality of sensor units mounted side by side on a DIN rail, enabling bidirectional data communication between adjacent sensor units. GB 2477443 A discloses process control systems for the communicative coupling of field devices with controllers. US 2016 / 092388 A1 and DE 10 2016 107491 A1 disclose field devices in conjunction with signal units, which are connected to each other and to a connection unit via a fieldbus for the exchange of process data. This connection unit is linked to an external data infrastructure via an external data network.

[0007] With the increasing digitalization associated with the buzzwords "Industrial Internet of Things (IoT)" and "Industry 4.0," which also extends to process plant components, there is a growing need to make data from sensor systems—especially measurement data, diagnostic data, parameter values, etc.—centrally available and to generate added value from this data (keywords here are "Big Data Analysis," "Predictive Maintenance," etc.). This central location is often understood to be an internet-accessible database, particularly a so-called cloud-enabled database. Typically, the data from the process plant components, especially the field devices, is transmitted to the database via Ethernet.

[0008] The fundamental problem with any such application (IIoT, etc.) is the lack of connectivity between field devices and the database, as field devices in many existing systems communicate with higher-level units using 4-20 mA technology and / or HART technology. For this purpose, the field devices are designed as two-wire devices. Each of these field devices is connected to the higher-level unit via a separate communication loop, which is typically located in a control cabinet. The cables of the individual communication loops are typically connected in the control cabinet to a terminal block with individual terminal modules, and from the terminal block, they are connected to the higher-level unit. The terminal block, the higher-level unit, and other components of the control cabinet are typically mounted on DIN rails.With 4-20 mA technology, the magnitude of the process values ​​determined by the field devices is transmitted to the higher-level units via varying energy values ​​in the range of 4 to 20 mA, corresponding to the current magnitude of the process values. With HART technology, an additional digital signal is modulated onto the 4-20 mA signal.

[0009] In new installations, this fundamental problem can usually be easily solved, as it can be addressed during the planning phase. For existing systems, gateways are available that can convert the 4-20 mA signal or the HART signal. However, this presents the problem of significant wiring effort, as the gateway must be connected in parallel to each individual communication loop, requiring each loop to be opened separately. Furthermore, sufficient space must be available in the control cabinet, which is often lacking in existing systems.

[0010] Based on this problem, the invention aims to provide a space-saving solution that makes it possible to make data from a non-Ethernet-enabled field device available in a central location.

[0011] The problem is solved by a system according to claim 1.

[0012] The terminal module can be designed in the form of conventional feed-through or terminal blocks, such as those offered by Phoenix Contact or Wago. These terminals are designed for mounting on a DIN rail. In contrast to conventional feed-through or terminal blocks, the terminal module of the system according to the invention incorporates an electronic module. This electronic module allows the terminal module of the system according to the invention to easily acquire and transmit data from a field device. For this purpose, the electronic module is designed to monitor the data traffic flowing through the communication loop. This data is then converted into a second protocol, in particular a proprietary protocol, and output via contacts that the terminal module of the system according to the invention has, unlike conventional feed-through or terminal blocks.

[0013] The communication loop is a two-wire communication loop. It is connected, in particular, to a field device used in automation technology. A communication loop according to the present invention uses 4-20 mA technology or HART technology. It is also possible to use the communication loop with other suitable communication technologies. Field devices mentioned in connection with the invention have already been given as examples in the introductory part of the description.

[0014] According to an advantageous embodiment of the terminal module of the system according to the invention, the electronic module includes a memory containing identification information for the terminal module. This information can be output via the contacts in addition to the telegrams converted into the second protocol. It may be provided that the identification information can be edited and, for example, adapted to the name of the field device.

[0015] The head module is dimensionally identical to, or at least very similar to, a terminal module of the system according to the invention. The telegrams converted and output by a terminal module are received by the head module, optionally collected, converted into a third protocol, in particular Ethernet, and output via the first network interface. An Ethernet-based network, for example the Internet, is connected to the network interface. This network interface is connected to a database, in particular a cloud-enabled database, to which the converted telegrams are transmitted. The head module itself does not, in particular, have a connection area for a connection to a communication loop.

[0016] According to an advantageous embodiment of the head module of the system according to the invention, the head module has a connection for a power supply unit and a power distribution unit, which power distribution unit is connected to the connection and contacts of the head module. In this way, the head module itself is supplied with the electrical energy required for operation. Furthermore, it is possible to supply terminal modules of the system according to the invention with the electrical energy required for operation.

[0017] According to a preferred embodiment of the head module of the system according to the invention, the head module is provided to have a web server. For example, it is provided that an operating unit can be connected to the head module. The operating unit can access the web server of the head module and read telegrams from a field device (via a terminal module) or configure the head module.

[0018] According to an advantageous embodiment of the head module of the system according to the invention, the head module has a second network interface. The second network interface can, on the one hand, have the same function as the first network interface, namely output the converted telegrams from the field devices. Alternatively, the network interface can be configured to grant access to the web server to a device connected to the second network interface, for example, the aforementioned control unit.

[0019] The system according to the invention offers the significant advantage that data from field devices can be easily made available to an Ethernet-based network, particularly for IIoT applications, even though the field devices do not conventionally support Ethernet. A further major advantage is the small footprint required for this solution. Traditionally, feed-through or terminal blocks are already present in a control cabinet, connecting the communication loops of the field devices to higher-level units. These terminal blocks simply need to be replaced by terminal modules of the system according to the invention. The connection between the field devices and the higher-level unit is maintained even with the terminal modules of the system according to the invention. In addition, the data from the field devices can be monitored and processed in an Ethernet-compliant manner.

[0020] According to an advantageous further development, the system additionally comprises a termination module, wherein the termination module is slid onto the DIN rail and is designed such that it can be connected to the contacts of the terminal module, and when connected to the contacts of the terminal module, a circuit is formed, including the head module, the terminal module, and the termination module. The circuit is thus closed. The source and sink of the circuit are located, in particular, on the side of the head module.According to an advantageous embodiment, the system additionally comprises further terminal modules, each connected to a further communication loop of another field device and positioned between the head module and the termination module. The contacts of the further terminal modules touch in such a way that the circuit includes the further terminal modules. The further terminal modules are configured to forward the converted telegrams of the terminal module and, in particular, to receive, convert, and transmit telegrams from their respective communication loops to the head module. In this way, telegrams from multiple field devices or multiple communication loops can be received or monitored and output via the first network interface. A plurality of terminal modules of the system according to the invention can be used.Only a head module and a concluding module are required.

[0021] The contacts of the individual terminal modules are designed such that they form a common line between the termination module and the head module, thus creating a closed circuit. The terminal modules located between a terminal module currently transmitting a telegram converted to the second protocol and the knock module are designed to relay the telegram sent by the transmitting terminal module along the terminal modules so that it reaches the head module.

[0022] In addition to terminal modules of the system according to the invention, conventional feed-through or terminal blocks can also be installed on the DIN rail between the head module and the termination module. These serve the conventional purpose of terminals in the control cabinet—to connect the communication loop of a field device to a higher-level unit—and do not contain any electronic components. However, it is essential to ensure that the conventional feed-through or terminal blocks have the same type of contacts as the terminal modules of the system according to the invention. Only then will the circuit not be interrupted and telegrams be able to be transmitted from the terminal modules to the head module.

[0023] According to an advantageous embodiment of the system according to the invention, the power distribution unit of the head module is designed to supply the terminal module and the other terminal modules with electrical energy. In this way, all terminal modules can be supplied with the electrical energy required for operation without the terminal modules needing their own power supply.

[0024] In an advantageous embodiment, the system according to the invention additionally comprises an operating unit, which is connected to the second network interface of the head module and is configured to access the head module's web server and retrieve data from the head module via this server. The data can, for example, be telegrams from the individual field devices connected to the terminal modules. It can also be status information from the field devices. The operating unit is, for example, an operating unit in the sense of the "Field Xpert" manufactured and distributed by the applicant. However, the operating unit can also be a computer unit, for example a laptop, or a mobile device, for example a tablet or a smartphone. Preferably, the operating unit communicates with the web server in accordance with the FDT standard.

[0025] According to a preferred embodiment of the system according to the invention, the electronic unit is designed to check the presence of terminal modules, whereby the identification information of the respective terminal module is requested during the check.

[0026] In an advantageous embodiment of the system according to the invention, the head module includes an optical indicator, wherein the electronic unit of the head module is configured to check the presence of the termination module, and wherein the optical indicator is configured to emit an optical signal if the termination module is present. Thus, it is easily apparent – ​​without the need to connect an operating unit – whether the circuit is closed or whether a fault exists and the connections between the individual components need to be checked.

[0027] According to a preferred embodiment of the system according to the invention, the web server of the head module is configured to present the available terminal modules with their corresponding identification information and / or make it available for retrieval. The identification information of all detected terminal modules can, for example, be queried via the web server. The identification information can also be edited via the web server. Furthermore, it may be possible to link the identification information of the terminal modules with the identification information of the field device connected to a terminal module.

[0028] According to an advantageous embodiment of the system according to the invention, the system is configured such that the operating unit is enabled to operate the field device. The operating unit is configured to transmit an operating telegram to the head station, which is configured to convert the operating telegram into a telegram conforming to the second protocol and transmit it to the terminal module. The terminal module is configured to convert the telegram into a telegram conforming to the first protocol and transmit it to the field device via the communication loop. In this way, a field device can be operated by means of the operating unit. "Operating" within the meaning of the present invention refers to querying measured values, parameter values, identification information, and / or diagnostic information of the field device, or to parameterizing the field device.The control unit is specifically connected to the second network interface of the head unit.

[0029] Furthermore, it can be provided that the field devices can be accessed via the database. The database is connected to the first network interface of the head unit via an Ethernet network. Depending on requirements, the same operating functions as described above for the control unit can be enabled via the database. Alternatively, it can be provided that the above operating functions are not enabled, but update functionalities are activated that are not available via the control unit. These update functionalities include, for example, updating the firmware of the field devices and / or updating the web server of the head unit.

[0030] The invention is explained in more detail with reference to the following figures. It shows Fig. 1: a schematic cross-section through a terminal module of the system according to the invention; and Fig. 2 : an embodiment of a system according to the invention.

[0031] Fig. 1 Figure 1 shows a schematic cross-section through a terminal module KL as used in accordance with the invention. The dimensions of the terminal module KL essentially correspond to those of a feed-through terminal or a terminal block, which are commercially available in various designs. The terminal module KL has a recess by means of which it can be slid onto a DIN rail HS. In this case, a DIN rail HS is installed in control cabinets of automation systems.

[0032] The terminal module KL has a first connection area AB1 and a second connection area AB2. A communication loop KS, originating from a field device FG, is connected to the first connection area AB1. The first connection area AB1 is connected to the second connection area AB2 via the housing of the terminal module KL. This second connection area serves to connect to a higher-level unit, such as a programmable logic controller (PLC). Therefore, the terminal module KL, like a conventional feed-through or terminal block, serves to connect a communication loop KS to a higher-level unit and to pass the data transmitted on the communication loop through to the terminals of the higher-level unit.

[0033] In contrast to conventional clamps known in the prior art, the one in Fig. 1The terminal module KL shown includes an electronic module EM and additional contacts KO. The electronic module serves the purpose of monitoring telegrams transmitted via the communication loop KS. In this example, these are HART telegrams. The monitored telegrams are then converted by the electronic module EM according to a proprietary protocol and can be output via the contacts KO. The terminal module KL is also supplied with the electrical power required for operation via the contacts KO.

[0034] Fig. 2 shows an embodiment of the system according to the invention. Besides the one in Fig. 1The terminal module shown has additional terminal modules KL', a head module KM, and a termination module AM ​​mounted on the DIN rail HS. Like terminal module KL, these additional components have the same contacts KO in an equivalent position, so that the respective contacts of the components touch when the components are correctly mounted on the DIN rail. This forms a closed circuit that begins in the head module KM, runs along terminal modules KL and KL', passes through the termination module AM, and ends along terminal modules KL and KL' at the head module.

[0035] The electrical energy required to operate the head module KM and the terminal modules KL and KL' is supplied to the head module KM by a power supply unit EV. A power distribution unit ET, integrated within the head module, supplies the terminal modules KL and KL' with electrical energy received from the power supply unit EV via the circuit. Advantageously, the termination module AM ​​is designed as a passive component. The presence of the termination module AM, and thus a correctly closed circuit, is indicated by an optical indicator IN, for example, a light-emitting diode, integrated into the head module KM.

[0036] If the system is correctly configured, the terminal module KL can transmit the telegrams, converted into the proprietary protocol, to the head module KM via the electrical circuit. The other terminal modules then forward the telegrams. An electronic module within the head module KM receives the telegrams and converts them into another protocol. These converted telegrams can then be transmitted to a communication network KN. For this purpose, the head module KM has a first network interface NS1, which serves to connect to a wireless or wired communication network KN. In the case of a wired communication network, this is typically an Ethernet-based network. In the case of a wireless communication network, it is a wireless network designed according to one of the common standards, such as Bluetooth or Wi-Fi.

[0037] The converted telegrams are transmitted via the communication network to a cloud-based database. Applications, particularly in the IIoT sector, can run on this database, further processing and analyzing the received telegrams and thus the data received from a field device. The database can also be enabled to access the field device via the system according to the invention and, for example, to update its firmware.

[0038] Furthermore, the head module has an additional network interface, NS2. This interface is used to connect an operator unit, such as a mobile device or laptop, particularly one based on FDT technology, to the head module KM. The head module KM then allows the operator unit BE to access a web server WS integrated into the head module KM. This web server presents the operator unit with, for example, all available "intelligent" terminal modules KL, KL'. To do this, the head module performs a scan and reads the identification information of the terminal modules KL, KL', which is stored in a memory SP on the respective terminal module KL, KL'. The web server WS also displays the current telegrams received by the terminal modules KL, KL', linked to their respective identification information.

[0039] The operating unit BE also enables operation of the field device FG. For this purpose, the operating unit transmits an operating telegram to the head station KM. The head station KM then converts the operating telegram into a telegram conforming to the proprietary protocol and transmits this to the corresponding terminal module KM. The terminal module KM itself, in turn, converts this telegram into a telegram conforming to the first protocol and transmits this to the field device FG via the communication loop KS. Any resulting response telegram is transmitted in reverse from the field device FG to the operating unit BE. "Operation" within the meaning of the present invention refers to querying measured values, parameter values, identification information, and / or diagnostic information of the field device FG, or to parameterizing the field device FG.

[0040] In addition to the described terminal module KL, a large number of other terminal modules of the system according to the invention can be used in the system, each of which is connected to a further communication loop KS' with a further field device.

[0041] In addition to the terminal modules of the system KL, KL' according to the invention, conventional feed-through or terminal blocks can also be installed on the DIN rail HS between the head module KM and the termination module AM. These serve the conventional purpose of terminals in the control cabinet—to connect the communication loop KS, KS' of a field device FG to a higher-level unit—and do not have an electronic module EM. However, it is essential to ensure that the conventional feed-through or terminal blocks have the same type of contacts KO as those of the terminal modules of the system KL, KL' according to the invention. Only then will the circuit not be interrupted and telegrams be able to be transmitted from the terminal modules KL, KL' to the head module KM. List of reference symbols

[0042] AB1, AB2 Connection areas AM Termination module BE Operating unit DB Database EM Electronic module ET Power distribution unit EV Power supply unit FG Field device HS DIN rail IN Optical indicator KL, KL' Terminal module KM Head module KN Communication network KO Contacts of the terminal module KS Communication loop NS1, NS2 First and second network interface of the head module SP Memory in electronic unit of the terminal module WS Web server

Claims

1. System for collecting data from an automation technology system, comprising: - At least one field device (FG) integrated in the system; - A top-hat rail (HS); - A programmable logic controller, PLC; - At least one terminal module (KL), wherein the terminal module (KL) has a housing, a first connection area (AB1) and a second connection area (AB2), whereby the first connection area (AB1) is connected to the second connection area (AB2) through the housing, where the PLC is connected to the second connection area (AB2), wherein a communication loop (KS) is connected to the first connection area (AB1), via which communication loop the field device (FG) is in communication connection with the PLC, and whereby the field device and the PLC are designed to exchange telegrams via the communication loop (KS) using a first protocol, whereby the first protocol is HART, wherein the terminal module (KL) has first contacts (KO) which are designed for connection to a further terminal module (KL'), and wherein the terminal module (KL) has an electronic module (EM), which electronic module (EM) is designed to receive the telegrams which are transmitted via the communication loop (KS) via the connection areas (AB1, AB2), to convert the telegrams received by the communication loop (KS) into a second protocol and to receive the telegrams which are transmitted via the communication loop (KS) into a second protocol, which are transmitted via the communication loop (KS), via the connection areas (AB1, AB2), converting the telegrams received from the communication loop (KS) into a second protocol and outputting the converted telegrams via the first contacts (KO); and - A head module (KM), wherein the head module (KM) has second contacts which are designed for connection to the first contacts (KO) of the terminal module (KL), wherein the head module (KM) has a first network interface (NS1) which is designed for connection to a wired or wireless communication network (KN) which uses a third protocol, the head module (KM) having an electronic module which is designed to receive the telegrams transmitted by the terminal module (KL) and converted into the second protocol via the second contacts, to convert them into the third protocol and to output them via the first network interface (NS1).

2. System according to claim 1, additionally comprising a termination module (AM), wherein the termination module (AM) is pushed onto the top-hat rail (HS) and is designed in such a way that it can be connected to the first contacts (KO) of the terminal module (KL) and, when connected to the first contacts (KO) of the terminal module (KL), a circuit including the head module (KM), the terminal module (KL) and the termination module (AM) is formed.

3. System according to claim 2, additionally comprising further terminal modules (KL') according to claim 1, which are each connected to a further communication loop (KS') of a further field device and which are mounted between the head module (KM) and the termination module (AM), wherein the first contacts of the further terminal modules (KL') touch each other in such a way that the circuit includes the further terminal modules (KL') and wherein the further terminal modules (KL') are designed to receive the telegrams of the terminal module (KL') converted to the second protocol, that the circuit includes the further terminal modules (KL') and wherein the further terminal modules (KL') are designed to forward the telegrams of the terminal module (KL) converted into the second protocol and in particular to receive telegrams from their respective communication loops (KS'), to convert them and to transmit them to the head module (KM).

4. System according to claim 2, wherein the head module (KM) contains an optical indicator (IN), wherein the electronic module of the head module (KM) is designed such that it checks for the presence of the termination module (AM), and wherein the optical indicator is designed to emit an optical signal if the termination module (AM) is present.

5. System according to claim 1, wherein the electronic module (EM) of the terminal module (KL) comprises a memory (SP) which has identification information of the terminal module (KL).

6. The system according to claim 1, wherein the head module (KM) has a connection for a power supply unit (EV) and a power distribution unit (ET), which power distribution unit (EV) is connected to the connection of the head module and the second contacts of the head module (KM).

7. System according to claim 1 or 6, wherein the head module (KM) comprises a web server (WS).

8. System according to claim 1, 6 or 7, wherein the head module (KM) has a second network interface (NS2).

9. System according to at least one of claims 6 to 8, wherein the energy distribution unit (ET) of the head module (KM) is designed to supply the terminal module (KL) and the further terminal modules (KL') with electrical energy.

10. System according to claim 8, additionally comprising an operating unit (BE) which is connected to the second network interface (NS2) of the head module (KM) and which is designed to access the web server (WS) of the head module (KM) and to retrieve data from the head module (KM) via this.

11. System according to claim 5, wherein the electronic module (EM) of the head module (KM) is designed to check the presence of terminal modules (KL, KL'), wherein the identification information of the respective terminal module (KL, KL') is requested in the course of the check.

12. System according to claim 11, wherein the web server (WS) of the head module (KM) is configured such that it presents and / or makes available for retrieval the existing terminal modules (KL, KL') with their corresponding identification information.

13. System according to at least one of claims 10 or 12, wherein the system is configured such that the operating unit (BE) is enabled to operate the field device (FG), wherein the operating unit (BE) is configured such that it transmits an operating telegram to the head module (KM), wherein the head module (KM) is configured for this purpose, converting the operating telegram into a telegram conforming to the second protocol and transmitting it to the terminal module (KL), the terminal module (KL) being configured such that it converts the telegram into a telegram conforming to the first protocol and transmits it to the field device (FG) via the communication loop (KS).